FSC Safety Manager

Installation Guide
for use with the Honeywell FSC System
Releases 42x and 500

FS20-500
.
 Implementation
FSC Safety Manager

FSC Safety Manager

Installation Guide
for use with the Honeywell FSC System
Releases 42x and 500

FS20-500
02/98
 Copyright, Notices, and Trademarks

© Copyright 1998 by Honeywell Inc.

Revision 04 – February 20, 1998

While this information is presented in good faith and believed to be accurate,

Honeywell disclaims the implied warranties of merchantability and fitness for a
particular purpose and makes no express warranties except as may be stated in
its written agreement with and for its customer.
In no event is Honeywell liable to anyone for any indirect, special or consequential
damages. The information and specifications in this document are subject to
change without notice.

TotalPlant, TDC 3000 and Universal Control Network are U.S. registered
trademarks of Honeywell Inc.
FSC is a trademark of Honeywell Safety Management Systems.
Other brand or product names are trademarks of their respective owners.

Honeywell
Industrial Automation and Control
Automation College
2820 West Kelton Lane
Phoenix, AZ 85023
(602) 313-5669

ii FSC Safety Manager Installation Guide 02/98

 About This Publication

This publication includes both general and detailed installation information for the various major
components of the FSC Safety Manager (FSC-SM) for use with the Honeywell FSC system
Releases 42x and 500. Specifically included are:

• general installation instructions for the FSC Safety Manager (FSC-SM) system,
• detailed installation instructions for installing the FSC Safety Manager Module (FSC-SMM),
and
• general installation instructions for the FSC-SM system.

Site planning information is contained in the TotalPlant Solutions (TPS) System Site Planning
Manual, which is in the System Site Planning binder. After installation of the FSC-SM, the
checkout procedure can be found in the FSC Safety Manager Service Manual, which is in this
binder.

This publication supports TotalPlant® Solutions (TPS) System network Releases 530 and 531.
TPS is the evolution of TDC 3000X.

All references in this manual to "FSC Safety Manager" or "FSC Safety

Manager Module" pertain only for use with the Honeywell FSC system.

02/98 FSC Safety Manager Installation Guide iii

iv FSC Safety Manager Installation Guide 02/98
 Table of Contents

SECTION 1 – FSC SAFETY MANAGER SYSTEM INSTALLATION.................................................1

1.1 Section Overview ..........................................................................................................1
1.2 Equipment Warehousing ..............................................................................................2
1.3 Move Preparation..........................................................................................................3
1.4 Unpacking and Placement..........................................................................................13

SECTION 2 – SYSTEM COMPONENT INSTALLATION.................................................................21

2.1 Section Overview ........................................................................................................21
2.2 Installation Considerations..........................................................................................22
2.3 Cabinet Installation .....................................................................................................23
2.4 Cabling Considerations...............................................................................................24
2.5 Cabling Installation......................................................................................................29
2.6 System Power Connections........................................................................................34
2.7 System Ground Connections ......................................................................................36
2.8 UCN Connections .......................................................................................................39

SECTION 3 – SYSTEM COMPONENT CONFIGURATION.............................................................43

3.1 Section Overview ........................................................................................................43
3.2 System Configuration Overview..................................................................................44
3.3 Module Configuration..................................................................................................45

SECTION 4 – CONFIGURATION .....................................................................................................47

4.1 Section Overview ........................................................................................................47
4.2 Configuration at FSC User Station..............................................................................48
4.3 Configuration at TPS Universal Station ......................................................................49

02/98 FSC Safety Manager Installation Guide v

 Figures

Figure 1-1 Typical Electronics Room Layout .............................................................................. 3

Figure 1-2 Location and dimensions of the cabinet bolt-down holes.......................................... 6
Figure 1-3 FSC-SM cabinet with back access (FTA-T).............................................................. 7
Figure 1-4 FSC-SM cabinet with front access (FTA-T) .............................................................. 8
Figure 1-5 FSC-SM cabinet with front and back access (FTA-T)............................................... 9
Figure 1-6 FSC-SM cabinet with front access (FTA-E) ............................................................ 10
Figure 1-7 FSC-SM cabinet with back access (FTA-E)............................................................ 11
Figure 1-8 FSC-SM cabinet with front and back access (FTA-E) ............................................ 12
Figure 1-8 Placement of equipment onto lumber ..................................................................... 14
Figure 1-9 Placement using a mobile lifter ............................................................................... 16
Figure 1-10 Lifting equipment by mobile lifter of crane............................................................... 17
Figure 1-11 Lifting equipment by mobile lifter of crane — part 2................................................ 18
Figure 1-12 Eyebolt crane method ............................................................................................. 19
Figure 2-1 FSC-SMM front plate............................................................................................... 29
Figure 2-2 Redundant FSC-SM UCN cabling........................................................................... 30
Figure 2-3 Typical routing layout of internal wiring between I/O modules and
FTA-T via SICs........................................................................................................ 31
Figure 2-4 Typical routing layout of internal wiring between I/O modules and
FTA-E via SICs........................................................................................................ 32
Figure 2-5 FSC Safety Manager cabinet power connections ................................................... 34
Figure 2-6 Connection of the UCN ........................................................................................... 40
Figure 4-1 US System Status display ....................................................................................... 51
Figure 4-2 US Engineering Main Menu display ........................................................................ 52
Figure 4-3 US NIM Build Type Select Menu............................................................................. 53
Figure 4-4 US UCN Node Configuration display ...................................................................... 54
Figure 4-5 US Node-Specific Configuration display ................................................................. 55
Figure 4-6 US Process Point Building display .......................................................................... 56

vi FSC Safety Manager Installation Guide 02/98

 Tables

Table 1-1 Move preparation checklist........................................................................................4

Table 1-2 Move preparation checklist – part 2...........................................................................5
Table 1-3 Important unpacking considerations........................................................................13
Table 1-4 Fork lift considerations.............................................................................................14
Table 1-5 Mobile lifter considerations ......................................................................................15
Table 1-6 Roller method considerations ..................................................................................18
Table 2-1 FSC system installation checklist ............................................................................22
Table 2-2 Raceway shielding ...................................................................................................24
Table 2-3 IEEE 518 wiring classification definitions.................................................................25
Table 2-4 Tray spacing ............................................................................................................26
Table 2-5 Tray/conduit spacing................................................................................................26
Table 2-6 Conduit spacing .......................................................................................................27
Table 2-7 Cabling guidelines ...................................................................................................28
Table 2-8 System grounding considerations............................................................................36
Table 4-1 Start-up and reconfiguration procedures .................................................................49
Table 4-2 UCN configuration ...................................................................................................50
Table 4-3 UCN node configuration ..........................................................................................53
Table 4-4 FSC-SMM data point configuration procedure ........................................................57

02/98 FSC Safety Manager Installation Guide vii

 Acronyms

AC ...........................................................................................................................Alternating Current
CP ......................................................................................................................................Central Part
CPU...................................................................................................................Central Processor Unit
DBM ..................................................................................................... Diagnostic and Battery Module
DC ...................................................................................................................................Direct Current
DCS............................................................................................................ Distributed Control System
EMI ..........................................................................................................Electromagnetic Interference
EPROM ..........................................................................Erasable Programmable Read-Only Memory
ESD .................................................................................................................. Electrostatic Discharge
FLD............................................................................................................... Functional Logic Diagram
FSC ............................................................................................................................ Fail Safe Control
FSC-DS .......................................................................................................FSC Development System
FSC-SM............................................................................................................... FSC Safety Manager
FSC-SMM................................................................................................FSC Safety Manager Module
FTA........................................................................................................... Field Termination Assembly
HM................................................................................................................................. History Module
I/O...................................................................................................................................... Input/Output
IEEE .............................................................................Institute of Electrical and Electronic Engineers
LCN ....................................................................................................................Local Control Network
LED .......................................................................................................................Light Emitting Diode
NCF .............................................................................................................Network Configuration File
NIM...............................................................................................................Network Interface Module
PLC ..................................................................................................... Programmable Logic Controller
SIC ........................................................................................................ System Interconnection Cable
SM ................................................................................................................................Safety Manager
SMM ................................................................................................................Safety Manager Module
TAC ......................................................................................................... Technical Assistance Center
TPS .........................................................................................................................TotalPlant Solution
TTL ........................................................................................................... Transistor - Transistor Logic
UCN............................................................................................................. Universal Control Network
US ..............................................................................................................................Universal Station
VBD ......................................................................................................................... Vertical Bus Driver
WD ........................................................................................................................................Watchdog

viii FSC Safety Manager Installation Guide 02/98

 References

For FSC-SM documentation:

Publication Publication Binder Binder

Title Number Title Number
FSC Safety Manager Installation FS20-500 Implementation TPS 3076
Guide FSC Safety Manager
FSC Safety Manager Implementation FS11-500 Implementation TPS 3076
Guidelines FSC Safety Manager
FSC Safety Manager Control FS09-500 Implementation TPS 3076
Functions FSC Safety Manager
FSC Safety Manager Parameter FS09-550 Implementation TPS 3076
Reference Dictionary FSC Safety Manager
FSC Safety Manager Configuration FS88-500 Implementation TPS 3076
Forms FSC Safety Manager
FSC Safety Manager Service Manual FS13-500 Implementation TPS 3076
FSC Safety Manager

For FSC documentation:

Publication Publication
Title Number
FSC Safety Manual [Link].8047
FSC Hardware Manual [Link].8048
FSC Software Manual [Link].8025

02/98 FSC Safety Manager Installation Guide ix

x FSC Safety Manager Installation Guide 02/98
 Section 1 – FSC Safety Manager System Installation
1.1 Section Overview

About this section This section provides general installation information for the FSC Safety
Manager (FSC-SM) system. Topics included in this section are:

Subsection Topic See Page

1.1 Section Overview.........................................................................................1

1.2 Equipment Warehousing .............................................................................2
1.3 Move Preparation ........................................................................................3
1.4 Unpacking and Placement ........................................................................13

Tools and test The following equipment is necessary for installation of the FSC Safety
equipment Manager:
• Mobile lifter/lift truck — refer to Subsection 1.4 (Unpacking and
Placement),
• Carrier band MAP tester — refer to Subsection 2.2 (Installation
Considerations),
• Hand tools and multimeter, as in a typical electrician's tool kit,
• UCN Connector Torque Wrench Kit (51109612-100),
• Set of SAE (inch) "crow's foot" wrenches for the above torque wrench,
• ESD kit (Honeywell part number 30185-H).

ATTENTION Installation of the FSC Safety Manager may only be

carried out by qualified and authorized personnel. Failure to comply with
the regulations and recommendations contained in this document may
cause severe damage to the equipment or serious injury to people.

REFERENCE — For detailed information regarding

• site planning and installation, refer to SM02-550 TPS System Site
Planning Manual in Binder TPS 3020-1 System Site Planning-1.
• post-installation checkout procedures, refer to the FSC Safety Manager
Service Manual in this binder.

02/98 FSC Safety Manager Installation Guide 1

1.2 Equipment Warehousing

Factory packing For shipment, the FSC Safety Manager is packed with desiccant packages,
wrapped in a moisture barrier and optionally enclosed for shipment as
required by the user.

Transit/warehousing The FSC Safety Manager can be shipped by a variety of means, but any
specifications trucking should be done by enclosed air-ride vans. The equipment is
usually trucked on the final leg of the journey to the user warehouse or
site. There it is stored off the ground on a solid piece or combination of
lumber pieces (minimum height 10 cm / 4 in) and indoors until needed for
installation. During the whole process, the environment must be
monitored and corrected if the following equipment transit/storage ratings
are exceeded:
• Temperature range: –20°C to +70°C (–4°F to +158°F)
• Relative humidity: 5% to 95%, non-condensing
• Vibration: 1 G, frequency 10-150 Hz (IEC 68-2-6)
• Shock: 15 G for 11 ms (IEC 68-2-27)

ATTENTION In order to minimize exposure to humidity, keep the

factory wrapping intact during storage and transit. If it is necessary to
unseal the equipment for customs or receiving, add more desiccant and
reseal the package.

2 FSC Safety Manager Installation Guide 02/98

1.3 Move Preparation

Background Several basic points need to be kept in mind when planning the movement
and unpacking of FSC Safety Manager cabinets. They include the
following:
• A single FSC Safety Manager cabinet is nominally 80 x 80 x 200 cm
(31½ x 32½ x 78¾ inches),
• Lifting eye bolts, which are removable, add about 5 cm (2 inches) to the
height, and
• Weight varies with options and can go as high as 385 kg (850 lb) per
cabinet.

As illustrated in Figure 1-1, a typical factory-assembled complex uses up

to four such cabinets bolted together.

Figure 1-1 – Typical Electronics Room Layout

0-30 V 30-250 V
Terminal Panel Terminal Panel

4 ft (1.25 m) Note:
Min. Typical Control Cabine ts These cabinets
are standard width,
but are 21.75 inches
54 in (1.37 m) (55 cm) deep.
(Reference)

Control Cabine ts

Single-Access Control Cabinets

Expansion Area

Power Distribution
Panel

Utility Room,
Maintenance Change House,
Equipment Lunchroom, Etc.

Continued on next page

02/98 FSC Safety Manager Installation Guide 3

1.3 Move Preparation, Continued

Checklist Table 1-1 provides a checklist to be used when planning the movement of
FSC Safety Manager cabinets.

Table 1-1 – Move preparation checklist

Check Action Notes
1 Travel Route Chart the equipment's route of travel regarding:
• loading doors — height and location,
• elevators — size, capacity, and availability,
• aisles — number, size, and layout,
• doorways — number and size,
• hallways — size, restrictions, and bends,
• stairs and ramps — may require some type of
lifting, and
• rigging of equipment — if needed.
2 Space Is there enough space to hold the equipment?
3 Floor Loading Will the floor in all areas be strong enough?
4 Power Distribution Check for proper transformer sizes, distribution
panels and sufficient outlets for support, test and
maintenance equipment.
5 Grounding Be sure that proper grounds are available.
6 Conduits and Make sure that conduits and cable trays are
Cable Trays large enough and the proper type to
accommodate all of the required cables.
7 Environment Are lighting and other environmental
requirements adequate?
8 Security Provide security clearances for the installation
crew if it is not composed of regular employees.
9 Responsibilities Are all responsibilities clearly defined and
understood?
10 Communications At minimum, three conveniently located
telephones are needed for:
• Honeywell Technical Assistance Center (TAC)
data terminal,
• Honeywell TAC voice, and
• Operator Emergency.

For additional information regarding actions described in the

Move Preparation Checklist, refer to SM02-550 — TPS System Site
Planning Manual in the Binder TPS 3020-1 System Site Planning-1.

4 FSC Safety Manager Installation Guide 02/98

1.3 Move Preparation, Continued

Preparation Table 1-2 provides a checklist to be used when preparing the electronics
room for the FSC Safety Manager cabinets.

Table 1-2 – Move preparation checklist – part 2

Check Action Notes
1 Static Electricity Reduce the ESD-borne failures by:
• stripping the floors of any wax to prevent
static charge buildup,
• using anti-static spray on floors, furniture and
fabric in the work area, and
• placing a sign on or near the equipment that
states circuit boards are not to be handled
without wearing a ground strap.
2 Tack Rugs Placed at all entrances, tack rugs catch dust, grit
and abrasives from other areas.
3 Fire Prevention Consult with the local fire prevention authority to
select fire extinguishers suitable for electrical
fires.
4 Room Layout Prepare an electronics room layout diagram for
cabinet placement.
• Refer to Figure 1-1.
5 Cabinet If this FSC Safety Manager cabinet is to be
Bolt-Down bolted down, pre-drill holes in the floor.
ATTENTION Refer to Figure 1-2 for
placement and dimensions of the bolt-down
holes.

Continued on next page

02/98 FSC Safety Manager Installation Guide 5

1.3 Move Preparation, Continued

Bolt-down holes Figure 1-2 provides the exact locations and dimensions of the cabinet
bolt-down holes.

Figure 1-2 – Location and dimensions of the cabinet bolt-down holes

25 mm (0.98")
REAR

Bolt-down hole
750 mm (29.53")
700 mm (27.57")

diameter:
14 mm (0.55")

100 mm (3.94") 600 mm (23.62") 100 mm (3.94")

800 mm (31.50")

FRONT

TOP VIEW

Continued on next page

6 FSC Safety Manager Installation Guide 02/98

1.3 Move Preparation, Continued

Cabinet entry The process signal cables can enter the FSC Safety Manager cabinet
through the top or bottom of the cabinet. The FSC-SM cabinet is prepared
for field termination assembly to interface boards (FTA-E) or terminals
(FTA-T). These interface boards or terminals may be located in the
FSC-SM cabinet or in cross-wiring cabinets next to the FSC-SM cabinet.
Figures 1-3 through 1-8 illustrate the placement and dimensions for
process wiring for FTAs located in the FSC-SM cabinet.

