SECTION 1: SYSTEM OVERVIEW

MODULE ONE
maxDNA maxDPU4E/F BASED
FUNCTIONS AND FEATURES
OBJECTIVE:
Identify maxDNA maxDPU4E/F based system hardware components and their
connectivity.

PURPOSE:
The maxDNA Distributed Control System is comprised of multiple hardware
components, with each component performing specific process control tasks
while communicating with other components in the system.
To properly maintain the maxDNA maxDPU4E/F based System, it is
important that you understand the purpose, function, and connectivity of each
hardware component.

RESOURCES:
This Student Guide

11/26/03

TPP431

1 1 1 Rel 4 TPP431_11 rev F0 maxDNA functions and features_P20.doc

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maxDNA SYSTEM ARCHITECTURE

The maxDNA maxDPU4E/F based System is comprised of one or more
workstations communicating with one or more remote processing units over
redundant 100 Mbps maxNET.

max STATION 1

max STATION 3

max STATION 2
Switched
Hub A-1

Network A
10 Mbps

Switched
Hub B-1

Network B
10 Mbps

Network A
100 Mbps
Full Duplex

Network A
10 Mbps
Network B
10 Mbps

Network B
100 Mbps
Full Duplex

Network A
10 Mbps

Network A
10 Mbps

Switched
Hub A-2

DPU4E/F 1-1

DPU4E/F 2-1

Switched
Hub B-2

DPU4E/F 1-2
Network B
10 Mbps

DPU4E/F 2-2
Network B
10 Mbps

Remote
Processing
Unit 1

Remote
Processing
Unit 2

Figure 1.1.1 maxSTATION Connectivity

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maxDNA Connectivity
Each Processor in the maxDNA maxSTATION communicates with the other
processors through a dual Ethernet. The path used by a given pair of processors
will be defined by one of the processors.
The Ethernet consists of a 100BASE-T type with a 100BASE-FL fiber optic link.
The fiber optic link does not allow any drops and contains two conductors. One of
the conductors is used for transmit data and the other is used for receive data. The
100BASE-T/F cables attach to a Frame Switch. This in turn connects to a HUB or
fast Ethernet device. The HUBs will connect the individual maxSTATION or RPU
to the Ethernet. In place of the HUBs other Frame switches could be connected to
improve the data through put of the network. The entire Ethernet will take on a star
connection configuration. At the user end of the Ethernet the devices will operate
using a 10 BASE-T network connection. There will be a single device attached to
this HUB port with no other drops.

Workstation Components
maxSTATION
The maxSTATION provides the human/machine interface (HMI) for the maxDNA.
Through this interface, the operator is able to monitor and control data and process
behavior.
Standard and custom graphic displays are used to accomplish monitor and control
tasks.
The maxSTATION also provides Engineering capabilities. Through the terminal
interface, the user can perform tasks, such as configuring the system, generating
reports, and viewing events, process history, and other functions.
maxSTATION Hardware
The maxSTATION consists of the following hardware components:

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Table Top or Tower Chassis Computer, Intel 1.6 GHz or faster Pentium CPU
motherboard, 512 KB L2 Cache, 128 MB RAM

Dual Ethernet adapters 10BaseT

Used for processor to processor communication

IDE hard disk

20.0 GB or larger Disk Drive Average seek time< 9.5 ms.

State of the Art EIDE CD-ROM Reader

Used for Software Installation

1.44 Mbytes 3 1/2 inch floppy disk drive

2 serial, 1 parallel port I/O card

Printer and mouse/track ball interface

PCI SVGA Windows Accelerator Video Controller

Supports 1024 X 768 by 64K colors at a refresh rate of 72 or 75 Hz

Color Monitor 17 inch or larger

Qwerty keyboard

Mouse or track ball

Used as a pointing device

maxSTATION Software Components

Windows XP
Used as the operating system

maxVUE run time application

Used to define operators maxSTATION

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maxDPUTOOLS application
Used to define engineering maxSTATION

Printers
Printers can be connected to individual maxSTATIONs and to the Ethernet. Any
Microsoft NT supported printer, such as the HP 1600C, can be attached to the
maxSTATION for use as a screen printer. It connects to the parallel port. This
printer can be setup as shared by the other stations on the maxNET.
Printers may also be connected to the maxNET using the dual Ethernet. The printer
can only be attached to one of the maxNET. If redundancy is required a second
printer must be used on the other maxNET . If printers are attached in this manner
then a driver utility such as AXIS print server must also be installed.

Remote Processing Units (RPUs)

The Remote Processing Unit (RPU) is the group of equipment that provides the
control, data acquisition, and I/O processing functions for the DCS. The equipment
includes controllers, field I/O interface modules, field terminations, communication
networks, and peripheral equipment such as communications interfaces, power
supplies, and cabinets. The RPU components are shown in Figure 1.2.1.

