Honeywell FSC-SM Installation Manual

Safety manager
Table of Contents
FSC Safety Manager
Installation Guide
for use with the Honeywell FSC System
Releases 42x, 5xx and 600
FS20-500
Table of Contents
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Summary of Contents for Honeywell FSC-SM

  • Page 1 FSC Safety Manager Installation Guide for use with the Honeywell FSC System Releases 42x, 5xx and 600 FS20-500...
  • Page 3 Implementation FSC Safety Manager FSC Safety Manager Installation Guide for use with the Honeywell FSC System Releases 42x, 5xx and 600 FS20-500 10/01...
  • Page 4 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.
  • Page 5 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.
  • Page 6 FSC Safety Manager Installation Guide 10/01...
  • Page 7: Table Of Contents

    Table of Contents SECTION 1 – FSC SAFETY MANAGER SYSTEM INSTALLATION ..........1 Section Overview ......................1 Equipment Warehousing....................2 Move Preparation ......................3 Unpacking and Placement ..................13 SECTION 2 – SYSTEM COMPONENT INSTALLATION ..............21 Section Overview ....................... 21 Installation Considerations ..................
  • Page 8 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) ............
  • Page 9 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 .................
  • Page 10 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 ................
  • Page 11 References For FSC-SM documentation: Publication Publication Binder Binder Title Number Title Number FSC Safety Manager Installation FS20-500 Implementation TPS 3076 FSC Safety Manager Guide FSC Safety Manager Implementation FS11-500 Implementation TPS 3076 Guidelines FSC Safety Manager FSC Safety Manager Control...
  • Page 12 FSC Safety Manager Installation Guide 10/01...
  • Page 13: Section 1 - Fsc Safety Manager System Installation

    Section 1 – FSC Safety Manager System Installation Section Overview This section provides general installation information for the FSC Safety About this section Manager (FSC-SM) system. Topics included in this section are: Subsection Topic See Page Section Overview ..................1 Equipment Warehousing ................
  • Page 14: Equipment Warehousing

    Equipment Warehousing For shipment, the FSC Safety Manager is packed with desiccant packages, Factory packing wrapped in a moisture barrier and optionally enclosed for shipment as required by the user. The FSC Safety Manager can be shipped by a variety of means, but any Transit/warehousing trucking should be done by enclosed air-ride vans.
  • Page 15: Move Preparation

    Move Preparation Several basic points need to be kept in mind when planning the movement Background 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...
  • Page 16: Table 1-1 Move Preparation Checklist

    Are all responsibilities clearly defined and understood? 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 —...
  • Page 17: Table 1-2 Move Preparation Checklist - Part 2

    Move Preparation, Continued Table 1-2 provides a checklist to be used when preparing the electronics Preparation room for the FSC Safety Manager cabinets. Table 1-2 – Move preparation checklist – part 2 Check Action Notes Static Electricity Reduce the ESD-borne failures by: •...
  • Page 18: Figure 1-2 Location And Dimensions Of The Cabinet Bolt-Down Holes

    Move Preparation, Continued Figure 1-2 provides the exact locations and dimensions of the cabinet Bolt-down holes bolt-down holes. Figure 1-2 – Location and dimensions of the cabinet bolt-down holes REAR Bolt-down hole diameter: 14 mm (0.55") 100 mm (3.94") 600 mm (23.62") 100 mm (3.94") 800 mm (31.50") FRONT...
  • Page 19: Figure 1-3 Fsc-Sm Cabinet With Back Access (Fta-T)

    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.
  • Page 20: Figure 1-4 Fsc-Sm Cabinet With Front Access (Fta-T)

    Figure 1-4 illustrates an FSC Safety Manager cabinet bottom configured Cabinet entry, for front access of the I/O field cables with FTA-T. continued Figure 1-4 – FSC-SM cabinet with front access (FTA-T) REAR Field cable duct FTA-T FSC I/O mounting rack...
  • Page 21: Figure 1-5 Fsc-Sm Cabinet With Front And Back Access (Fta-T)