The FSC-SM cabinet is also prepared for top or bottom entry as per user
specification. For bottom entry, sliding floor plates are provided which can
be adjusted to provide entry slots. For top entry, one sliding plate is
provided which can be adjusted to provide entry slots. For top or bottom
entry, the cables should be clamped firmly to the cabinet. The clamping
devices should be able to withstand a 45 kg (100 lb) pull. This prevents
damage inside the cabinet when pulling on cables outside the cabinet.

The FSC-SM cabinet includes a cable clamp rail at the bottom or at the
top.

Figure 1-3 illustrates an FSC-SM cabinet bottom configured for back

access of the I/O field cables with FTA-T.

Figure 1-3 – FSC-SM cabinet with back access (FTA-T)

FTA-T REAR

Field cable duct

FSC I/O mounting rack

Turning point
swing frame

FRONT

TOP VIEW

Continued on next page

02/98 FSC Safety Manager Installation Guide 7

1.3 Move Preparation, Continued

Cabinet entry, Figure 1-4 illustrates an FSC Safety Manager cabinet bottom configured
continued for front access of the I/O field cables with FTA-T.

Figure 1-4 – FSC-SM cabinet with front access (FTA-T)

Field cable duct REAR

FTA-T

FSC I/O mounting rack

Turning point
swing frame

FRONT

TOP VIEW

Continued on next page

8 FSC Safety Manager Installation Guide 02/98

1.3 Move Preparation, Continued

Cabinet entry, Figure 1-5 illustrates an FSC Safety Manager cabinet bottom configured
continued for front and back access of the I/O field cables with FTA-T.

Figure 1-5 – FSC-SM cabinet with front and back access (FTA-T)

FTA-T REAR

Field cable duct

FSC I/O mounting rack

Turning point
swing frame

FRONT

TOP VIEW

Continued on next page

02/98 FSC Safety Manager Installation Guide 9

1.3 Move Preparation, Continued

Cabinet entry, Figure 1-6 illustrates an FSC Safety Manager cabinet bottom configured
continued for front access of the system cables with FTA-E.

Figure 1-6 – FSC-SM cabinet with front access (FTA-E)

FTA-E REAR System cables

Field cable tray

FSC I/O mounting rack

Turning point
swing frame

FRONT

TOP VIEW

Continued on next page

10 FSC Safety Manager Installation Guide 02/98

1.3 Move Preparation, Continued

Cabinet entry, Figure 1-7 illustrates an FSC Safety Manager cabinet bottom configured
continued for back access of the system cables with FTA-E.

Figure 1-7 – FSC-SM cabinet with back access (FTA-E)

FTA-E REAR

Field cable tray

System cables

FSC I/O mounting rack

Turning point
swing frame

FRONT

TOP VIEW

Continued on next page

02/98 FSC Safety Manager Installation Guide 11

1.3 Move Preparation, Continued

Cabinet entry, Figure 1-8 illustrates an FSC Safety Manager cabinet bottom configured
continued for front and back access of the system cables with FTA-E.

Figure 1-8 – FSC-SM cabinet with front and back access (FTA-E)

FTA-E REAR System cables

Field cable tray

FSC I/O mounting rack

Turning point
swing frame

FRONT

TOP VIEW

12 FSC Safety Manager Installation Guide 02/98

1.4 Unpacking and Placement

Unpacking Unpack the equipment, check the shipment against the invoice, and
immediately notify your Honeywell representative if any items are
missing. Table 1-3 lists important considerations when unpacking the
equipment.

Table 1-3 – Important unpacking considerations

IF … THEN …

the FSC Safety Manager system is the component parts are packaged in
comprised of individual modules labeled boxes.

the package has visual damage the equipment inside may also be
damaged.

the package is removed and inform the insurance company and

equipment has visual damage your Honeywell representative. In any
case, do not operate the equipment
until confirmation from Honeywell
Safety Management Systems has
been obtained.

Moving The FSC Safety Manager equipment can be moved in any one of four
methods:
• fork lift,
• mobile lifter,
• roller, or
• crane.

Special consideration for each of these methods is provided in the

following information.

CAUTION When moving the FSC Safety Manager equipment:

• use lifters with a capacity of 1100 kg (2500 lb) or greater, and
• do not tilt the cabinet more than 45º front or back to avoid damaging
the doors (they are not recessed).

Continued on next page

02/98 FSC Safety Manager Installation Guide 13

1.4 Unpacking and Placement, Continued

Fork lift The FSC-SM cabinet is moved by fork lift to the final location. Table 1-4
lists special considerations regarding the use of a fork lift to move the
equipment.

Table 1-4 – Fork lift considerations

Number Consideration

1 Move the equipment to the electronics room by fork lift; remove the
fork lift by placing the equipment onto the lumber pieces by 10 cm
(4 inches) as illustrated in Figure 1-9.

2 Tip the cabinet off the lumber and onto the floor; remove the lumber.

3 Manually move the cabinet to the exact final position.

Figure 1-9 – Placement of equipment onto lumber

Solid piece or combination

of lumber pieces to match skid
or pallet height (nail together).

Move cabinet onto the lumber.

Continued on next page

14 FSC Safety Manager Installation Guide 02/98

1.4 Unpacking and Placement, Continued

Mobile lifter As illustrated in Figure 1-7, the FSC Safety Manager is placed on a
transport skid made from angle iron. It is then moved with a mobile lifter.
Table 1-5 lists special considerations regarding the use of a mobile lifter to
move the equipment.

Table 1-5 – Mobile lifter considerations

Number Consideration

1 Tilt the equipment slightly and slide one of the angle irons used to
make up a transport skid underneath the cabinet as in Figure 1-10.

2 Repeat the above step for the other angle.

3 Insert a strip of heavy cardboard between each angle iron and the
equipment finish.

4 Tighten the angle irons against the cabinet by tapping slightly.

5 Insert and tighten two 12 mm (0.5 in) minimum, threaded cross rods
as in Figure 1-10 and Figure 1-11.

6 Spread the lifter forks to 80 cm (31.5 in) centers and put them under
each cross rod. Place the fork's dowels between the cross rods and
the cabinet, just touching the cross rods.

7 Place wooden spacer blocks along the forks, long enough to press
the cross rods against the fork dowels.

8 Position a protective plate using braces as in Figure 1-10. Be sure

that the plate does not press against handles or other cabinet
hardware.

9 Raise both lifter forks evenly until the equipment clears the shipping
skid; pull it out of the way.

10 Wheel the equipment to the final position in the electronics room;

lower it to the floor.

11 Pull out the mobile lifters. Dismantle and remove the angle iron
transport skid.

12 Manually place the cabinet in the exact final position.

Continued on next page

02/98 FSC Safety Manager Installation Guide 15

1.4 Unpacking and Placement, Continued

Mobile lifters, Figure 1-10 – Placement using a mobile lifter

continued

Wooden brace and

protective plate

Hydraulic
jack

Fork dowel

Cross rod
Equip ment
2" x 4"
Spacer block
Mobile lifter
(2 req'd)

Angle iron
transport skid

Continued on next page

16 FSC Safety Manager Installation Guide 02/98

1.4 Unpacking and Placement, Continued

Mobile lifters,
continued

Figure 1-11 – Lifting equipment by mobile lifter of crane

Spreader

1.25 cm (0.5 in) (minimum)

Angle iron threaded cross rods with nuts
support

Continued on next page

02/98 FSC Safety Manager Installation Guide 17

1.4 Unpacking and Placement, Continued

Roller method As illustrated in Figure 1-12, using the roller method the FSC Safety
Manager is moved to its final destination by placing pipe rollers under a
transport skid made of angle iron. Table 1-6 lists special considerations
regarding the use of the roller method to move the equipment.

Table 1-6 – Roller method considerations

Number Consideration

1 Use one of the previous methods to move the cabinet to a location

where rollers are to be used.

2 Install the angle iron transport skid as in the mobile lifter method.

3 Place 12 mm (1/2 inch) pipes under the transport skid as in Figure

1-12.

ATTENTION The load must be on the angle irons, not the

cabinet.

4 Roll the cabinet to its final location.

ATTENTION At least three pipes must be under the transport

skid at all times.

5 When the cabinet is near the final location, tilt it and pull out the
pipes, the middle one last.

6 Dismantle the transport skid and position the cabinet manually to

the exact final location.

Figure 1-12 – Lifting equipment by mobile lifter of crane — part 2

Angle iron
supports

2.5 cm (1 in) pipes (minimum)

Continued on next page

18 FSC Safety Manager Installation Guide 02/98

1.4 Unpacking and Placement, Continued

Crane method In this method the cabinet is lifted into place with a crane. Use either an
angle iron transport skid (see Figure 1-12) or the lifting eyebolts installed
on each cabinet (see Figure 1-13).