Distributed Processing Unit

The Distributed Processing Unit (maxDPU4E/F) is the process controller. It is
loaded with a configuration created by the process engineer and executes that
configuration to provide the control and data acquisition functions required. The
maxDPU4E/F can be redundant or stand-alone.

I/O Modules
Rugged, high performance I/O modules provide signal conditioning for signals from
field devices connected to the I/O terminations. There are modules for digital and
analog inputs and outputs as well as other special purpose modules.

Network Switches
Communication with the maxDPU4E/F 's is via redundant Ethernet. Max Control
Systems uses Ethernet switches to connect the maxDPU4E/Fs and workstations
together for communication. Redundant switches are often mounted in the RPU
cabinets to reduce the cable lengths.

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Power Supplies
The power supplies commonly supplied in each maxDNA RPU are a system power
supply, a field transmitter power supply, and a logic (field contact wetting) power
supply.

P
S

P
S

P
S

P
S

P
S

P
S

Fan Tray

Ethernet
Switches

Switch

Fan Tray
Assembly

Switch

DPUs

Power
Supplies

D I
P /
U O

I
/
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I
/
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I
/
O

I
/
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I
/
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I
/
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D I
P /
U O

I
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I
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I
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I
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O

I
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I
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I
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I
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I
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I
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Field Wiring
Terminations

Figure 1.1.2 Remote Processing Unit Components

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I/O Modules

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MODULE 1: maxDNA FUNCTIONS & FEATURES

RPU Components
Model PDP Distributed Processing Unit

Figure 1.2.3 Model PDP Distributed Processing Unit

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DPU Functionality
The DPU provides the following functions for the MAX 1000 + PLUS Distributed
Control System:

P
S

P
S

P
S

P
S

P
S

P
S

DPU Functions:

I/O

I/O

D
P
U

I/O

I/O

I/O

I/O

D
P
U

I/O

I/O

I/O

I/O

I/O

I/O

I/O

I/O

1. Perform control and

data acquisition
functions
2. Control I/O Bus and
I/O Modules
3. External device
communications

Figure 1.1. 1.2.4 - Distributed Processing Unit

Master of I/O bus

Up to 60 I/O modules per maxDPU4E/F without using BEMs
Up to 256 I/O addresses per maxDPU4E/F
Analog and Digital I/O Buffering
I/O alarming
Input hardware failure (open TC, transmitter fail)
Hi, Lo
I/O communications failure

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Execution of all control and data acquisition functions including

Control Functions (PID, Steam Power, etc)

Data Acquisition Functions (Analog and Digital Input/Output etc)
Comprehensive process alarming

Hi, Lo, Hi-Hi, Lo-Lo, Deviation

Rate-of-Change, Rate-of-Change output value clamps
Adjustable hysteresis for value alarms
Alarm after time delay
Automatic acknowledge on clear, re-alarm after time delay, return-to-normal
alarm
Control interlock capabilities
Cascaded control
Forceback signal
External override
M/A Station
Manual via interlock
Automatic by interlock or operator
Cascade by interlock or operator
First out detection
External device communications
One external communications link to PLCs, etc.
Redundant maxNET

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WORKSHOP 1.1.1 maxSTATION COMPONENTS

OBJECTIVE
To familiarize the student with the Hardware associated with the maxDNA
system.

PREREQUISITES
None

PROCEDURE
A. In this workshop the student will examine the hardware components of the maxDNA
maxSTATION. Please note the location and ease or difficulty associated with
component replacement.
1. ____ Examine the front of the maxSTATION cabinet and note the following.
a. ____ Power ON/OFF switch.
b. ____ Power on indicator.
c. ____ Hard disk activity indicator.
d. ____ Floppy drive.
e. ____ CD ROM drive and the CD tray open/close button.
2. ____ Examine the rear of the maxSTATION cabinet and note the following.
a. ____ Power ON/OFF switch.
b. ____ Power cable connection.
CAUTION
When working on the maxSTATION hardware, you should maintain
a good ground connection to prevent any Electrostatic Discharge
Damage (ESD). If you were not near a good grounding source, then
any attempt to use a wrist strap on the frame of the processor with
the power cord removed would be useless. The power ground will
provide an adequate ground source to prevent ESD damage. You
should be aware that an additional safety hazard would be present
due to the continued application of a power source.

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c. ____
d. ____
e. ____
f. ____
g. ____

Monitor cable.
Keyboard cable.
Mouse/Trackball cable.
Ethernet cables there should be two of these.
There may be a printer cable attached to the maxSTATION.