    Figure 1-5 illustrates an FSC Safety Manager cabinet bottom configured Cabinet entry, for front and back access of the I/O field cables with FTA-T. continued Figure 1-5 – FSC-SM cabinet with front and back access (FTA-T) FTA-T REAR Field cable duct...
  • Page 22: Figure 1-6 Fsc-Sm Cabinet With Front Access (Fta-E)

    Continued Figure 1-6 illustrates an FSC Safety Manager cabinet bottom configured Cabinet entry, for front access of the system cables with FTA-E. continued Figure 1-6 – FSC-SM cabinet with front access (FTA-E) FTA-E REAR System cables Field cable tray FSC I/O mounting rack...
  • Page 23: Figure 1-7 Fsc-Sm Cabinet With Back Access (Fta-E)

    Continued Figure 1-7 illustrates an FSC Safety Manager cabinet bottom configured Cabinet entry, for back access of the system cables with FTA-E. continued Figure 1-7 – FSC-SM cabinet with back access (FTA-E) FTA-E REAR Field cable tray System cables FSC I/O mounting rack...
  • Page 24: Figure 1-8 Fsc-Sm Cabinet With Front And Back Access (Fta-E)

    Figure 1-8 illustrates an FSC Safety Manager cabinet bottom configured Cabinet entry, for front and back access of the system cables with FTA-E. continued Figure 1-8 – FSC-SM cabinet with front and back access (FTA-E) FTA-E REAR System cables Field cable tray...
  • Page 25: Unpacking And Placement

    Unpacking and Placement Unpack the equipment, check the shipment against the invoice, and Unpacking 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 …...
  • Page 26: Figure 1-8 Placement Of Equipment Onto Lumber

    Unpacking and Placement, Continued The FSC-SM cabinet is moved by fork lift to the final location. Table 1-4 Fork lift lists special considerations regarding the use of a fork lift to move the equipment. Table 1-4 – Fork lift considerations...
  • Page 27: Table 1-5 Mobile Lifter Considerations

    Unpacking and Placement, Continued As illustrated in Figure 1-7, the FSC Safety Manager is placed on a Mobile lifter 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.
  • Page 28: Figure 1-9 Placement Using A Mobile Lifter

    Unpacking and Placement, Continued Figure 1-10 – Placement using a mobile lifter Mobile lifters, 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 FSC Safety Manager Installation Guide 10/01...
  • Page 29: Figure 1-10 Lifting Equipment By Mobile Lifter Of Crane

    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 10/01 FSC Safety Manager Installation Guide...
  • Page 30: Figure 1-11 Lifting Equipment By Mobile Lifter Of Crane - Part 2

    Unpacking and Placement, Continued As illustrated in Figure 1-12, using the roller method the FSC Safety Roller method 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.
  • Page 31: Figure 1-12 Eyebolt Crane Method

    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.
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  • Page 33: Section 2 - System Component Installation

    Section 2 – System Component Installation Section Overview This section provides general installation information for various About this section components of the FSC Safety Manager (FSC-SM) system. Topics included in this section are: Subsection Topic See Page Section Overview ..................21 Installation Considerations................
  • Page 34: Installation Considerations

    The FSC Safety Manager system may encompass a single cabinet or a Introduction 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.
  • Page 35: Cabinet Installation

    Cabinet Installation After placement, the cabinet or cabinet complex requires the attachment of Introduction power and ground, and cabling installation. Refer to Section 1 — FSC Safety Manager System ATTENTION Installation for information regarding the warehousing, movement, unpacking and placement of the FSC Safety Manager cabinets. 10/01 FSC Safety Manager Installation Guide...
  • Page 36: Cabling Considerations

    Cabling Considerations When installing an FSC Safety Manager System, it is important to Introduction consider: • conduit and tray shielding and spacing, and • cable and wire classifications. Conduit or cable trays should be used to route the network trunk line Shielding within the plant for short distances or for several miles.
  • Page 37: Table 2-3 Ieee 518 Wiring Classification Definitions

