Model PDP Series 400 Maxdpu4F Hardware Guide: 278705 Rev. A5

Model PDP Series 400 maxDPU4F
Hardware Guide
278705 Rev. A5
Refer to this publication for complete and accurate information that helps you better operate and service Metso
Automation equipment. Your comments and suggestions are welcome.
Metso Automation
1180 Church Road
Lansdale, PA 19446
Attention: Manager, Technical Publications
Copyright 2007 by Metso Automation MAX Controls Inc.

Printed in the United States of America
All rights reserved
Metso Automation • 278705 •

Contents
CHAPTER 1 ...................................................................................................................... 1-1
Introduction .................................................................................................................................................................1-1
Distributed Processing Unit Functionality.................................................................................................................1-1
Model Numbers .................................................................................................................................................1-1
Distributed Processing Unit Hardware ..............................................................................................................1-2
Control Processor ..............................................................................................................................................1-2
Performance.......................................................................................................................................................1-2
I/O Bus Interface ...............................................................................................................................................1-2
Fully Self Describing Object Oriented Database...............................................................................................1-2
Fully Software Backplane Compliant................................................................................................................1-3
Sequence of Events............................................................................................................................................1-3
Distributed Processing Unit Specifications .......................................................................................................1-3
Powering the DPU .............................................................................................................................................1-3
Mounting the DPU ................................................................................................................................................1-4
Positioning the DPU in a Standard maxPAC Chassis .......................................................................................1-4
Positioning the DPU When Upgrading .............................................................................................................1-4
Mounting Procedures.........................................................................................................................................1-4
DPU Front Panel Controls and Features................................................................................................................1-5
Mode Switch......................................................................................................................................................1-5
maxNET Interface Ports ....................................................................................................................................1-5
Network Status LEDs ........................................................................................................................................1-5
Backup Port .......................................................................................................................................................1-5
Backup LED ......................................................................................................................................................1-5
Serial Port (Optional).........................................................................................................................................1-5
Reset Button ......................................................................................................................................................1-5
IOM Status LED................................................................................................................................................1-6
I/O Status LED ..................................................................................................................................................1-6
CP Status LED...................................................................................................................................................1-6
State LED ..........................................................................................................................................................1-6
Takeover Button ................................................................................................................................................1-6
IRIG-B Port (Optional)......................................................................................................................................1-6
CHAPTER 2 ...................................................................................................................... 2-1
DPU Front Panel Input/Output Connections ...........................................................................................................2-1

Overview ...................................................................................................................................................................2-1
Ethernet Network Connections..............................................................................................................................2-1
Configuring the Ethernet Switch .......................................................................................................................2-1
Backup Link ..........................................................................................................................................................2-2
Serial Port ..............................................................................................................................................................2-2
IRIG-B Interface Port (Optional) ..........................................................................................................................2-2

CHAPTER 3 ...................................................................................................................... 3-1
DPU Switch Setting and Button Controls ................................................................................................................ 3-1

Overview .................................................................................................................................................................. 3-1
Setting the Mode Switch................................................................................................................................... 3-1
Using the Reset Button ..................................................................................................................................... 3-2
Using the Takeover Button ............................................................................................................................... 3-2
CHAPTER 4 ...................................................................................................................... 4-1
Interpreting Status LEDs........................................................................................................................................... 4-1

Overview .................................................................................................................................................................. 4-1
Interpreting LED Status While DPU Is Booting Windows CE ............................................................................ 4-1
Interpreting LED Status during Normal DPU Operation ..................................................................................... 4-3
Interpreting Virtual I/O LED Status during Normal DPU Operation................................................................... 4-4
LED Indications During Soft Reset ...................................................................................................................... 4-4
CHAPTER 5 ...................................................................................................................... 5-1
Installing Windows CE and maxDNA Software onto the DPU CompactFlash Memory .................................... 5-1
Overview .................................................................................................................................................................. 5-1
Writing the CompactFlash Using the DPU4FSetup Utility .................................................................................. 5-1
Network Flash using Mode “E”........................................................................................................................ 5-2
Network Flash using Mode “C”........................................................................................................................ 5-3
Flash using a CompactFlash Reader/Writer ..................................................................................................... 5-3
CHAPTER 6 ...................................................................................................................... 6-1
Redundant DPU Operation ....................................................................................................................................... 6-1

Overview .................................................................................................................................................................. 6-1
Automatic Failover / Manual Takeover ............................................................................................................ 6-1
Automatic Failover ........................................................................................................................................... 6-1
CHAPTER 7 ...................................................................................................................... 7-1
Configuring and Starting the DPU ........................................................................................................................... 7-1

Demanding a Blank Startup.................................................................................................................................. 7-1
Starting a Standalone (single) DPU ...................................................................................................................... 7-2
Starting a Backup Pair of DPUs ........................................................................................................................... 7-2
Performing a Hot Software Upgrade .................................................................................................................... 7-4
Replacing a DPU in a Backup Pair....................................................................................................................... 7-5
Restarting a DPU after Failover............................................................................................................................ 7-7
Alarm Annunciation ............................................................................................................................................. 7-7
CHAPTER 8 ..................................................................................................................... 8-1
IRIG-B Interface......................................................................................................................................................... 8-1

Overview .................................................................................................................................................................. 8-1
maxDPU4F IRIG-B Specifications................................................................................................................... 8-2
IRIG-B Cabling ................................................................................................................................................ 8-2
DPU Configuration for IRIG ............................................................................................................................ 8-2
iv Metso Automation • 278705•

CHAPTER 9 ...................................................................................................................... 9-1
DPU-Specific Function Blocks....................................................................................................................................9-1

Overview ...................................................................................................................................................................9-1
Backup.......................................................................................................................................................................9-2
DPMS ........................................................................................................................................................................9-2
DPUTemp..................................................................................................................................................................9-3
SBPLimits..................................................................................................................................................................9-3
Chapter 1
Introduction
Distributed Processing Unit Functionality

The Model PDP Distributed Processing Unit (DPU), which runs under the
Windows CE.net real-time multitasking operating system, is the hardware
processing engine of the maxDNA distributed control system. The DPU
performs primary data acquisition, control, and data processing functions.
The DPU, also known as maxDPU4F, is a self-contained microprocessor-

based, rack-mounted unit, which occupies a single slot in a Remote
Processing Unit cabinet using an 8-wide maxPAC backplane. It is designed
to operate with user-defined combinations of maxDNA Model IOP
Input/Output Modules.
The DPU is also available with an optional serial port that may be accessed
by optional software running in a workstation. Together, they provide a
means for communicating with certain types of field devices (e.g., some
Programmable Logic Controllers).
As a station on maxNET, the DPU scans and processes information for use
by other devices in the maxDNA system. Each DPU performs:
• Comprehensive alarming and calculations
• Logging of Sequence of Events (SOE) data at 1 millisecond resolution
• Acquisition of trend information and other data
• Continuous scanning of Model IOP I/O modules
• Execution of predefined algorithms, called Function Blocks, for process

control and data acquisition.
Model Numbers
Model PDP401 – DPU4F #181550, #181555, or #181580
Model PDP403 – DPU4F #181550, #181555, or #181580 and Backup Cable