B. Examine the other components that allow the maxSTATION its functionality.
1. ____ The Monitor
a. ____ Power connection.
b. ____ On/Off switch.
c. ____ Intensity adjustment.
d. ____ Contrast adjustment.
e. ____ Degauss push button/adjustment.
2. ____ The Keyboard.
a. ____ Operators Keyboard.
b. ____ QWERTY or Engineers Keyboard.
c. ____ The Mouse/Trackball connections.
C. Logoff of Windows XP
1. ____ Press Ctrl-Alt-Delete to bring up the Windows XP Security pop-up. This box
shows the present user, the date and time logged on, and has six control
buttons: Lock, Workstation, Logoff, Shut Down, Change
Password, Task Manager, and Cancel. Click Logoff to log off the
workstation without shutting down.

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2. ____ Move the pointer to the lower left corner of the screen and click Startand
Shut Down.The Shut Down Windows pop-up will appear.

Figure 1.1.5 Windows XP Shut Down Windows Pop-up

3. ____ Click on the down arrow and select the Shut down the computer?text and
then click OK. This will shut down the computer just as if Shut Downhad
been selected in the Windows XP Security pop-up in Step 1. A Shut down can
also be performed at the Logon Information pop-up by clicking on Shut
Down.
4. ____ Power off the maxSTATION with the power off button on the front panel or
use the power off switch on the back of the unit.
D. Examine the components inside of the maxSTATION case.
1. ____ Remove the screws from the back of the maxSTATION case.
2. ____ Slide the case toward the back of the unit several inches and then lift the right
panel of the case straight up to remove it from the unit.
WARNING
Do not remove the power cord from the maxSTATION. You
must be careful when probing the inside of the case because of
the presence of AC voltage. There is a potential shock hazard.
The power cord connection is used to provide a ground to
prevent Electrostatic Discharge damage.

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CAUTION
Be sure to wear an ESD wrist strap whenever you are probing inside
of the maxSTATION case.
3. ____ Examine the Motherboard.
a. ____ Locate the Ram location on the motherboard.
b. ____ Can you determine how much RAM is installed in the maxSTATION
by observation? ________________________
c. ____ Locate the Processor Chip on the motherboard.
d. ____ Can you determine which processor is installed on this motherboard?
_____________________________________
e. ____ Notice the different types of adapter slots on the motherboard.
f. ____ Do you know the designations for these slots? ________
________________________________________________
g. ____ What types of adapters are installed in these slots? ___________
________________________________________________
h. ____ Take note of how the motherboard is attached to the case.
4. ____ Examine the Floppy disk drive.
a. ____ Notice the presence of a red stripe on the flat cable attached to the
floppy drive.
b. ____ Where does the floppy drive cable get terminated? _____________
________________________________________________
c. ____ How is the floppy drive attached to the case? _________________
________________________________________________
d. ____ If you needed to change the floppy drive, how would you proceed?
_______________________________________________________
_____________________________________________________
5. ____ Examine the Hard Disk drive.
a. ____ Notice the presence of a red stripe on the flat cable attached to the
hard disk drive.
b. ____ Locate the other end of the hard drive cable.
c. ____ Where does it terminate? _________________________________
d. ____ What do you think the red stripe on the cable indicates?
6. ____ Examine the CD ROM drive.

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a. ____ Notice the presence of a red stripe on the flat cable attached to the
CD ROM drive.
b. ____ Locate the other end of the drive cable.
c. ____ Where does it terminate? _________________________________
d. ____ Why do you think the Floppy, Hard Disk, and CD-ROM drives
terminate on the motherboard? ____________________________
_______________________________________________________
_____________________________________________________
E. Restore the maxSTATION.
1. ____ Replace the cover on the maxSTATION case. Be careful when placing the
cover back on the case that the tabs on the sides of the case go back into the
proper position. Hold the case near the front bottom on both sides and slide it
into its final position. Replace the two screws that hold the sides of the case to
the rest of the assembly.
F. Logon to Windows XP
1. ____ Turn on power to the maxSTATION computer and monitor. As the computer
boots, Windows XP displays the following text message at the bottom of the
screen. For Trouble Shooting or Advanced startup options for Windows XP
press F8. Pressing the <F8> key will select this option and give you the
following display. If no key is pressed, the system will continue to Boot in the
normal fashion.
Windows XP Advanced Options Menu
Please select an option:
Safe Mode
Safe Mode with Networking
Safe Mode with Command Prompt
Enable Boot Logging
Enable VGA Mode
Last Known Good Configuration
Directory Services Restore Mode (Windows XP domain controllers only)
Boot Normally
Use and arrow to move the highlight to your choice
Press <Enter> to choose