    Cabling Considerations, Continued It is recommended that noise creating sources (those with time varying Spacing 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.
  • Page 38: Table 2-4 Tray Spacing

    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)
  • Page 39: Table 2-6 Conduit Spacing

    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)
  • Page 40: Table 2-7 Cabling Guidelines

    Cabling Considerations, Continued Observe the guidelines presented in Table 2-7 when routing cables to the Cabling and wiring FSC Safety Manager cabinet. Pay special attention to separating data guidelines cables from power cables to avoid electrical noise problems. Table 2-7 – Cabling guidelines Consideration Description Maintain a 60°C (140°F), or less, ambient air temperature at the bottom of each FSC...
  • Page 41: Cabling Installation

    Figure 2-1 illustrates the front plate of the FSC Safety Manager Module FSC-SMM cabling (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 Honeywell Honeywell Honeywell Honeywell STATUS...
  • Page 42: Figure 2-2 Redundant Fsc-Sm Ucn Cabling

    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 CP 1...
  • Page 43: Figure 2-3 Typical Routing Layout Of Internal Wiring Between I/O Modules And Fta-T Via Sics

    Cabling Installation, Continued Power supply wiring For information regarding the wiring of the FSC Safety ATTENTION Manager card file power supply modules, refer to Subsection 2.7 — System Power Connections, in this section. Field wiring is not connected directly to the I/O modules themselves. I/O module wiring Rather, as illustrated in Figure 2-3 and Figure 2-4, these connections are made via Field Termination Assemblies (FTAs) available as either an:...
  • Page 44: Figure 2-4 Typical Routing Layout Of Internal Wiring Between I/O Modules And Fta-E Via Sics

    Cabling Installation, Continued Figure 2-4 illustrates a typical routing layout of the internal wiring I/O module wiring, between I/O modules and FTA-E via system interconnection cables continued (SICs). Figure 2-4 – Typical routing layout of internal wiring between I/O modules and FTA-E via SICs FTA-E Backplane FTA connector...
  • Page 45 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.
  • Page 46: System Power Connections

    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...
  • Page 47 System Power Connections, Continued Power is supplied to each FSC Safety Manager Module via the system bus Module power connections of the Central Part. 10/01 FSC Safety Manager Installation Guide...
  • Page 48: System Ground Connections

    System Ground Connections The FSC Safety Manager cabinets, backplanes, termination panels, Background 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.
  • Page 49 System Ground Connections, Continued Grounding considerations, continued Table 2-8 – System grounding considerations (continued) Step Action Firmly tighten all screws on FSC-SMM module front plates and Central Part coverplates. Consult IEEE Standard 518-1977, the National Electric Code, and Subsections 2.4 and 2.5 of this document before wiring the system components.
  • Page 50: System Ground Connections

    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.
  • Page 51: Ucn Connections

    UCN Connections Unlike other UCN devices, the UCN node address is configured at the Node address FSC user station (using the FSC Development System software and FSC selection Navigator software), and becomes slot-dependent. The installation procedure and cabling information can be found in the UCN installation UCN Site Planning and Installation manual in the UCN Site Planning and Installation binder.
  • Page 52: Figure 2-6 Connection Of The Ucn

    Armored Trunk Dot designates isolated trunk port Note that redundant devices on the same UCN should use the same taps. FSC-SM FSC-SM CP 1 CP 2 75 Terminators in all Unused Sockets Continued on next page FSC Safety Manager Installation Guide...
  • Page 53 UCN Connections, Continued Connection of the UCN trunk lines are made at the front panel of the FSC Trunk cable Safety Manager Module. Refer to Figure 2-2 for more details. Use the connection procedure that is found in the TPS System Site Planning manual as the installation guide.
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  • Page 55: Section 3 - System Component Configuration

    Section 3 – System Component Configuration Section Overview This section provides general installation information for various About this section components of the FSC Safety Manager (FSC-SM) system. Topics included in this section are: Subsection Topic See Page Section Overview ..................43 System Configuration Overview..............
  • Page 56: System Configuration Overview