#050292
Model PDP406 – DPU4F w/IRIG & Comm. #181551, #181555, or #181581

Model PDP Series 400 maxDPU4F Hardware Guide
Model PDP408 – DPU4F w/IRIG & Comm #181551, #181555, or #181581

and Backup Cable #050292
Distributed Processing Unit Hardware

A DPU consists of a printed circuit board containing the Control Processor
(CP) and Input/Output Processor (IOP) and is installed in a maxPAC chassis.
The DPU’s front panel contains status LEDs, a MODE Switch, Backup
Connector, Network Connectors, and takeover and reset buttons. An
optional assembly also contains a Serial Port Connector for interface to PLCs
and a BNC Connector for interface to an IRIG-B time source. See "Front
Panel Controls and Features," later in this chapter.
Control Processor
The DPU is comprised of a single printed circuit board that contains a
Pentium-class (AMD Geode) Control Processor and a dedicated micro-
controller for scanning I/O. There are also sockets on the board for 64
Mbytes (minimum) of CompactFlash and 128 Mbytes of DRAM.
Performance
A multi-speed processing system is built into the maxDPU4F, which allows
objects to be executed in three different time classes. From as fast as 10 msec
to 1/2 second. Up to 8,500 control objects (Function Blocks) can be executed
in the DPU. Note also that Function Blocks can be combined to create
libraries of Standard and Custom Blocks. A Function Block can be as small
as an Atomic Block, such as an AND or OR gate.
A data point management system (DPMS) keeps track of the object size and
the total execution time for each time class.
I/O Bus Interface

A Motorola 68332 32-bit I/O processor and field programmable gate array
(FPGA) are used to interface to both the Model IOP I/O bus and to the I/O
Bus Expander Module (BEM) for remote I/O applications. Up to 60 Model
IOP I/O modules can reside on each electrical bus. See Publication 278596,
maxPAC Hardware Reference Guide, and for earlier Model 564 I/O, see
278563, Model IOP I/O System Installation and Preparation. The maximum
length of the Model 564 I/O bus is 30 ft. The length of the remote I/O link
with fiber optic extenders is up to 2000 m. When fiber optic extenders are
used, even a greater number of I/O modules may be supported by the DPU.
A configuration tool is available to help the user verify that a proposed

configuration of I/O modules and extenders is within the allowable limits.
Fully Self Describing Object Oriented Database
1-2 Metso Automation • 278705 •

Introduction
All information regarding the operation of the DPU is kept in DPU memory,
including: tag names, descriptions, tuning constants, alarm limits, etc. In
addition, all graphical configuration data (sheet number, object location,
wiring) is stored in the DPU.
This means that there is no possibility that the configuration observed is

different than that which is installed in the DPU.
Objects are stored in a fully hierarchical database, allowing for easy cut and
paste changes and protection of control strategies.
Fully Software Backplane Compliant

With the software backplane installed, the DPU can access any exposed data
stored anywhere in a connected system as long as the connected system also
uses the SPB Protocol. Peer-to-peer transfers are rapid and transparent. No
independent transfer agent is required.
The Software Backplane uses subscription services where data is only

transmitted when changes are detected.
Sequence of Events
Each DPU includes a built-in Sequence-of-Events (SOE) recorder that can
monitor up to 512 discrete inputs. These inputs are scanned 1,000 times a
second and state changes are time stamped with 1 ms resolution and stored in
the DPU's 10,000-event buffer. Each input has a separately configurable
digital filter for contact debounce.
Distributed Processing Unit Specifications

Operating temperature range 0 to 60 degrees C
Storage temperature range (-)25 to 70 degrees C
Relative humidity range 5 to 90% noncondensing
Power requirements 24 Vdc ±4 Vdc
Current: 0.9 A @ 24 Vdc
Powering the DPU

The DPU operates from the main 24 Vdc power supply system in the
maxDNA system cabinets.
Metso Automation • 278705 • 1-3

Mounting the DPU

The DPU is mounted on the Input/Output (I/O) backplane with maxPAC and
earlier Model 564 Input/Output modules.
Positioning the DPU in a Standard maxPAC Chassis

The DPU must be mounted in the left most position of the Model IOP rack to
allow for the best airflow. The Backup cable and Ethernet communications
cables should be laced to the left side of the chassis with at least a 1 inch
bend radius to allow for easy removal of the DPU, while limiting the strain
on the RJ45 connectors.
When using a second DPU for backup, it should be mounted vertically

beneath the primary DPU for ease of connection of the two-foot backup
cable. The cable is to be held in place by tying to the cable hold downs on
the side of the IOP rack.
The DPU is designed to allow installation and removal with the +24 V dc
power supply turned on.
Positioning the DPU When Upgrading

The DPU can be mounted on the right side of a Six Wide maxPAC chassis or
any slot of the Four Wide Model 564 chassis. In either case, remove all
mounting hardware and termination panels that supported the earlier model
DPU. Install a Chassis 4 Wide maxPAC adapter (Metso Automation
#047350) in the cleared space using the two mounting holes located in the
back panel metal frame.
If the previous DPU was a DPU4E, the Ethernet cables that were plugged
into the termination panel can be plugged directly into the front panel of the
DPU card. Make sure that the settings of the Ethernet switch match the setup
file. See Chapter 5 for the configuration setup.
If the previous DPU was a DPU3, DPU4A, or DPU4B; new Ethernet

switches and cables will need to be installed. Consult the factory for details
about this type of upgrade.
In all upgrade situations, the backup cable must be replaced with a DPU4F
backup cable (Metso Automation # 050292).
Mounting Procedures
Before mounting any hardware, refer to the cabling and field wiring sections
of Publication 278596, maxPAC Hardware Reference Guide, and Publication
278563, Model IOP Input/Output System Installation and Preparation.
To install the DPU in the rack, refer to Chapter 7 Starting the DPU.

Introduction
DPU Front Panel Controls and Features

All DPU controls, indicator LEDs, and push button switches are accessible
from the DPU’s front panel. Use this front panel to monitor or control
different aspects of the DPU. There are no internal switches or jumpers to be
set during installation.
Mode Switch
The Mode Switch is a 16 position rotary switch. It is read after a reset or
power up cycle of the DPU to determine its operational mode. The switch is
also read during online operation to allow setting of the mode to “Running”,
“Locked”, or “Offline”. See Chapter 3 for details.
maxNET Interface Ports

Dual Ethernet 10/100Base-T ports are provided to interface with the
maxNET communication network. The DPU communications is configured
to be 10Mbit Full Duplex, 100Mbit Full Duplex, or Auto-Negotiate. This
configuration setting is accomplished by inserting the DPU’s CompactFlash
into a reader/writer connected to the workstation and running the
DPU4FSetup utility. See Chapter 5 for details.
Network Status LEDs

These LEDs report the status of maxNET Network A and B links.
Backup Port
A 100 MB Ethernet interface is provided to pass database information to a
hot standby DPU. A custom Category 5 Ethernet cable (Part #050292) is
used to connect both DPUs via this port. A status signals are also passed
between DPUs through this port to indicate which DPU is in control.
Backup LED
This LED shows the status of redundancy for DPUs configured as a backup
pair.
Serial Port (Optional)

The optional Serial port is an eight-pin RJ45 connector that supports RS232
signal levels. This port can be used by the DPU to interface with external
PLC type equipment.
Reset Button

Pressing this button will cause the DPU to stop controlling and go through a
reset cycle. This should not be done casually as it can cause a severe
disruption to your process.
Refer to Chapter 3 for more detailed information on the use of this button.
IOM Status LED

The IOM LED shows the operational state of the IOM Processor.
I/O Status LED

This LED shows the status of I/O bus transactions.
CP Status LED
The CP Status LED reports the health of the Control Processor.
State LED
The State LED reports the current control state of this DPU.
Takeover Button
Pressing the Takeover button can force a previously inactive DPU to go
active. This should not be done casually as a manually forced takeover
occurs regardless of the inactive DPU’s ability to control. This can have
severe consequences to your process.
Refer to Chapter 3 for more detailed information on the use of this button.
IRIG-B Port (Optional)

The IRIG port is a BNC connector that supports an interface to a GPS
receiver. This option allows time synchronization to global time.