Figure 1-13 – Eyebolt crane method

x x
One
bay
x x

x x
Two
bays x x

x x
Three
bays
x x

x x
Four
bays x x

Leveling and FSC Safety Manager cabinets do not include levelers; it may be necessary
bolt-down to hand-fit shims underneath the cabinet in order to make the cabinet sit
solidly.

The FSC-SM cabinet has four holes in the bottom for bolting it to a floor.
A partially filled cabinet should be bolted down. Cabinets that are bolted
together are not easily moved and do not ordinarily require bolting down.
Refer to Figure 1-2 for bolt-down dimensions.

02/98 FSC Safety Manager Installation Guide 19

 Left blank intentionally

20 FSC Safety Manager Installation Guide 02/98

 Section 2 – System Component Installation
2.1 Section Overview

About this section This section provides general installation information for various
components of the FSC Safety Manager (FSC-SM) system. Topics
included in this section are:

Subsection Topic See Page

2.1 Section Overview.......................................................................................21

2.2 Installation Considerations ........................................................................22
2.3 Cabinet Installation ....................................................................................23
2.4 Cabling Considerations .............................................................................24
2.5 Cabling Installation ....................................................................................29
2.6 System Power Connections ......................................................................34
2.7 System Ground Connections.....................................................................36
2.8 UCN Connections......................................................................................39

ATTENTION This section describes in detail only those installation

procedures and considerations specific to the FSC Safety Manager Module
(FSC-SMM) and the TotalPlant Solutions (TPS) system. Installation
procedures and considerations specific to the FSC components can be
found in the FSC documentation.

REFERENCE — For detailed information regarding

• site planning and installation, refer to SM02-550 — TPS System Site
Planning Manual in Binder TPS 3020-1 System Site Planning-1.
• post-installation checkout procedures, refer to FS13-500 — FSC Safety
Manager Service Manual in this binder.

02/98 FSC Safety Manager Installation Guide 21

2.2 Installation Considerations

Introduction The FSC Safety Manager system may encompass a single cabinet or a
multi-cabinet complex, or may be delivered without a cabinet.

If your FSC-SM system includes a cabinet or cabinets, then power, ground

and cabling are brought to the system and connected. The system is
configured and installation is complete.

Should your FSC-SM system not include a cabinet or cabinets, the

individual chassis must be mounted to a structure and power and ground
supplied by a choice of methods.

Installation checklist When installing an FSC-SM system, consider the installation checklist as
shown in Table 2-1.

Table 2-1 – FSC system installation checklist

Step Action Done
(✔)

1 Carefully review all documentation available for the equipment,

paying close attention to cautionary notes.

2 Install the FSC-SM equipment in accordance with the

requirements as laid down in the Integration Guidelines for FSC
System cabinets.

3 Use technically qualified personnel to service the FSC-SM

components.

22 FSC Safety Manager Installation Guide 02/98

2.3 Cabinet Installation

Introduction After placement, the cabinet or cabinet complex requires the attachment of
power and ground, and cabling installation.

ATTENTION Refer to Section 1 — FSC Safety Manager System

Installation for information regarding the warehousing, movement,
unpacking and placement of the FSC Safety Manager cabinets.

02/98 FSC Safety Manager Installation Guide 23

2.4 Cabling Considerations

Introduction When installing an FSC Safety Manager System, it is important to

consider:
• conduit and tray shielding and spacing, and
• cable and wire classifications.

Shielding Conduit or cable trays should be used to route the network trunk line
within the plant for short distances or for several miles. The same conduit
should not carry both data and power wiring because of problems created
by electromagnetic interference (EMI). The choice of materials and
configuration for the cable conduit can determine the degree of protection
from this interference.

Table 2-2, showing raceway shielding, is taken from IEEE Standard 518
for the installation of electrical equipment. It compares different types of
conduits and raceways for magnetic field attenuation at 60 Hz and for
electrostatic attenuation at 100 kHz.

Table 2-2 – Raceway shielding

Raceway Thickness 60 Hz Magnetic 100 kHz Magnetic
Type mm (in.) Field Attenuation Field Attenuation

Ratio dB Ratio dB

Free air 1:1 0 1:1 0

2 inch (5 cm) aluminum conduit 3.91 (0.154) 1.5:1 3.3 2.150:1 66.5

#16 gauge aluminum tray 1.52 (0.060) 1.6:1 4.1 15.500:1 83.9

#16 gauge aluminum tray 1.52 (0.060) 3:1 9.4 20.000:1 86.0

#16 gauge galvan. iron tray 1.52 (0.060) 3.2:1 10.0 22.000:1 86.8

2 inch (5 cm) IPS copper pipe 3.96 (0.156) 3.3:1 10.2 10.750:1 80.6

#16 gauge aluminum tray 1.52 (0.060) 4.2:1 11.5 29.000:1 89.3

#14 gauge aluminum tray 1.90 (0.075) 6:1 15.5 23.750:1 87.5

2 inch (5 cm) metallic tubing 1.65 (0.065) 6.7:1 16.5 3.350:1 70.5

2 inch (5 cm ) rigid galvanized

conduit 3.91 (0.154) 40:1 32.0 8.850:1 78.9

Continued on next page

24 FSC Safety Manager Installation Guide 02/98

2.4 Cabling Considerations, Continued

Spacing It is recommended that noise creating sources (those with time varying
voltage or time varying current) be separated from data signal cable.
Cables with similar levels of noise susceptibility should be grouped
together, and those with similar levels of noise generation should be
separately grouped in trays and conduits.

IEEE 518 defines four classes of wiring that differ in signal level and
noise susceptibility as provided in Table 2-3.

Table 2-3 – IEEE 518 wiring classification definitions

Class Definition

Data 1 High noise susceptibility. Analog signals of less than 50 V and

digital signals of less than 15 V.

Data 2 Medium susceptibility. Analog signals greater than 50 V, regulating

signals of 50 V with currents less than 20 A; AC feeders less than
20 A.

Data 3 Low susceptibility. Switching signals greater than 50 V, analog

signals of 50 V with currents less than 20 A; AC feeders less than
20 A.

Data 4 Power AC and DC buses of 0-1000 V with currents of 20-800 A.

ATTENTION Data 3 and Data 4 classes have one subclass each for
applications that require special cable and spacing. Table 2-4, Table 2-5
and Table 2-6 in this section list the subclass for Data 3—listed as Data
3A; the subclass for Data 4 is listed as Data 4A. Examples of Data 3A and
Data 4A subclass cables include:
• signals from communicating fields and line resistors,
• signals from shunts to regulators, and
• power greater than 1000 volts or greater than 800 amperes, or both.

Table 2-4, Table 2-5 and Table 2-6 list the recommended minimum
distances between trays, trays and conduits, and conduits, respectively.
The dimensions provided in the tables are between the top of one
tray/conduit and the bottom of the tray/conduit above, or between sides of
adjacent trays/conduits.
Trays containing Data 1 or Data 2 cables should have solid bottoms and
covers to complete shielding. Ventilation slots or louvers may be used
only in trays containing Data 3 cables.

Continued on next page

02/98 FSC Safety Manager Installation Guide 25

2.4 Cabling Considerations, Continued

Spacing, continued

Table 2-4 – Tray spacing

Cable Data 1 Data 2 Data 3 Data 3A Data 4 Data 4A
Class mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.)
Data 1 Note 2 152.4 (6) 152.4 (6) 660.4 (26) 660.4 (26)
Data 2 Note 2 152.4 (6) 152.4 (6) 457.2 (18) 660.4 (26)
Data 3 152.4 (6) 152.4 (6) 0.0 (0) Note 1 304.8 (12)
Data 3A 152.4 (6) 152.4 (6) 0.0 (0) 203.2 (8) 457.2 (18)
Data 4 660.4 (26) 457.2 (18) Note 1 203.2 (8) 0.0 (0)
Data 4A 660.4 (26) 660.4 (26) 304.8 (12) 457.2 (18) 0.0 (0)

ATTENTION Note the following considerations:

• Note 1:
– Data 3 and Data 4 cables may be run in a common tray but should be
separated by a barrier. This barrier does not have to be grounded.
• Note 2:
– Data 1 and Data 2 cables may be in a common tray, provided they are
separated by a grounded steel barrier.