    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. The FSC-SM is configured for redundant operation. There can only be one Redundant FSC-SMM FSC-SMM in each Central Part.
  • Page 57: Module Configuration

    Module Configuration The FSC Safety Manager is configured at the FSC user station using the Introduction FSC Development System software (R42x) or FSC Navigator software (R5xx, R600). There are basically three configuration levels: • General FSC system configuration, • Central Part module configuration, and •...
  • Page 58 Module Configuration, Continued The Central Parts can only function correctly if they are properly Central Parts 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).
  • Page 59: Section 4 - Configuration

    PC. Refer to the FSC Software Manual. In order to successfully configure the FSC-SM system, you will need to be Version needed for using release 42x , 5xx or 600 of the FSC software and release 53x or 62x configuration for the TotalPlant Solution (TPS) system.
  • Page 60: Configuration At Fsc User Station

    FSC user software application. There are several things that need to be configured before the configuration 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, •...
  • Page 61: Configuration At Tps Universal Station

    US configurations: • Universal Control Network (UCN), • Node-specific (FSC-SM device), and • FSC-SMM data points. This section covers the FSC-SM configuration process at the US. It Configuration assumes that you have completed the implementation steps for start-up assumptions and have prepared the History Module (HM) and the system for network configuration.
  • Page 62: Table 4-2 Ucn Configuration

    Configuration at TPS Universal Station, Continued Once you have completed the start-up process for the US, follow the steps UCN configuration outlined in Table 4-2. Table 4-2 – UCN configuration Step Action Press the RESET button. ATTENTION The RESET button is located under the black metal panel at the top of the operator keyboard.
  • Page 63: Figure 4-1 Us System Status Display

    Configuration at TPS Universal Station, Continued Once you have loaded the Universal Personality, the System Status display First US 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 14:05:00 SYS VERS:...
  • Page 64: Figure 4-2 Us Engineering Main Menu Display

    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 FSC Safety Manager Installation Guide 10/01...
  • Page 65: Figure 4-3 Us Nim Build Type Select Menu

    Enter the requested data in the given slots. All configuration information should be taken from the FSC-SM Configuration Forms you have filled out. Select the FSC-SM for UCN node type and FSC for the FSC-SM platform. Press the [F12 LOAD] key to load your configuration.
  • Page 66: Figure 4-4 Us Ucn Node Configuration Display

    Configuration at TPS Universal Station, Continued Note that the network number can be from 1 to 20. The node number can UCN Node range from 1 to 63, using odd numbers only. Configuration display, continued Figure 4-4 – US UCN Node Configuration display 11 Jun 97 14:05:00 PED >>>>>>>...
  • Page 67: Figure 4-5 Us Node-Specific Configuration Display

    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 14:05:00 PED >>>>>>>...
  • Page 68: Figure 4-6 Us Process Point Building Display

    Configuration at TPS Universal Station, Continued You must once again return to the NIM Build Type Select Menu to access Process Point the FSC-SMM data point building displays. To do this, press the [F1 PED] Building display key. Select the PROCESS POINT BUILDING target, once you have returned to the NIM Build Type Select Menu.
  • Page 69: Table 4-4 Fsc-Smm Data Point Configuration Procedure

    ATTENTION Data entered should be based on the FSC-SM Configuration Forms you have filled out. Press the [F12 LOAD] key to load the data in the FSC-SM database. Press the [F9 WLK BACK] key to return to the Process Point Building display.
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  • Page 71 Index A, B Bolt-down, 19 Engineering Main Menu display, 52 Bolt-down holes, 6 Environmental conditions, 2 Building FSC-SMM data points, 57 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...
  • Page 72 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...
  • Page 73 READER COMMENTS Honeywell IAC's Automation College welcomes your comments and suggestions to improve future editions of this and other documents. You can communicate your thoughts to us by fax or mail using this form, or by placing a toll-free telephone call. We would like to acknowledge your comments—please include your complete name, address, and telephone number.
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