Chapter 2
DPU Front Panel Input/Output

Connections
Overview
All input/output connections are contained on the front DPU chassis panel.
The chassis contains:
• Two 10/100 Ethernet ports

• One Backup Link Port
• One Serial Port (Optional)
• One IRIG-B Interface Port (Optional)
This chapter describes each link in some detail.
Ethernet Network Connections

The DPU chassis contains two 10/100 Ethernet ports using RJ-45 connectors
to interface with the maxNET communication network. Network A and
Network B operate as independent networks. Because the Ethernet channels
are independent, a fault on one network or processor will not affect the
operation of the other, or cause a DPU failover. Ethernet messages are
sent/received based upon the DPU’s Ethernet address with minimal control
processor intervention.
Configuring the Ethernet Switch

Each DPU connects to the maxNET through two Ethernet switches – one for
Network A and one for Network B. For maximum performance, the
maxNET should be run at 100Mbps/Full Duplex. This is best done by
configuring the DPUs and the switch ports to Auto Negotiate for the speed
and duplex settings.
Note: When using the Cisco Catalyst 2950 Ethernet Switches, the switch and
DPU must be set to Auto-Negotiate.

Backup Link
A 100 Mbps Ethernet link is used to pass database information between an
active DPU and an inactive standby DPU. A custom Category 5e cable
(Metso #050292) connects the DPU backup pair together via the backup
link’s RJ-45 connector. Secondary DPUs will typically be installed in the
lower chassis just below the primary DPUs.
Serial Port
The DPU front panel contains a serial port utilizing an 8-pin RJ45 style
connector.
Table 2-1 provides the pin-outs for the 8-pin port. The signal levels are
standard RS232.
If a Stand Alone DPU or DCM is used, there is a cable that converts the RJ45
to the standard DB9. The part number is Metso # 075113.
The serial port supports redundancy when a backup pair of DPUs is used.
The serial port is only operational if the DPU is “Active”. The RS232
drivers on the “Inactive” DPU are turned off. The use of this feature requires
a redundancy cable to connect between the two DPUs and the RS232 device.
(Metso Automation # 050355). This cable has an RJ45 for each DPU and a
common DB9 connector with male pins.
Table 2-1. RJ-45 Serial Port Pin-outs
DPU4F Pin No. Single Cable #075113

(RJ45) Signal Name Redundancy Cable #050355
Pin No. (DB9 – male pins)
1 NC
2 NC
3 NC
4 Circuit Ground 5
5 RxD 2
6 TxD 3
7 CTS 8
8 RTS 7
IRIG-B Interface Port (Optional)

The DPU front panel optionally contains an IRIG-B ports for connecting to
an external time source. The connector is a BNC and is transformer coupled
on the DPU. See Chapter 8 for more details.

DPU Front Panel Input/Output Connections

Chapter 3
DPU Switch Setting and

Button Controls
Overview
The DPU front panel contains a hexadecimal rotary switch and pushbuttons
for Reset and Takeover. The mode switch is used to determine the
operational mode of the DPU. Refer to this chapter for discussions of these
DPU front panel switches and buttons.
Setting the Mode Switch

The mode switch, a 16 position rotary switch located near the top of the
DPU4F. The following defines the operation for each of the mode settings
for normal and test functionality. An “X” in the “Normal Use” column
indicates that the mode is one that DPU end users are expected to use. The
other modes are intended for factory personnel use.
Setting Normal Description

Use
0 X On-line operation but Locked which inhibits database
changes.
1 X Off-line operation. In this mode the outputs are “Frozen”
and therefore will not change. The State LED will be red.
The mode switch can be changed from “1” and back to “F”
without resetting the DPU.
2 (reserved)
3 (reserved)
4 (reserved)
5 (reserved)
6 (reserved)
7 (reserved)
8 Advanced Operational Mode – Operates as in normal mode
with additional diagnostic features. The local keyboard,
monitor, and mouse will be operational as well as serial
diagnostic messages. Used for factory debug. Performance
of the DPU will be degraded in this mode.
9 Execute diagnostics using the local keyboard, monitor, and
mouse. Always reset the DPU when exiting this mode.
A (reserved)
B X If this mode is set during a re-boot of the DPU, the DPU
will clear the Configuration Database from CompactFlash

and go on line as in mode “F”. Once the DPU is on-line the

Mode switch should be moved back to the “F” position so
that an unexpected restart of the DPU will not erase the
new database.
C X Network Flash mode where DPU uses a fixed IP and MAC
address. Used when the DPU needs to be configured for
first time use or change of address. The software can also
be upgraded on the DPU’s CompactFlash.
D Debug mode. This is a factory test mode. The DPU
applications will not start automatically.
E X Network Flash mode used to upgrade software on the
DPU’s CompactFlash. Some configuration parameters can
also be modified if necessary.
F X Normal operating mode. Will use the database stored in
flash if available.
Using the Reset Button

Pressing this button will cause the DPU to stop controlling and go through a
reset cycle. This should not be done casually as it can cause a severe
disruption to your process.
If the Reset button is pressed for less than 2 seconds, the DPU will save the
current configuration database and then reset itself (Soft Reset). If the Reset
button is depressed for longer than 3 seconds, the DPU will immediately
reset. (Hard Reset) NOTE: during normal operation the DPU continually
saves the configuration database to CompactFlash. For typical databases,
this will be done every 5 minutes. If a hard reset is performed, the DPU will
still contain a recent database and will attempt control once restored. This is
different from previous versions of the DPU where the configuration
database was not routinely saved. In previous DPUs, a Hard reset would
prevent the database save and the DPU would come up blank. To prevent
control or the use of a previous database, set the Mode Switch to “B” and the
DPU will clear the database during the boot cycle.
Using the Takeover Button

Pressing the Takeover button can force a previously inactive DPU to go
active. This should not be done casually as a manually forced takeover
occurs regardless of the inactive DPU’s ability to control. This can have
severe consequences to your process.
If the Takeover button is pressed on an inactive standalone DPU (i.e., backup

is not enabled), the inactive DPU will go active regardless of its health,
database, or key switch position. In this mode
If the Takeover button is pressed on the inactive DPU of a DPU pair (backup
enabled), the inactive DPU will go active regardless of its health or mode
switch position as long as it is hot. A “hot” DPU is one that has a database
that matches that of the other member of its pair (including the case where
neither DPU has a database).

DPU Switch Settings and Button Controls
Once takeover occurs, the now inactive DPU will “warm” (synchronize) its
database from the now active DPU. This will force the inactive DPU’s
database to match that of the active DPU. When the inactive DPU becomes
“hot”, it will automatically go active if the active DPU’s quality is
significantly below the quality of the inactive DPU.
If you wish to guarantee that an inactive DPU goes active and stays active,
you must “kill” the currently active DPU. This can be done by either
unplugging the DPU from its chassis or by writing to the “ForceFatal”
attribute of the active DPU.
Pressing the Takeover button on an active DPU has no effect.