Table 2-5 – Tray/conduit spacing

Cable Data 1 Data 2 Data 3 Data 3A Data 4 Data 4A
Class mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.)
Data 1 25.4 (1) 101.6 (4) 101.6 (4) 457.2 (18) 457.2 (18)
Data 2 25.4 (1) 101.6 (4) 101.6 (4) 304.8 (12) 457.2 (18)
Data 3 101.6 (4) 101.6 (4) 0.0 (0) 0.0 (0) 203.2 (8)
Data 3A 101.6 (4) 101.6 (4) 0.0 (0) 152.4 (6) 304.8 (12)
Data 4 457.2 (18) 304.8 (12) 0.0 (0) 152.4 (6) 0.0 (0)
Data 4A 457.2 (18) 457.2 (18) 203.2 (8) 304.8 (12) 0.0 (0)

Continued on next page

26 FSC Safety Manager Installation Guide 02/98

2.4 Cabling Considerations, Continued

Spacing, continued

Table 2-6 - Conduit spacing

Cable Data 1 Data 2 Data 3 Data 3A Data 4 Data 4A
Class mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.)
Data 1 25.4 (1) 76.2 (3) 76.2 (3) 304.8 (12) 304.8 (12)
Data 2 25.4 (1) 76.2 (3) 76.2 (3) 228.6 (9) 304.8 (12)
Data 3 76.2 (3) 76.2 (3) 0.0 (0) 0.0 (0) 152.4 (6)
Data 3A 76.2 (3) 76.2 (3) 0.0 (0) 152.4 (6) 228.6 (9)
Data 4 304.8 (12) 228.6 (9) 0.0 (0) 152.4 (6) 0.0 (0)
Data 4A 304.8 (12) 304.8 (12) 152.4 (6) 228.6 (9) 0.0 (0)

Cable, wire and Select the proper cables for each type of system connection. All
conduit selection Programmable Logic Controller (such as the FSC) system wires and
cables can be classified into two categories:
• High level conductors
– used to carry high voltage and/or high current,
– typically IEEE 518 Data 2, Data 3, and Data 4 categories, and
– include AC I/O lines; high level DC I/O lines connected to such
devices as switches, relays, or solenoids; and AC power lines.
• Low level conductors
– used to carry low voltage and/or low current,
– typically IEEE 518 Data 1 category, and
– include communication cables; DC I/O lines connected to solid state
devices such as proximity switches or photoelectric sensors; TTL
signal lines; analog signal lines; encoder signal lines; and motion
control signal lines.

Continued on next page

02/98 FSC Safety Manager Installation Guide 27

2.4 Cabling Considerations, Continued

Cabling and wiring Observe the guidelines presented in Table 2-7 when routing cables to the
guidelines FSC Safety Manager cabinet. Pay special attention to separating data
cables from power cables to avoid electrical noise problems.

Table 2-7 – Cabling guidelines

Consideration Description

1 Maintain a 60°C (140°F), or less, ambient air temperature at the bottom of each FSC
Safety Manager system.

2 Do all wiring according to IEEE Standard 518-1977.

3 Separate all AC and low-level DC wiring. See Table 2-4, Table 2-5 and Table 2-6 for
the recommended minimum distances.

4 Shields of data communications cables must be terminated at both ends. Shields of

analog signal cables must be terminated to ground only at the signal source. If a
termination is not made, or is intermittent, noise immunity is lost.

5 Data and power cables should cross at right angles and not run in parallel for any
distance.

6 Ensure that the entire communications network system is grounded to earth ground.

7 Maintain shield continuity. Ensure that shield leads are not broken.

8 Route cables around rather than through high noise areas.

28 FSC Safety Manager Installation Guide 02/98

2.5 Cabling Installation

REFERENCE — For information regarding general cabling

considerations, refer to Subsection 2.4 — Cabling Considerations.

FSC-SMM cabling Figure 2-1 illustrates the front plate of the FSC Safety Manager Module
(FSC-SMM). Connections to the UCN are made via the two UCN F-style
connectors in the center of the module (A and B).

Figure 2-1 – FSC-SMM front plate


 FSC
TM

STATUS

TX
P

A A
B

10008/2/U

Continued on next page

02/98 FSC Safety Manager Installation Guide 29

2.5 Cabling Installation, Continued

FSC-SMM cabling, Figure 2-2 illustrates the UCN cabling required of a redundant FSC Safety
continued Manager system.

In this case two FSC-SMM modules are installed, one in each Central
Part. RG-6 UCN drop cables are run from the drop ports on UCN A to
UCN A F-style connectors of each FSC-SMM. RG-6 UCN drop cables are
also run from the drop ports on UCN B to UCN B F-style connectors of
each FSC-SMM.

For detailed information on cabling requirements, refer to the

Integration Guidelines for FSC System Cabinets.

Figure 2-2 – Redundant FSC-SM UCN cabling

UCN A RG-11
Honeywell

A
NIM
A
B CP 1 A
A RG-6
B Drop Cables

B
CP 2
A B
B
B

UCN B RG-11

CAUTION Remove the UCN cable from the FSC-SMM port without
breaking UCN cable continuity, or communication will be lost to other
UCN devices.

Continued on next page

30 FSC Safety Manager Installation Guide 02/98

2.5 Cabling Installation, Continued

Power supply wiring ATTENTION For information regarding the wiring of the FSC Safety
Manager card file power supply modules, refer to Subsection 2.7 —
System Power Connections, in this section.

I/O module wiring Field wiring is not connected directly to the I/O modules themselves.
Rather, as illustrated in Figure 2-3 and Figure 2-4, these connections are
made via Field Termination Assemblies (FTAs) available as either an:
• FTA-T (to I/O field cables via terminals), or
• FTA-E (to interface board via system cables).
The FTAs are electrically passive devices which simply pass incoming or
outgoing signals between the field and the I/O module.
Figure 2-3 illustrates a typical routing layout of the internal wiring
between I/O modules and FTA-T via system interconnection cables
(SICs).

Figure 2-3 – Typical routing layout of internal wiring between I/O modules and FTA-T via SICs

FTA-T
Backplane

FTA connector

I/O module connector

I/O module
System I/O cable

Terminal block

Continued on next page

02/98 FSC Safety Manager Installation Guide 31

2.5 Cabling Installation, Continued

I/O module wiring, Figure 2-4 illustrates a typical routing layout of the internal wiring
continued between I/O modules and FTA-E via system interconnection cables
(SICs).

Figure 2-4 – Typical routing layout of internal wiring between I/O modules and FTA-E via SICs

FTA-E
Backplane

FTA connector

I/O module connector

I/O module
System I/O cable

Elco 56/54-pin (E56) connector

Continued on next page

32 FSC Safety Manager Installation Guide 02/98

2.5 Cabling Installation, Continued

Communication
module cabling

For more information on communication module cabling, refer

to the FSC Hardware Manual and the Integration Guidelines for FSC
System Cabinets.

FSC user station

cabling

For more information on FSC user station cabling, refer to the

FSC Hardware Manual.

02/98 FSC Safety Manager Installation Guide 33

2.6 System Power Connections

Cabinet power Figure 2-5 illustrates a typical power connection layout for an FSC Safety
connections Manager cabinet.
Conductors and breakers, used to supply power to the cabinet, are sized
using rules in the Integration Guidelines for FSC System Cabinets. Refer
to your site planning drawings and this figure to install power.
A cabinet will have a terminal bar at the bottom of the cabinet to connect
two or more feeders.

Figure 2-5 – Typical FSC-SM cabinet power and ground connections

FSC-SM Cabinet
120/240 V
Entry Panel Main Switch
H
150 kA MOV
Suppressor N

H
N
Cold G
Water
Pipe

Building All ground cables are 25 mm² (AWG 4)

Frame when not enclosed by conduit.
They must be 2.5 mm² (AWG 14) or larger
Lightning when enclosed by conduit. To Power
Air Terminal Supply Units

Ground
Wires to
Backplanes
and
Lightning Safety Comm. Equipm.
Ground Ground

Safety GND
Distribution Rail

Continued on next page

34 FSC Safety Manager Installation Guide 02/98

2.6 System Power Connections, Continued

Module power Power is supplied to each FSC Safety Manager Module via the system bus
connections
of the Central Part.

02/98 FSC Safety Manager Installation Guide 35

2.7 System Ground Connections

Background The FSC Safety Manager cabinets, backplanes, termination panels,

communications equipment and field wiring must be properly grounded to
ensure correct and safe operation. This subsection provides the necessary
information needed to make these connections.

For basic information regarding the FSC's grounding

requirements, refer to Integration Guidelines for FSC System Cabinets.

Grounding Adequate grounding is important for safety considerations and for

considerations reducing electromagnetic noise interference. All earth ground connections
must be permanent and provide a continuous low impedance path to earth
ground for induced noise currents and fault currents. Table 2-8 lists the
steps to be performed when grounding your system.