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2. ____ When the computer has finished booting, it displays the Windows XP logo
screen and the Begin Logon pop-up. Press <Ctrl> + <Alt> + <Delete> to bring
up the Logon Information pop-up.
Note
Do not worry about loosing your work when you press Ctrl-AltDelete in Windows XP. It does not reboot the computer, rather, it
invokes a portion of the Windows XP security system that allows
you to log on and log off.
3. ____ At the Logon Information pop-up, click the account name engineer(without
the quotation marks), click in the password dialog box and enter the password
engineer.
Note
Passwords in Windows XP are case sensitive; thus class0 and
Class0are different passwords. On the other hand, account names
are not case sensitive, so that CLASS0and class0are the same
account.
This concludes Workshop 1.1.1

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WORKSHOP 1.1.2 maxNET COMPONENTS

OBJECTIVE
To familiarize the student with the Hardware associated with the MAXdna
MAXnet.

PREREQUSITES
None

PROCEDURE
A. In this workshop the student will examine the hardware components of the maxDNA
maxNET. Please note the location and ease or difficulty associated with component
replacement.
1. ____ Examine the Frame Switch and note the following.

Figure 1.1.6 Rear view of the Cisco Catalyst 1900 switch.

a. ____
b. ____
c. ____
d. ____

The RJ45 connectors attached to the different ports.

The LEDs associated with the individual ports.
The port select switch.
What function do you think the port select switch supports? _____
_______________________________________________________
e. ____ The console D connector. How could this be used? ____________
_______________________________________________________
_______________________________________________________
2. ____ Examine an Ethernet cable.
a. ____ How many conductors are there in this cable? __________________
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b. ____ Notice that the RJ45 connector is larger than the standard telephone
connector.
c. ____ Do you notice any capability for coax connections? ____________
d. ____ Could we use a Frame Switch for a Fiber Optic connection? _____
3. ____ Examine a HUB assembly and take note of the following.
a. ____
b. ____
c. ____
d. ____

The type and number of cable connectors. ___________________

The power source.
The 10BASE2 cable connector.
How many devices are attached to each of the RJ45 connectors?
_______________________________________________________
e. ____ What do you think is the purpose of the HUB? ______________
_______________________________________________________
_______________________________________________________

This concludes Workshop 1.1.2

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WORKSHOP 1.1.3 RPU COMPONENTS

OBJECTIVE
To familiarize the student with the Hardware associated with the maxDNA
Remote Processing Unit (RPU).

PREREQUISITES
None

PROCEDURE
A. In this workshop the student will examine the hardware components of the maxDNA
Remote Processing Unit (RPU). Please note the location and ease or difficulty
associated with component replacement.
1. ____ From the front of the RPU cabinets open the door and note the following.

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Figure 1.1.7 The RPU Cabinet Assembly

a. ____ At the top of the cabinet note the Frame and Power supply
assemblies. These supply the 24vdc necessary to operate the DPU
and the 564 I/O modules or maxPAC modules.
b. ____ The power supplies are modular in that you can add to or delete from
the total number supplies.
c. ____ The power supplies run in parallel with one another.
d. ____ Below the power supply assembly is a fan tray assembly.
e. ____ Can you ascertain the power source of the fans used in this assembly?
_____________________________________________
f. ____ Below the Fan Tray assembly is located the maxNET switches.
g. ____ Below the switches are a number maxpac assemblies.
h. ____ Note the DPUs on the left side of the backplane.
i. ____ At the front of the DPU assembly are the ethernet cable connections.
j. ____ The rest of the backplane is populated with maxpac I/O modules as
well as subsequent maxpac backplane assemblies.
k. ____ Note the cable on the right side of the backplane, which ties the
maxpac assemblies together at the parallel bus.

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2. ____ Open the door at the back of the RPU cabinet and note the following.
a. ____
b. ____
c. ____
d. ____

At the top of the cabinet is the power supply assembly rack.

Note the type of terminators associated with the 24vdc supplies.
The next item down was the switch assemblies.
Observe the connections for the Ethernet cables which will allow the
RPU communications capability with the rest of the maxDNA
system.
This concludes Workshop 1.1.3

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MODULE ONE
maxDNA maxDPU4E/F BASED
FUNCTIONS AND FEATURES ..................................... 1
maxDNA SYSTEM ARCHITECTURE ........................................ 2
maxDNA Connectivity......................................................................................... 3
Workstation Components .................................................................................... 3
Printers ................................................................................................................ 5
Remote Processing Units (RPUs)......................................................................... 5
RPU Components ................................................................................................ 7
Model PDP Distributed Processing Unit .............................................................. 7
WorkSHOP 1.1.1 maxSTATION COMPONENTS ........................................ 10
WorkSHOP 1.1.2 maxNET COMPONENTS ................................................. 16
WorkSHOP 1.1.3 RPU COMPONENTS ........................................................ 18