Chapter 4
Interpreting Status LEDs
Overview
Refer to this chapter when you need to interpret the meanings of the 9 status
LEDs on the DPU front panel. At various times the LEDs flash green,
yellow, red or display no color to indicate the associated hardware’s
functional status. Discussions in the following sections explain what the
color changes may indicate under different DPU states.
The status LEDs are divided into the following sections:
Network Status LEDs

maxNET Network A health – 1 Green and 1 Yellow
maxNET Network B health – 1 Green and 1 Yellow
Backup link health – 1 Multicolor Green/Red/Yellow
Operational Status LEDs

IOM Health – 1 Multicolor Green/Red/Yellow
I/O Status – 1 Multicolor Green/Red/Yellow
CP Health – 1 Multicolor Green/Red/Yellow
State – 1 Multicolor Green/Red/Yellow
All or some of the LEDs display a set of color codes associated with the
following DPU states:
• DPU during a Windows CE boot

• DPU during normal operation
• DPU responding to soft reset
Interpreting LED Status While DPU Is Booting Windows CE

The following is a description of the LED sequencing starting from a reset to
the completion of initialization.
After Reset

After a reset, the IOM and CP LEDs are Yellow, while all others are off.
Once Windows CE is loaded into memory the CP initializes the FPGAs. This
results in the IOM LED going red and the I/O LED going off. The CP then
releases the IOM processor that causes it to execute startup diagnostics. The
I/O LED changes colors rapidly while executing the diagnostics. When
complete the IOM LED turns green and the I/O LED goes off.
If the BIOS on the CompactFlash is different than the one stored in onboard
flash it will be written to the onboard flash. During this time the CP and
State LEDs will alternately blink red. DO NOT stop the DPU during this
period or the flash could become corrupt and the DPU will need to be
returned to the factory for repair. Once the BIOS is written, the DPU will go
through another reset cycle. Most updates will not require a BIOS change.
Next the CP goes yellow while rebuilding the database. This can be brief or
up to 30 seconds depending on the size of the stored database. The CP LED
then turns to blinking green/yellow. This is a “heartbeat” signifying that the
CP is operational. The State LED goes red temporarily and then to green.
The network “A” and “B” LEDs start off blinking yellow until the DPU
hears communication from another station in its domain. The LED goes
solid yellow and then to green. If the LED remains solid yellow, it signifies
that this DPU is receiving a message from another station and the message
shows that the other station does not hear this DPU.

Interpreting the Status LEDs
Interpreting LED Status during Normal DPU Operation

maxNET NETWORK LEDs
LED Green Yellow Blinking Yellow Off
Network A Network A Some Network Error Network failure - DPU not Operational
Or Operational ** DPU does not hear or LED Bad
Network B from any station
** Each device (DPUs and Workstations) send messages that contain a list of all stations from which it is currently
receiving messages. If the DPU receives messages from a station that does not report receiving messages from it,
the DPU illuminates the Yellow LED. The problem may or may not be this DPU.
General Status LEDs

LED Green Yellow Red Off
Backup Backup Network Some Backup Communications Not DPU not Operational,
Network Operational and Network Failures in Established to other DPU has failed,
backup is enabled backup mode or the Backup DPU the backup cable is
DPUs are configured unplugged or the LED
in Stand Alone mode Bad
IOM Operational IOM N/A IOM Failed / Timed- IOM not initialized
out
Reset Required
I/O All configured I/O Some configured I/O No configured I/O No I/O cards
cards are working cards are working cards are working configured in the
correctly correctly, some are correctly database or IOM
not failure
CP Blink Yellow/Green – Blink Yellow/Green – Card Failure Card Failure
Healthy Heartbeat Healthy Heartbeat
Solid Green- CP Solid Yellow
failure (<20sec)– Loading, or
saving the Database
Solid Yellow (>20sec)
– CP failure
State See Below See Below See Below DPU not Operational
or LED Bad
DPU STATE LED

DPU States Active DPU State/LED Inactive DPU State/LED
Standalone DPUs Solid Green Solid Yellow
Backup Warming Blinking Green/Red Blinking Yellow/Red
Hot Backup Blinking Green/Yellow Blinking Yellow/Off
Backup Enabled No Backup Blinking Green/Off N/A
Available
Offline Solid Red Solid Red
Booting Off then Blinking Red Off then Blinking Red
Fatal Error Solid Red Solid Red

Interpreting Virtual I/O LED Status during Normal DPU Operation

The previous DPU (DPU4E) contained four I/O LEDs. The DPU4F contains
one I/O LED that is the combination of the four. The maxVUE DPU4F
Detail and DPU4FPair Detail displays show the four individual “virtual”
LEDs. These LEDs display the status of each of the four I/O queues. In
general, the I/O cards of a given type are assigned to the labeled LEDs;
however, due to I/O bus transaction processing requirements, some of the I/O
modules of different types or different applications are assigned to different
queues. The following table shows the queue assignments for each type or
application of an I/O module.
DI AO/DO AI Unlabeled LED

I/O Card LED LED LED (Item Queue)
SOE DI X
Slow DI X
AI 564 X
TC 564 X
RTD 564 X
AO 564 X
Counter Timer 564 X
Quad PAT 564 or maxPAC X X

Output Driver 564 X
DO 564 or maxPAC X
AI maxPAC X X
TC maxPAC X X
RTD maxPAC X X
AO maxPAC X X
Counter Timer maxPAC X X
Over Speed Module maxPAC X X

Turbine Valve Module maxPAC X X
LED Indications During Soft Reset

The CP and State LEDs turn red during the save of the database to the
CompactFlash. The DPU will then reset causing the I/O and CP LEDs to
turn yellow and all others off. See the startup sequence for details about the
restart.

Chapter 5
Installing Windows CE and

maxDNA Software
onto the DPU CompactFlash Memory
Overview
The DPU utilizes a CompactFlash for storing and retrieving all software and
configuration information for the DPU. The CompactFlash is non-volatile
and can be removed to allow updating or moving a configuration from one
DPU4F to another. The CompactFlash is a minimum of 64 Megabytes and is
industrial grade to allow for operation in harsh environments, as well as,
supporting a very large number of write cycles. If replacing the
CompactFlash, always use Metso part # 050263.
The CompactFlash contains the following files:
• Core Processor’s CE Windows operating system and application

firmware
• Input Output Manager (IOM) Flash Firmware
• Configuration File for Shared Memory FPGA
• Configuration File for IO FPGA
• IOM Diagnostic Code Firmware
• BIOS – Embedded BIOS code
• Initialization file containing DPU Name, IP Address, and general
configuration information
It is possible to update all of the DPU software in the field should it ever
become necessary to do so.
Writing the CompactFlash Using the DPU4FSetup Utility

Configure the DPU and install or update the software using the DPU4Fsetup
program. This program will allow the user to configure the IP Address, DPU
name, and other configuration options. The proper version of software can
also be selected for installation on the CompactFlash. Perform either a
Network Flash using Mode “E”, a Network Flash using Mode “C” or use a
CompactFlash Reader/Writer. The DPU4Fsetup program can be started by
selecting “Start – Programs – maxDNA – maxDPUs Utilities –

DPU4Fsetup”. Additional information on performing these updates can be

found by running the DPU4FSetup program and clicking on the “?” at the
top of the dialog.
Use the instructions below to perform one of the following:
Network Flash using Mode “E” – for updating software on a

previously configured DPU.
Network Flash using Mode “C” – for updating software and/or

configuration file on a DPU that has not been configured with the
proper IP address and DPU name.
Flash using a CompactFlash Reader/Writer – must be used for a

CompactFlash that does not contain maxDNA software and can be
used for all other updates.
CAUTION : If the software update includes a change to the BIOS, the new
BIOS will automatically be written to a flash chip on the DPU4F the first
time the DPU is booted. The CP and STATE LED’s will quickly alternate
Red denoting that the BIOS is being written. DO NOT reset or power down
during this period since it will cause the BIOS to be corrupted. If this occurs,
the DPU will not boot and must be sent back to the factory for repair.
Network Flash using Mode “E”

This mode can only be used if the DPU was previously configured for the
proper IP address and DPU name. It is used to perform a software version
update.
1. Set the Mode Switch to “E”.
2. If the DPU is already installed, reset the DPU. If the DPU is not
installed, insert the DPU part of the way into the chassis short of making
connection to the backplane. Plug in the Network A and B cables and
then insert the DPU fully into the chassis securing it with the two
thumbscrews.
3. Wait until Backup, CP, and State LEDs blink yellow and off.
4. Use the DPU4Fsetup program to write the new software to the DPU.
Select the proper DPU from the pull-down list and select Primary,
Secondary or Stand Alone. Select the proper version of Software to be
installed. Use the “Read DPU Via Net” to bring up the network settings
and then use “Write DPU Via Net”.
5. When writing is complete change the mode switch to “F” and reset the
DPU.