Table 2-8 – System grounding considerations

Step Action

1 Use the system grounding techniques described in this subsection

and those defined in the FSC documentation before making ground
connections. Establish:
• AC safety ground by making a
– temporary connection using the grounding terminal on front of
each power supply module, and
– permanent, redundant connection to safety ground attaching
No. 8 AWG from ground to each card file using a crimped ring
lug and 1/4" bolt.
• signal ground by tying together the signal ground and safety
ground at one and only one point.
• shield ground by connecting one end of the shield of each field
cable between an analog termination panel and analog field
device.

2 Select the proper voltage (115 Vac or 230 Vac) for all configurable
modules before supplying power to the system.

3 Securely fasten all cover plates in order to maintain system integrity

and to ensure system grounding.

Continued on next page

36 FSC Safety Manager Installation Guide 02/98

2.7 System Ground Connections, Continued

Grounding
considerations,
continued
Table 2-8 – System grounding considerations (continued)
Step Action

4 Firmly tighten all screws on FSC-SMM module front plates and

Central Part coverplates.

5 Consult IEEE Standard 518-1977, the National Electric Code, and

Subsections 2.4 and 2.5 of this document before wiring the system
components.

Cabinet ground Figure 2-5 illustrates a typical power and ground connections layout for an
connections FSC Safety Manager cabinet.

Ground wires from all mechanical parts and every backplane in the cabinet
are collected at a bus bar located at the bottom of the cabinet. This bus bar
must be connected to building safety ground with a 2.5 mm² (AWG 14)
wire in conduit or a 25 mm² (AWG 4) wire without conduit. Each cabinet
must be connected individually to building safety ground and not
daisy-chained with other cabinets or equipment.

Continued on next page

02/98 FSC Safety Manager Installation Guide 37

2.7 System Ground Connections, Continued

Safety ground The FSC Safety Manager cabinet and external termination panels are
properly connected to safety ground in accordance to the specifications
and techniques stipulated by FSC.

The FSC Safety Manager backplanes and communication equipment are

properly connected to safety ground. To insure proper operation of the
FSC-SM, safety ground must be configured in accordance with the
specifications and techniques stipulated by FSC.

For more information on cabinet grounding, refer to the

Integration Guidelines for FSC System Cabinets.

Shield ground Field wiring between analog field devices for both the internal and
external termination panels must be properly connected to shield (earth)
ground. To insure proper communication over these links, shield ground
must be configured in accordance to the specifications and techniques
stipulated by FSC.

For more information on shield grounding, refer to the

Integration Guidelines for FSC System Cabinets.

Communication Communication equipment connected to the FSC Safety Manager must be

equipment grounding grounded in accordance to the specifications and techniques stipulated by
FSC.

For more information on communication equipment grounding,

refer to the Integration Guidelines for FSC System Cabinets.

38 FSC Safety Manager Installation Guide 02/98

2.8 UCN Connections

Node address Unlike other UCN devices, the UCN node address is configured at the
selection FSC user station (using the FSC Development System software and FSC
Navigator software), and becomes slot-dependent.

UCN installation The installation procedure and cabling information can be found in the
UCN Site Planning and Installation manual in the UCN Site Planning and
Installation binder.

Figure 2-6 illustrates a typical UCN installation. Connection of the UCN

system is made at the front panel of the FSC Safety Manager Module.

ATTENTION For detailed information regarding the connection of the

UCN to the FSC Safety Manager, refer to Subsection 2.5 — Wiring and
Cabling Installation under the topic, "FSC-SMM Cabling," in this
document.

Continued on next page

02/98 FSC Safety Manager Installation Guide 39

2.8 UCN Connections, Continued

UCN installation,
continued

Figure 2-6 – Connection of the UCN

LCN "A" Coaxial Cable

LCN "B" Coaxial Cable LCN
System
Install as in
Universal Network Network SW02-300,
History
Station Interface Interface Binder
Module
Module Module TPS1020

75 Terminator
Redundant
Pair
75 Terminator
UCN Drop
Cables (50 meters
maximum length)
UCN Trunk PM * Each trunk cable (segment)
"A" "B" Cables*
PMM PMM length is restricted to
multiples of a basic length
(2.6 meters for standard
RG-11 type UCN Trunk).

Optional
Armored
Trunk
Dot designates
isolated trunk port

Note that redundant devices on

the same UCN should use the
same taps.
FSC-SM FSC-SM
SMM CP 1 SMM CP 2

75 Terminators in all
Unused Sockets

Continued on next page

40 FSC Safety Manager Installation Guide 02/98

2.8 UCN Connections, Continued

Trunk cable Connection of the UCN trunk lines are made at the front panel of the FSC
connection Safety Manager Module. Refer to Figure 2-2 for more details. Use the
procedure that is found in the TPS System Site Planning manual as the
installation guide.

02/98 FSC Safety Manager Installation Guide 41

 Left blank intentionally

42 FSC Safety Manager Installation Guide 02/98

 Section 3 – System Component Configuration
3.1 Section Overview

About this section This section provides general installation information for various
components of the FSC Safety Manager (FSC-SM) system. Topics
included in this section are:

Subsection Topic See Page

3.1 Section Overview.......................................................................................43

3.2 System Configuration Overview ................................................................44
3.3 Module Configuration ................................................................................45

ATTENTION This section describes in detail only those installation

procedures and considerations specific to the FSC Safety Manager Module
(FSC-SMM) and the TotalPlant Solution (TPS) system. Installation
procedures and considerations specific to the FSC components can be
found in the FSC documentation.

02/98 FSC Safety Manager Installation Guide 43

3.2 System Configuration Overview

Introduction The FSC Safety Manager (FSC-SM) system consists of a redundant Fail
Safe Control (FSC) system fitted with a redundant pair of FSC Safety
Manager Modules (FSC-SMMs).
Each FSC Central Part contains a central processor unit (CPU), a
watchdog (WD) and communication modules (COM). Each Central Part
has its own dedicated I/O modules and/or shared I/O modules.

Redundant FSC-SMM The FSC-SM is configured for redundant operation. There can only be one
modules FSC-SMM in each Central Part.

In this configuration, each FSC-SMM is independently connected to the

UCN. One of the two will function as the primary, carrying out all UCN to
FSC-SM communication and data transfer operations. The other
FSC-SMM functions as the secondary or backup link between the UCN
and FSC. Database synchronization and status and control transfers
between the Primary and Secondary take place over the UCN.

44 FSC Safety Manager Installation Guide 02/98

3.3 Module Configuration

Introduction The FSC Safety Manager is configured at the FSC user station using the
FSC Development System software (R42x) or FSC Navigator software
(R500). There are basically three configuration levels:
• General FSC system configuration,
• Central Part module configuration, and
• I/O module configuration.
Each of these levels is discussed in more detail below.

The starting point for all configuration operations in the FSC

Development System software (R42x) is the Configure FSC system option
from the FSC-DS main menu.
The starting point for all configuration operations in the FSC Navigator
software (R500) is the System Configuration option, which can be called
up in three ways:
• Menu bar: Project / System Configuration
• Button bar: I/O
• Navigation area: FSC Project Configuration / System Configuration

General FSC system The FSC user software (FSC Development System or FSC Navigator)
configuration allows the user to configure a number of general system settings such as:
• requirement class,
• FSC system type specification (R42x) or system configuration (R500),
• process safety time,
• number of cabinets, and
• number of racks.

For detailed information on the FSC user software and on

configuring the FSC system, refer to the FSC Software Manual.

Continued on next page

02/98 FSC Safety Manager Installation Guide 45

3.3 Module Configuration, Continued

Central Parts The Central Parts can only function correctly if they are properly
configured, which can be done using the FSC user software (FSC
Development System or FSC Navigator). A Central Part (CP) includes
several standard items such as the redundant power supplies, the
watchdog module and the central processing unit (CPU). It also has a
number of free slots in which can be installed:
• communication modules (such as the FSC-SMM),
• diagnostic and battery module (DBM), and
• several vertical bus drivers (VBDs).

For detailed information on Central Part requirements and

configuration, refer to the FSC Hardware Manual and the FSC Software
Manual.

I/O modules The allocation of I/O modules within an FSC system and their
configuration requirements depend on the safety application and on the
FSC system configuration. Use the FSC user software to allocate I/O
modules and to enter their safety relation values.

For detailed information on I/O module requirements and

configuration, refer to the FSC Hardware Manual and the FSC Software
Manual.