Installing Windows CE and maxDNA Software
Network Flash using Mode “C”

This mode should be used if the DPU contains a version of DPU software but
was never configured for the proper IP address and DPU name. Make sure
there is only one DPU set to Mode “C” at any one time or there would be
duplicated IP addresses on the network.
1. Set the Mode Switch to “C”.
2. If DPU is already installed, reset the DPU. If the DPU is not installed,
insert the DPU part of the way into the chassis short of making
connection to the backplane. Plug in the Network A and B cables and
then insert the DPU fully into the chassis securing it with the two
thumbscrews.
3. Wait until Backup, CP, and State LEDs blink yellow and off.
4. Use the DPU4Fsetup program to write the new software to the DPU.
Select the check box “Mode C DPU”. Do not use the “Read DPU Via
Net” since the configuration in the DPU is not valid. Set all
configuration parameters and version of Software to be used. Select
“Write DPU Via Net” to send the software and configuration file to the
DPU.
5. When writing is complete change the mode switch to “F” and reset the
DPU.
Flash using a CompactFlash Reader/Writer

This mode must be used if the CompactFlash does not contain a version of
maxDNA software. If can also be used to update the software or change the
configuration file.
1. If the DPU is not installed, remove the CompactFlash by using the eject
button. If the DPU is installed, unscrew the thumbscrews and slide the
DPU out far enough to eject the compact flash. (You may need to
remove the network cables.)
2. Use the DPU4Fsetup program to write the new software to the DPU. If
the DPU was previously configured, select “Read Flash Card” to retrieve
DPU name, IP address and network settings. If the DPU was not
configured or you want to change the configuration, enter all of the
necessary parameters. Select the version of Software to be used. Click
on “Write Flash Card” to send the software and configuration file to the
card.
3. Set the DPU Mode switch to “F”.
4. Insert the CompactFlash card into the DPU. Insert the DPU part of the
way into the chassis short of making connection to the backplane. Plug

in the Network A and B cables and backup cable. Then insert the DPU
fully into the chassis securing it with the two thumbscrews.
Additional information on performing these updates can be found by running

the DPU4FSetup program and clicking on the “?” at the top of the dialog.

Chapter 6
Redundant DPU Operation
Overview
In a redundant configuration, two DPUs are connected to form a backup pair.
One DPU is designated as the primary unit and the other DPU the secondary
unit. The IP address of the secondary DPU is always one number greater than
the address of the primary DPU. The primary is always the even address
while the Secondary is the odd address.
The installation, preparation, and adjustment procedures included in this

publication apply to both DPUs in a redundant configuration. This chapter
provides information on switches and cabling in a redundant configuration.
Automatic Failover / Manual Takeover

Process control can be transferred automatically (Failover), or can be
manually commanded to takeover. Automatic Failover can occur from either
the primary DPU to the secondary DPU or from the secondary to primary
based on the health of each DPU.
Automatic Failover
Process control is automatically transferred from the primary DPU to the
secondary DPU when the primary DPU experiences a severe diagnostic
alarm or when communication between primary and secondary DPU is lost.
However, if the secondary DPU is itself experiencing a severe diagnostic
alarm, it will refuse control, unless the primary DPU loses power or is reset.
Each DPU monitors the state of its own health as well as that of its backup.
The DPU looks at things like the state of its CP, IOM and backup link. It
also checks to see if it can hear good messages from the other DPU over
Network A and B and over the backup link.
From this information, each DPU calculates a health value for itself. This
value, along with other information, is used by the DPU when it is deciding
whether or not it should take control away from the currently active DPU.
Manual Takeover
To manually command the inactive DPU to assume control, press the

takeover button on the front panel of the unit. Manual takeover will occur
only if the inactive DPU is healthy enough to assume control. If a severe

diagnostic alarm or a fatal alarm condition exists in the inactive DPU then
the Takeover button will be ignored. For a more complete discussion of
manual takeover, see Chapter 3, “Using the Takeover Button.”
Pressing the Takeover button, on the Active DPU, has no effect.

Chapter 7
Configuring and Starting the DPU
Startup States
Refer to this chapter to learn how to:
• Start a standalone DPU

• Start DPUs in a backup pair
• Perform a Hot Software Upgrade
• Replace a DPU in a backup pair
When a DPU is first powered, it checks for a valid configuration and

database existing in its flash memory and proceeds to load it. The DPU then
listens over the backup link to see if another DPU is active and in control
before it operates on the loaded configuration.
If no backup DPU is present (no backup link communications, no Network

A/B communications, no active pulses on the backup link cable) then, the
DPU continues to operate with its loaded configuration and intended
operation as either a standalone DPU or a backup DPU. It becomes the
Active DPU since no other DPU is in control.
If a backup DPU is present then, this DPU listens to the other DPU over the
backup link as to its current operation as Standalone or Redundant DPU. If
the other active DPU is set as a Redundant DPU (NOT Standalone) then, this
inactive DPU will erase its configuration/database and proceed to gather
configuration and database information over the backup link. This DPU will
move from an empty state to a warming state and then to a hot standby state
and becomes ready to assume control when commanded to take over.
Demanding a Blank Startup

When a DPU is first placed in service it is advisable to clear any previous
configuration data that may remain in its flash memory. To do this, before
applying power to the DPU, set the Mode switch to ‘B’ on the DPU. After
the DPU has gone through its startup sequence as described in "Starting a
Standalone DPU," be sure to set the Mode switch back to ‘F’ to prevent
inadvertent loss of the database.

Note: if a DPU is moved from one location to another where the IP Address
is different, the initialization file on the DPU CompactFlash needs to be
modified. Use the DPU4Setup utility to make the necessary changes. The
default setting on the utility is to automatically erase any configuration
databases. It is still advisable to set the Mode switch to ‘B’ before installing
the DPU in the new location to additionally guarantee that it will come up
cold.
Starting a Standalone (single) DPU

Perform the following steps to ensure that a DPU is completely configured
before it is allowed to assume control.
To start a standalone DPU (single, not part of a DPU pair):
1. Configure the DPU and install the software using the DPU4Fsetup
program. Refer to the Chapter titled Installing Windows CE and
maxDNA Software onto the DPU CompactFlash Memory. This program
will allow the user to configure the IP Address, DPU name, and other
configuration options. The proper version of software can also be
selected for installation on the CompactFlash. For the Redundancy
option select “Station is Stand Alone” so that a backup cable (Metso #
050292) or jumper plug (Metso # 081388) are not required.
2. Since the DPU was reset at the end of the software installation, wait until
the CP LED begins to blink Yellow/Green signifying that the DPU is
operational.
3. Use the DPU4F Detailed Status Display to verify that the DPU is
operational.
4. Load the DPU configuration using the maxDPUTOOLS Download

Program from the maxSTATION.
5. Acknowledge all system alarms from the DPU and make sure that they
all clear. (Process alarms should be evaluated to determine if the DPU is
operating properly and it is OK to proceed to Unfreezing outputs.)
6. Utilize the Unfreeze feature to allow all or selective outputs to go to their

new computed values.
Starting a Backup Pair of DPUs

When starting a backup pair of DPUs, it is preferred (but not required), to
bring the primary DPU up first and make sure it is running properly before
starting the secondary.