46 FSC Safety Manager Installation Guide 02/98

 Section 4 – Configuration
4.1 Section Overview

About this section This section provides general information for various software
configuration procedures for the FSC Safety Manager (FSC-SM) system.
Topics included in this section are:

Subsection Topic See Page

4.1 Section Overview.......................................................................................47

4.2 Configuration at FSC User Station ............................................................48
4.3 Configuration at TPS Universal Station .....................................................49

Introduction There are three main areas which need to be configured to properly use the
FSC Safety Manager within the TotalPlant Solution (TPS) system. These
are the following:
• FSC Functional Logic Diagrams (FLDs) programming,
• Configuration of the FSC-SM at the FSC user station, and
• Configuration of FSC-SMM points at the TPS Universal Station (US).

Preconfiguration This section assumes the following steps have been completed:
assumptions
• The FSC user station hardware (i.e. cabling) has been properly installed
and connected.

Refer to the wiring section of this manual.

• The FSC user software (FSC Development System or FSC Navigator)

has been successfully loaded onto the PC.

Refer to the FSC Software Manual.

Version needed for In order to successfully configure the FSC-SM system, you will need to be
configuration using release 42x or 500 of the FSC software and release 530 or 531 for
the TotalPlant Solution (TPS) system.

02/98 FSC Safety Manager Installation Guide 47

4.2 Configuration at FSC User Station

Functional Logic Functional Logic Diagrams (FLDs) define the control program for the
Diagrams (FLDs) safety application. They are created using the FSC user software:
programming
FSC Development System (R42x) or FSC Navigator (R500).

For detailed information on FSC Functional Logic Diagrams

programming, refer to the FSC Software Manual.

FSC user software The FSC user software is used to define and configure the safety
configuration application. There are several things that need to be configured before the
FSC-SM can function properly in the TPS system. The definition and
configuration process consists of the following steps:
• defining the hardware configuration of the FSC-SM,
• defining the variables (which includes assigning attributes to them and
allocating them to system components),
• allocating system memory for the FSC-SMM,
• assigning a UCN address to the FSC-SMM,
• assigning DCS addresses to the variables,
• compiling the application, and
• transferring the application to the FSC system (either to EPROMs or by
downloading it to the system).

For detailed information on the software configuration of

FSC-SM, refer to the FSC Software Manual.

48 FSC Safety Manager Installation Guide 02/98

4.3 Configuration at TPS Universal Station

Introduction Once the FSC user software configuration has been successfully
completed, you will need to use the Universal Station (US) to finish
FSC-SM system configuration. This section will discuss the following
US configurations:

• Universal Control Network (UCN),

• Node-specific (FSC-SM device), and
• FSC-SMM data points.

Configuration This section covers the FSC-SM configuration process at the US. It
assumptions assumes that you have completed the implementation steps for start-up
and have prepared the History Module (HM) and the system for network
configuration.

Table 4-1 outlines the start-up process for the TPS system. If these
procedures have not been done, refer to the LCN bookset –
Implementation Startup & Reconfiguration, binder TPS 2030-1.

Table 4-1 – Start-up and reconfiguration procedures

Step Action Result

1 Prepare the system for Universal Personality is in "this US". Current

network configuration. time and date is in "this US". The system
start-up floppy is in a secure place.

2 Configure the network. A site-specific Network Configuration File

(NCF), required as input to subsequent
procedures, is available.

3 Prepare the History The History Module can now be used as a

Module. source for configuration programs and data.

Continued on next page

02/98 FSC Safety Manager Installation Guide 49

4.3 Configuration at TPS Universal Station, Continued

UCN configuration Once you have completed the start-up process for the US, follow the steps
outlined in Table 4-2.

Table 4-2 – UCN configuration

Step Action

1 Press the RESET button.

ATTENTION The RESET button is located under the black metal

panel at the top of the operator keyboard.

2 Press the LOAD button on the operator keyboard. The system will
state 'Loading in progress'.

3 A prompt will appear: "N, 1, 2, 3, 4?". Press N for Network

and press the <Enter> key.

4 Another prompt will appear: "OPR, UNP, X?". Press U for

Universal Personality and press the <Enter> key.

Continued on next page

50 FSC Safety Manager Installation Guide 02/98

4.3 Configuration at TPS Universal Station, Continued

First US display Once you have loaded the Universal Personality, the System Status display
will be the first display to come up. Figure 4-1 shows this display.

Figure 4-1 – US System Status display

MAKE SELECTION 11 Sep 96 [Link] 3
SYS VERS: R510 SYSTEM STATUS FROM US13
NCF VERS: 09Feb95 [Link]
CABLE A: OK CABLE B: OK

US01 US02 US03 US04 US05 US06 US07 US08 US09 US10 US11 US12 US13

OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OK
US14 US15 US16 US17 US18 US19 US20 NM21 NM22 NM23 NM24 NM25 NM26
UCN 02 UCN 02
OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OK OFF OFF
NM27 NM28 NM29 NM30 NM31 HG37 HG39 HM43 AM45 AM46 CG 49

OFF OFF OFF OFF OFF OFF OFF OK OFF OFF OFF

LOAD LOAD SHOW DE- NTWK/HWY NODE STATUS LCN TIME/

SELECT CONFIG LOADS SELECT STATUS STATUS DETAIL DIAG DATE
LOAD LOAD LOAD SELECT DUMP SHUT LCN
ISOL FAIL PWR_ON AUX INFO NODE DOWN OVERVIEW

Continued on next page

02/98 FSC Safety Manager Installation Guide 51

4.3 Configuration at TPS Universal Station, Continued

Engineering Main In order to configure your UCN, you will need to bring up the Engineering
Menu display Main Menu display. To do this, hold the [CTRL] key on the engineering
keyboard and press the [HELP(M)] key. Figure 4-2 shows this display.

Once you have brought this display up, select the NETWORK
INTERFACE MODULE target.

Figure 4-2 – US Engineering Main Menu display

11 Jun 97 [Link] 3
ENGINEERING MAIN MENU

UNIT NAMES HIWAY GATEWAY PICTURE EDITOR

AREA NAMES LOGIC BLOCKS FREE FORMAT LOGS

CONSOLE NAMES APPLICATION MODULE BUTTON CONFIGURATION

LCN NODES COMPUTING MODULE HM HISTORY GROUPS

NETWORK INTERFACE
SYSTEM WIDE VALUES MODULE

VOLUME CONFIGURATION

DOCUMENTATION TOOL
BUILDER COMMANDS AREA DATA BASE

Support Functions and Utility Programs

COMMAND
PROCESSOR SYSTEM MENU SYSTEM STATUS CONSOLE STATUS

SUPPORT SMCC/
UTILITIES MAINTENANCE R530 (C) HONEYWELL INC., 1984-97

Continued on next page

52 FSC Safety Manager Installation Guide 02/98

4.3 Configuration at TPS Universal Station, Continued

NIM Build Type Select The NIM Build Type Select Menu display will be the next display to come
Menu display up. This display is shown in Figure 4-3. Select the UCN NODE
CONFIGURATION target to configure the UCN.

Figure 4-3 – US NIM Build Type Select Menu

11 Jun 97 [Link] 3

MENU PAGE 01 OF 01
NIM BUILD TYPE SELECT MENU

UCN
NODE
CONFIGURATION

NODE
SPECIFIC
CONFIGURATION

PROCESS
POINT
BUILDING

LIBRARY
CONFIGURATION

F1=PED F3= F5=OVERWRITE F7=RECON F9 =WLK BACK F11=

F2=RECALL DISP F4= F6= F8=PED STATUS F10=WRITE F12=LOAD

UCN Node You should now be in the UCN Node Configuration display. Figure 4-4
Configuration display shows this display. Do the steps in Table 4-3 to configure the UCN.

Table 4-3 – UCN node configuration

Step Action

1 Enter the requested data in the given slots. All configuration

information should be taken from the FSC-SM Configuration Forms
you have filled out.

2 Select the FSC-SM for UCN node type and FSC for the FSC-SM
platform.

3 Press the [F12 LOAD] key to load your configuration.

ATTENTION The node number you select must correspond with the
node number you entered for the UCN configuration at the FSC user
station.