To start DPU backup pairs:
1. Configure the Primary DPU and install the software using the
DPU4Fsetup program. Refer to the Chapter titled Installing Windows
CE and maxDNA Software onto the DPU CompactFlash Memory. This
program will allow the user to configure the IP Address, DPU name, and
other configuration options. The proper version of software can also be
selected for installation on the CompactFlash. For the Redundancy
option select “Station is a Primary DPU” for the first DPU and “Station
is a Secondary DPU” for the second.
operational.
3. Verify that the status LEDs on the DPU front panel are in the proper
state:
• “A” Network - Green

• “B” Network – Green if dual network and off if single network.
• Backup – Off (will turn Yellow when Secondary operational,
Secondary LED will also be Yellow)
• IOM - Green
• I/O - Off
• CP – Blinking Green/Yellow
• State – Green (when Secondary becomes operational, the Secondary
State LED will be Yellow)
4. Use the DPU4F Detailed Status Display to verify that the DPU is
operational. The Primary DPU State should be Active Stand Alone.
5. Repeat steps 1 to 4 for the Secondary DPU. The Primary DPU should
remain Active Stand Alone and the Secondary should be Inactive Stand
Alone.
6. Acknowledge all DPU alarms and verify that they clear.
7. Load the Primary DPU using the maxDPUTOOLS utility program from
the maxSTATION.
8. Enable Backup and make sure the Secondary DPU properly warms up.
9. Utilize the Unfreeze feature to allow all or selective outputs to go to their

new computed values.

Performing a Hot Software Upgrade

These instructions are for upgrading the software on a DPU pair that is in on-
line operation. Perform the following steps to ensure that a DPU is always in
control and that an unexpected failover does not occur during the
replacement process.
To perform a Hot Software Upgrade:
1. As a precaution, it is advisable (but not required) to put the points that

will be affected by the DPU pair into manual.
2. Make sure the active DPU does not have any severe outstanding alarms.
3. Disable Backup for the pair from either the DPU4F Detail Display or
maxDPUTOOLS.
4. Update the software on the inactive DPU using the instructions found in
the Chapter titled Installing Windows CE and maxDNA Software onto
the DPU CompactFlash Memory. (The preferred method for a hot
upgrade would be to use Network Flash Using Mode “E”.)
operational. The State LED should be yellow, signifying that it is
inactive.
6. From either the DPU4F Detail Display or maxDPUTOOLS, enable

backup to permit the active DPU to warm up the inactive DPU.
7. Once the DPU has ‘warmed’ (the pair is ‘hot), the following are the
expected states of the LEDs:
• ‘A’ Network – Green

• ‘B’ Network – Green if dual network and off if single network
• Backup – Green
• IOM – Green
• I/O – Green if any Redundant I/O, Off if no Redundant I/O
• State – Blinking Yellow/Off
8. Acknowledge all alarms from the new DPU and make sure they clear.
9. Transfer control to the upgraded DPU by either pressing its Takeover

button or by command through the DPU4F Detail Display or
maxDPUTOOLS. (Note: in this state the newly inactive DPU will not
‘warm’ since it has an older version of software than the active DPU.)
10. Disable Backup for the pair from either the DPU4F Detail Display or
maxDPUTOOLS.

11. Update the software on the newly inactive DPU as was done for the other
DPU in step 4.
operational. The State LED should be yellow, signifying that it is
inactive.
13. From either the DPU4F Detail Display or maxDPUTOOLS, enable

backup to permit the active DPU to warm up the inactive DPU.
14. Once the DPU has ‘warmed’ (the pair is ‘hot), the following are the
• IOM – Green
15. Acknowledge all alarms from the new DPU and make sure they clear.
16. It is preferred, but not required, to have the Primary DPU be the active
DPU. This can be accomplished by forcing a Takeover to the Primary if
it is not already in that state.
17. From maxDPUTOOLS, make sure the DPU is not running with frozen
outputs.
18. Make sure there are no severe alarms coming from the DPU.
19. If points were placed in manual at the start of this upgrade, they can be
returned to normal operation.
Replacing a DPU in a Backup Pair

When replacing a DPU in a backup pair, it is necessary to prevent the new
unit from gaining control until it is properly configured and up to date.
Perform the following steps to ensure that an unexpected failover does not
occur during the replacement process.
To replace a DPU in a backup pair:
1. Make sure the DPU that is to remain in place is active and there are no
severe outstanding alarms.
2. Disable Backup for the pair using the DPU4F Detail Display.

3. Pull the DPU being replaced far enough out of its chassis to disconnect
power.
4. Remove the Backup Cable, Network, “A” Cable, and Network “B” Cable
from the extracted DPU.
5. Remove the DPU from the chassis.
6. Either move the CompactFlash from the original DPU to the replacement
DPU or configure the new CompactFlash using the DPU4FSetup utility.
It is very important that the configuration file on the CompactFlash have
the proper DPU name and IP address and other configuration parameters.
a) Using the original CompactFlash: Move the CompactFlash from the

original DPU to the new DPU. Insert the DPU part of the way into
the chassis and connect all of the cables. Set the Mode Switch to ‘F’.
Fully insert the DPU into the chassis and secure with the
thumbscrews. Proceed to step 7.
b) Using the CompactFlash that is part of the new DPU: go to the

Chapter titled Installing Windows CE and maxDNA Software onto
the DPU CompactFlash Memory. The preferred method would be to
use the CompactFlash writer connected to the workstation to
initialize the CompactFlash. However, mode “C” Network Flash
could be used if a writer is not available. If mode “C” is used, make
sure the Mode Switch is set to “C” prior to installing the DPU in the
chassis so that the DPU does not attempt to load an old
configuration. Be sure to keep the default “Erase Database” when
using the DPU4F Setup program.
7. The DPU should have been reset at the end of the previous step. When
booting is complete, the following are the expected states of the LED’s:
• Backup – Yellow
• IOM – Green
• I/O – Off
• State - Yellow
8. Use the DPU4F Detail Display to verify the proper status of the new
DPU and make sure there are no outstanding alarms.
9. From the DPU4F Detail Display enable backup to permit the active DPU
to warm up the inactive DPU.
10. Once the DPU has ‘warmed’ (the pair is ‘hot’), the following are the

• IOM – Green
11. Acknowledge all alarms form the new DPU and make sure they clear.
Restarting a DPU after Failover

If an inactive DPU detects a problem with the active DPU, it will
immediately take control of the process and force the other DPU to become
inactive. If the originally active DPU is still operating, it will detect the loss
of control and go into an offline mode, setting its State LED to red. In this
mode the DPU will not warm from the new active DPU until manual
intervention.
DO NOT reset the active DPU since there is no available backup and all the
outputs will be reset. Pressing the reset button on the inactive DPU will
cause it to restart and, if capable, warm from the active. If it does not
properly warm, it should be replaced.
Alarm Annunciation
Diagnostic alarms originating at a DPU are posted as remote alarms on the
maxSTATION Alarm List. Refer to Publication 278558, Alarm Message
Reference Guide, for a description of these alarms. DPU front panel LEDs
also indicate certain fatal diagnostic alarms.

Chapter 8
IRIG-B Interface
Overview
IRIG-B is an international time signal standard. Many vendors sell very
accurate clocks that generate IRIG-B signals. IRIG-B is also available as an
output from many GPS satellite receivers. Such IRIG time signals are
typically accurate to within microseconds.
The maxDPU4F is available with an optional IRIG-B input (models PDP406

and PDP408, DPU assembly #181551). These DPUs have a BNC connector
through which the IRIG-B signal is applied and internal circuitry to decode
the signal. Once it decodes the signal, the DPU uses it as the basis for its
internal clock. Normally, the IRIG DPU is assigned the roll of a Time
Master (via a database setting) and it broadcasts the accurate time to the rest
of the DPUs, DBMs and direct access workstations in its domain. In this
way, the entire domain can be synchronized to an accurate clock.
The IRIG signal should be applied to both the primary and secondary of a
maxDPU4F pair to provide a redundant time source should one of the DPUs
fail.
The IRIG-B (B122) time signal is an amplitude modulated 1KHz sine wave.
Figure 1 shows a portion of a typical waveform. V1 and V2 represent the
peak-to-peak amplitudes of the two modulation levels.
Figure 1. IRIG-B Waveform

maxDPU4F IRIG-B Specifications

Interface Supported: IRIG-B Amplitude Modulated (B122)
Input range (V1): 3V to 10V peak-to-peak with 0VDC offset
Modulation Ratio (V1/V2): 2:1 to 4:1 (3:1 is optimal)
Input Impedance: >10K ohms
Input connector: BNC for coaxial cable
IRIG-B Cabling
The IRIG-B input is transformer coupled within the DPU. The BNC
connector is not grounded at the DPU. To prevent ground loop problems, the
IRIG-B signal/coaxial cable should only be grounded at the IRIG source.
The IRIG-B input does not have surge or transient protection so care should
be taken to ensure that the IRIG cable is not routed through electrically
hostile (noisy) areas. Keep it away from field wires, motor wires and other
noisy signals. To reduce the likelihood of noise pickup, do not run the IRIG
cable parallel to noisy wires.
Since the IRIG input on the DPU is high impedance and the IRIG sources
have low output impedance (typically 50 or 600 ohms), the signal may be
applied in parallel to multiple DPUs via BNC “T” or “Y” connectors.
However, if that single cable is damaged, all of the parallel-wired DPUs
could lose their IRIG signal. For more redundancy in an installation use
separate outputs from the IRIG source and wire each output to only one
DPU. For even more redundancy, use more than one IRIG source with one
driving a primary DPU and the other driving the secondary.
DPU Configuration for IRIG

The TimeSync atom in the DPU4F must be configured for IRIG operation.
Configuration and operating information is contained in the time

synchronization chapter in the System Resources User’s Guide (manual
#278609). That chapter also contains other important information on time
synchronization.

Chapter 9
DPU-Specific Function Blocks
Overview
The maxDPU4F contains a number of built in function blocks that are used
to configure and monitor some basic DPU features. These function blocks
are created automatically when the DPU starts (as opposed to being entered
by the user into maxDPUTOOLS and then being downloaded to the DPU).
They are contained within the System group and may be accessed by means
of the Point Browser.
It should be noted that most of the function block parameters are

automatically set by the DPU when it creates these blocks. Relatively few of
the values are user configurable. maxDPUTOOLS may be used to enter
values for the settings that are user configurable (e.g., to tell the DPU if it is a
Time Master or a Time Slave).
The values of many important attributes are shown in the maxDPU4F Status
and Detail displays.
The function blocks are briefly described below. Where appropriate,

additional information is either referenced or contained within this chapter.
DPMS – The DPMS function block is a container for a broad mix of

attributes concerned with the basic operation of the DPU.
Backup – This function block contains attributes that control and monitor
how two DPUs function as a pair (i.e., backup mode or stand alone).
UsrObj (_AlmTagText) – This function block is used to provide a template

for the standard text that appears when alarms occur.
UsrObj (_AlmEvtText) – This function block is used to provide a template

for the standard text that appears when events occur.
TimeSync – This function block is used to configure the DPU’s roll in

receiving or generating the system’s time reference. For more information,
refer to the Time Synchronization chapter of publication 278609, System
Resources User’s Guide.
Security_MCS – This function block is a collection of security-related

attributes. These attributes contain the settings for a security schemes

database that is downloaded by maxDPUTOOLS. See publication 278609,

System Resources User’s Guide, to learn how to set up a security schemes
database.
Security_Custom – This function block is a collection of security-related

attributes. These attributes contain the settings for a security schemes
database that is downloaded by maxDPUTOOLS. See publication 278609,
System Resources User’s Guide, to learn how to set up a security schemes
database.
QueOvrn – This function block is used to generate an alarm in the event that
the Normal time class software queue overruns.
NetAlarm – This block is used to generate an alarm if the DPU detects a

problem with Network A and/or Network B.
CommSec – The Communications Security function block provides statistics

on the numbers and types of messages that the DPU rejected for reasons of
security.
DPUTemp – This function block provides attributes that monitor the

temperature measured by the DPU’s on-board sensor.
DCM – The DCM function block is used to describe the quality of the
maxLINKS connections that are made to a DCM (Distributed
Communications Module). A DCM is a special type of DPU that is used to
provide serial communications links to foreign devices (e.g., PLCs). Refer to
publication 278714, Distributed Communications Module, for more
information.
SBPLimits – This function block is used to restrict (limit) the number of

subscriptions to the DPU. Limiting subscriptions increases DPU robustness
and security.
Backup
The Backup function block contains attributes that monitor and control how
two DPUs function as a pair (Backup mode or Stand Alone mode).
Attributes show the state, heath, and active/inactive status for both this DPU
and the other DPU of the pair. Two other attributes are used to display the
Time Since Boot and Time Since State Change of the DPU. Other attributes
are used to show the status of the DPU’s main memory (e.g., OK or memory
error detected) and, if possible, the reason for the last fatal error detected by
the DPU.
DPMS
The DPMS function block is a container for a broad mix of attributes
concerned with the basic operation of the DPU.

DPU Specific Function Blocks
Some attributes are used to store information about the identity of the DPU
such as the name of the DPU, IP address, serial number, revision level of the
DPU assembly, revision level of the software and so on.
Another group of attributes is used to describe the current state of the DPU
so that the DPU Detail display can be animated. This group includes
attributes such as those for the color of the IOM, CP, I/O and State LEDs.
The fourth major group contains DPU operating parameters such as the
values used by three function block execution time classes (Normal, High,
and Critical).
DPUTemp
This function block is responsible for reporting the temperature of the DPU
as measured by an on-board sensor. In addition to the actual temperature,
this block also provides alarms with configurable limits.
Important attributes are:
Out – The DPU temperature in degrees C.
LimHi – The high alarm limit in degrees C (default = 60)
LimHiHi – The high-high alarm limit in degrees C (default = 70)
LimLo – The low alarm limit in degrees C (default = 10)
LimLoLo – The low-low alarm limit in degrees C (default = 5)
The default values are consistent with the DPU’s operating temperature range
of 0 - 60°.
SBPLimits
The SBP Limiter is used to restrict (limit) the number of subscriptions to the
DPU. Limiting subscriptions increases DPU robustness and security. It also
protects against slow DPU response time (e.g., slow data update rate as seen
by maxVUE). The function block also generates alarms when the number of
subscriptions reaches a high alarm limit.
It is important to note that the SBP Limits function block only restricts new
subscriptions. It does not have any effect on existing subscriptions. To use a
very simple example, assume that a DPU currently has 100 subscriptions and
the SBP Limiter is configured to limit the total number of DPU subscriptions
to 120. This means that the DPU will accept no more than 20 additional
subscriptions. All subscription requests beyond this total will be rejected by
the DPU and the requestor will receive an appropriate error message. Now
assume that the DPU currently has 100 subscriptions. Further assume that
the user now configures the SBP Limiter to accept a total of only 50
subscriptions. The 100 existing subscriptions will not be effected. They will
still be honored and the requestors will still receive the data they want.