Continued on next page

02/98 FSC Safety Manager Installation Guide 53

4.3 Configuration at TPS Universal Station, Continued

UCN Node Note that the network number can be from 1 to 20. The node number can
Configuration display, range from 1 to 63, using odd numbers only.
continued

Figure 4-4 – US UCN Node Configuration display

11 Jun 97 [Link] 3

PED >>>>>>> POINT:$NM02N13 UNIT:SY PAGE 01 OF 01

UCN NODE CONFIGURATION

NETWORK NUMBER (NTWKNUM) 02

NODE NUMBER (NODENUM) 13

UCN NODE TYPE (NODETYP) NOTCONFG NIM PM APM

HPM LM SM

SM PLATFORM (SMPLTFM) TRICON FSC

NODE ASSIGNMENT (NODEASSN) THISNIM REMOTNIM

DIGITAL COMPOSITE PV
STATE TEXT
MOVING TEXT (MOVPVTXT) MOVING

BAD TEXT (BADPVTXT) BAD

F1=PED F3= F5=OVERWRITE F7=RECON F9 =WLK BACK F11=

F2=RECALL DISP F4= F6= F8=PED STATUS F10=WRITE F12=LOAD

Continued on next page

54 FSC Safety Manager Installation Guide 02/98

4.3 Configuration at TPS Universal Station, Continued

Node-specific To configure the node-specific data, return to the NIM Build Type Select
configuration Menu by pressing the [F9 WLK BACK] key (refer back to Figure 4-3).
Select the NODE SPECIFIC CONFIGURATION target. The
Node-Specific Configuration display is shown in Figure 4-5.

Enter and select the desired configuration. Press the [F12 LOAD] key.

ATTENTION Make sure the network and node numbers entered for this
display match those entered in the UCN Configuration display.

There is no need to configure the redundant FSC-SM device. All

FSC-SM-related information will be automatically transferred to the
"new" primary FSC-SM should there be a failover or switchover to the
backup.

Figure 4-5 – US Node-Specific Configuration display

11 Jun 97 [Link] 3

PED >>>>>>> POINT:$NM02B13 UNIT:SY UNENTERED PAGE 01 OF 03

NODE-SPECIFIC CONFIGURATION
NETWORK NUMBER (NTWKNUM) 02
NODE NUMBER (NODENUM) 13
NODE TYPE (NODETYP) PM APM HPM
LM SM

SM PLATFORM (SMPLTFM) TRICON FSC

*****************************************************************
* *
* WARNING: IF THE POINT MIX OR THE SCAN *
* RATE IS CHANGED, THEN THE NODE'S FULL *
* DATA BASE WILL BE SET TO ITS DEFAULT. *
* THE DISPLAY LINES WHICH CAN CAUSE THE *
* DATA BASE TO BE DEFAULTED ARE STARRED *
* AND HAVE AN ASTERISK (*) IN COLUMN 80. *
* *
*****************************************************************

F1=PED F3= F5=OVERWRITE F7=RECON F9 =WLK BACK F11=

F2=RECALL DISP F4= F6= F8=PED STATUS F10=WRITE F12=LOAD

Continued on next page

02/98 FSC Safety Manager Installation Guide 55

4.3 Configuration at TPS Universal Station, Continued

Process Point You must once again return to the NIM Build Type Select Menu to access
Building display the FSC-SMM data point building displays. To do this, press the [F1 PED]
key.

Select the PROCESS POINT BUILDING target, once you have returned
to the NIM Build Type Select Menu. Figure 4-6 shows the display which
will be brought up.

Figure 4-6 – US Process Point Building display

11 Jun 97 [Link] 3
MENU PAGE 01 OF 01
NIM BUILD TYPE SELECT MENU
NIM PROCESS POINT BUILD TYPE ANALOG ANALOG
INPUT OUTPUT
DIGITAL DIGITAL DIGITAL
INPUT OUTPUT COMPOSITE
REGULATORY REGULATORY
PV CONTROL

LOGIC

FLAG TIMER NUMERIC

ARRAY DEVICE
CONTROL
PROCESS
MODULE

F1=PED F3= F5=OVERWRITE F7=RECON F9 =WLK BACK F11=

F2=RECALL DISP F4= F6= F8=PED STATUS F10=WRITE F12=LOAD

Continued on next page

56 FSC Safety Manager Installation Guide 02/98

4.3 Configuration at TPS Universal Station, Continued

Building FSC-SMM This subsection takes you through the general steps for FSC-SMM data
data points point configuration. To build FSC-SMM data points, you will need to
follow the steps listed in Table 4-4.

For more information refer to Section 4 — Data Point Detailed

Description in the FSC Safety Manager Control Functions.

ATTENTION Information on the definition of a specific parameter can

be provided to you online by pressing the [HELP] key for the parameter
you have selected.

Table 4-4 – FSC-SMM data point configuration procedure

Step Action

1 Once you are in the Process Point Building display, select the
FSC-SMM point type you wish to configure.

2 Enter and select the desired configuration scheme. Use the

[PAGE FWD] button on the operator keyboard to move to the next
configuration page as needed.

ATTENTION Data entered should be based on the FSC-SM

Configuration Forms you have filled out.

3 Press the [F12 LOAD] key to load the data in the FSC-SM database.

4 Press the [F9 WLK BACK] key to return to the Process Point Building
display.

5 Repeat steps 1 to 4 for the next FSC-SMM data point type until all
point types are configured.

ATTENTION FSC aliases must be configured before points can be

downloaded against given aliases.

02/98 FSC Safety Manager Installation Guide 57

 Left blank intentionally

58 FSC Safety Manager Installation Guide 02/98

 Index

A, B E
Bolt-down, 19 Engineering Main Menu display, 52
Bolt-down holes, 6 Environmental conditions, 2
Building FSC-SMM data points, 57

F
C Field termination assemblies
Cabinet entry, 7, 8, 9, 10, 11, 12 FTA-E, 7
Cabinet ground connections, 37 FTA-T, 7
Cabinet power connections, 34 Fork lift, 14
Cable conduits, 24 FSC Development System (FSC-DS), 45, 48
Cable entry to cabinet, 7, 8, 9, 10, 11, 12 FSC Navigator, 45, 48
Cable trays, 24 FSC user station cabling, 33
Cable, wire and conduit selection, 27 FSC-SMM cabling, 29
Cabling Redundant, 30
Communication module, 33 FSC-SMM data points, 57
FSC user station, 33 Functional Logic Diagrams (FLDs), 48
FSC-SMM, 29
Redundant, 30
Cabling guidelines, 28 G
Central Parts, 46
Communication equipment grounding, 38 General FSC system configuration, 45
Communication module cabling, 33 Grounding
Conductors Cabinet connections, 37
High level, 27 Communication equipment, 38
Low level, 27 Safety, 38
Conduit spacing, 27 Shield, 38
Conduits, 24 Signal, 38
Configuration Grounding considerations, 36
Central Parts, 46
FSC Development System (FSC-DS), 48
FSC Navigator, 48 H
General, 45 High level conductors, 27
I/O modules, 46 History Module, 49
Universal Station (US), 49
Configuration of FSC Safety Manager, 45, 47
Crane, 19 I, J, K
I/O module wiring, 31, 32
D I/O modules, 46
Installation checklist, 22
Data points, 57
Data signal cable, 25

02/98 FSC Safety Manager Installation Guide 59

 Index

L S
Leveling, 19 Safety ground, 38
Low level conductors, 27 Shield ground, 38
Shielding, 24
Shock, 2
M Software
FSC Development System (FSC-DS), 45, 48
Mobile lifter, 15 FSC Navigator, 45, 48
Module configuration, 45 Spacing
Module power connections, 35 Conduits, 27
Move checklist Trays, 26
Electronics room, 5 Trays/conduits, 26
FSC-SM cabinets, 4 Storage ratings, 2
Moving FSC-SM cabinets, 3, 4, 5, 13 System configuration, 44
Moving the equipment System status display, 51
Crane method, 19
Fork lift, 14
Mobile lifter, 15
Roller method, 18
T
Temperature, 2
Test equipment, 1
N, O Tools, 1
Tray spacing, 26
Network configuration, 49 Tray/conduit spacing, 26
NIM Build Type Select Menu display, 53 Trunk cable connection, 41
Node-specific configuration, 55
Noise generation, 25
Noise susceptibility, 25 U
UCN installation, 39
P, Q UCN Node Configuration display, 53
Universal Personality, 51
Power supply wiring, 31 Universal Station (US), 49
Process Point Building display, 56 Unpacking, 13
US configuration, 49
R
Redundant cabling, 30 V
Redundant FSC-SMM modules, 44 Version needed for configuration, 47
Relative humidity, 2 Vibration, 2
Roller, 18

W, X, Y, Z
Wiring classifications, 25
Wiring guidelines, 28

60 FSC Safety Manager Installation Guide 02/98

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Title of Document: FSC Safety Manager Issue Date: 02/98

Installation Guide
Document Number: FS20-500 Writer: HSMS Product Marketing

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