However, no new subscriptions will be accepted. All new subscribers will

receive an error message instead of the requested data.
The SBP Limiter does not restrict immediate data reads or data writes. These
are always accepted by the DPU regardless of the limits configured for
subscriptions.
There are seven configurable limits that the SBP Limiter uses to restrict data
access. These are called Hard Limits and are listed below. When a Hard
Limit is reached, an alarm is generated and new subscriptions will be
rejected.
HardLimConnBgnd – This is the maximum number of subscriptions

permitted that use the background priority level for their connection to the
SBP (Software Back Plane). Background is the lowest priority level for
connections. maxSTORIAN uses background priority for retrieving data
from the DPU.
The alarm text that will appear for this limit is:
“Subs Limit xx by AAAA:cc” (where xx is the subscription count, AAAA is
the Station name, and cc is the connection number).
HardLimConnLoop – This is the maximum number of subscriptions

permitted that use the loop priority level for their connection to the SBP.
Loop is the highest priority level for connections. It is used for DPU-to-DPU
(Peer-to-Peer) communications.
HardLimConnNorm – This is the maximum number of subscriptions

permitted that use the normal priority level for their connection to the SBP.
Normal is the medium priority level for connections. It is used by maxVUE
and is the default priority for other programs.
HardLimOutRef – This is the maximum number of subscriptions that this

DPU is allowed to make to external sources.
External Ref Limit xx (where xx is the count of external references).
HardLimStnSub – This is the maximum number of subscriptions allowed to

come from any one station. This limit prevents a single workstation from
hogging all of the DPU bandwidth.

Stn Subs Limit xx by AAAA (where xx is the count, AAAA is the Station
name).
HardLimTotalSub – This is the maximum number of subscriptions the DPU

will permit regardless of their source or priority.
Total Subs Limit xx (where xx is the count of total subscriptions to the
DPU).
HardLimUnOptRef – This is the maximum number of Unoptimized

References that are permitted in this DPU. An unoptimized reference is a
subscription to data that cannot be obtained by simply reading a value. Thus,
the unoptimized subscriptions present more of a load on the DPU than do
simple reads. For that reason, they are not desirable. Examples of
unoptimized subscriptions are reading a floating point number into an integer
variable (the number must be converted to the proper format before being
used) or reading a value that does not normally exist but that must be
calculated every time that it is needed. The Point Browser indicates an
unoptimized reference by using a yellow background color for the value in
the reference field.
UnOpt Ref Limit xx (where xx is the count of unoptimized references).
For each hard limit, the SBPLimiter function block also provides a
corresponding high alarm limit. The High Alarms are provided as a warning
that the subscriptions are approaching the hard limit values. The DPU does
not limit subscriptions when a High Alarm limit is reached.
The high alarm limits are listed below. Refer to the preceding text on Hard
Limits for descriptions of the high alarm limits.
HiLimConnBgnd
“Subs Limit High xx by AAAA:cc” (where xx is the subscription count,
AAAA is the Station name, and cc is the connection number).
HiLimConnLoop
HiLimConnNorm

HiLimOutRef
External Ref High xx (where xx is the count of external references).
HiLimStnSub
Stn Subs High xx by AAAA (where xx is the count, AAAA is the Station
name).
HiLimTotalSub
Total Subs High xx (where xx is the count of total subscriptions to the
DPU).
HiLimUnOptRef
UnOpt Ref High xx (where xx is the count of unoptimized references).
It is important to note that the user does not have to configure the SBPLimits
function block. Default values are automatically installed for both the hard
limits and the alarm limits. The default values have been carefully selected
to maximize functionality and to minimize the problems created by having
too many subscriptions. It is strongly recommended that the user does not
change the default values (especially for the hard limits).
There are a number of symptoms that can indicate that a DPU is overloaded
with subscriptions. These are:
1. Slow screen updates (data appears to be “frozen”)
2. maxVUE Display striping
3. Slow response to the Point Browser
4. Error messages from the SBP (“Cannot Allocate Buffer” or

“SBP Time Out”)
5. SBP Limiter alarms from the DPU
6. DPU failover
If the user’s system experiences SBP Limiter alarms or has DPUs reject
subscriptions, the proper course of action is to go to the source (e.g., the

workstation that is requesting too many subscriptions) and force it to reduce

its load.
The first step in this process it to identify the offender(s) (those programs or
stations that are requesting too many subscriptions). The SBPLimits function
block provides statistics attributes for that purpose. These attributes display
the name (Id) and subscription count (Cnt) from the biggest subscribers.
The following attributes identify the Loop, Normal and Background

connection priorities for the top five sources of subscriptions.
Loop1Id and Loop1Cnt – provide the name (Id) and number (Cnt) of
subscriptions from the Loop priority connection with the highest number of
subscriptions.
Loop2Id, Loop2Cnt, Loop3Id, Loop3Cnt, Loop4Id, Loop4Cnt, Loop5Id and

Loop5Cnt - provide the same type of information for the four next highest
Loop priority subscribers.
Norm1Id and Norm1Cnt - provide the name and number of subscriptions

from the Normal priority connection with the highest number of
subscriptions.
Norm2Id, Norm2Cnt, Norm3Id, Norm3Cnt, Norm4Id, Norm4Cnt, Norm5Id

and Norm5Cnt - provide the same type of information for the four next
highest Normal priority subscribers.
Bgnd1Id and Bgnd1Cnt - provide the name and number of subscriptions

from the Background priority connection with the highest number of
subscriptions.
Bgnd2Id, Bgnd2Cnt, Bgnd3Id, Bgnd3Cnt, Bgnd4Id, Bgnd4Cnt, Bgnd5Id and

Bgnd5Cnt - provide the same type of information for the four next highest
Background priority subscribers.
Note that the Point Browser normally only displays the values for the biggest
subscribers (Loop1, Norm1 and Bgnd1). To see the values for numbers 2
through 5, select “Expert” in the Point Browser’s “View” selection box.
The identities and subscription counts for the top five workstations that are
subscribing to the DPU are shown by the following attributes.
Stn1Id and Stn1Cnt – show the name and number of subscriptions coming
from the workstation issuing the most subscriptions to the DPU.
Stn2Id, Stn2Cnt, Stn3Id, Stn3Cnt, Stn4Id, Stn4Cnt, Stn5Id and Stn5Cnt –

show the same type of information for the four next highest subscribers.
Note that the Point Browser normally only displays the values for the
workstation issuing the most subscriptions to the DPU (Stn1Id, Stn1Cnt). To

see the values for numbers 2 through 5, select “Expert” in the Point
Browser’s “View” selection box.
TotalSubCnt – shows the total number of subscriptions to this DPU

regardless of their priority or from whom they come.
OutRefCnt – shows the number of subscriptions that this DPU is issuing to

external sources.
UnOptRefCnt – shows the number of unoptimized subscriptions in this DPU.
Figure 9-1 shows a portion of a Point Browser’s display of a typical

SBPLimits function block. Norm1Id and Norm1Cnt show that Chernobog is
the station that has issued the most (106) subscriptions to this DPU. The
subscriptions are coming in on SBP connection #32 (indicated by “:32” after
the station name). Station Aphrodite has issued the next highest number of
subscriptions with one coming in on connections #4 & #9. Dionysis also has
one subscription to this DPU on connection #6 and one on connection #9.
Figure 9-1 SBPLimits Statistics

If we now go to workstation Chernobog and look at its RRS window (Figure

9-2), we see that SBP connection 32 (shown in the “Num” column) comes
from maxVUE runtime (shown in the “Username” column).
Figure 9-2 maxRRS Window for Chernobog
After determining whom the biggest subscribers are, the next step is to
modify them to reduce the number of subscriptions they issue to the DPU.
The following list covers some basic methods for doing this.
1. Close unneeded maxVUE displays. When you are done looking at a

display, close it and swap to a display that contains less data from the
DPU.
2. Do not point large numbers of workstations at a DPU. Reduce the

number of workstations that are showing maxVUE displays of the
same DPU.
3. If an applications program requires a piece of data for multiple

calculations, do not read (subscribe to) the data in every calculation.
Instead, only subscribe to it once and store the reading in an internal
variable. Then use the internal variable in the other calculations.
4. Trend less data or store it at a lower sample rate or with a larger

“delta”.

Only as a last resort should the Hard Limits be increased. Increasing the
limits used by the SBPLimits function block runs the risk of overloading the
DPU.
Remember that the SBPLimits function block only causes the DPU to reject
new subscriptions. Subscriptions that already exist are not limited. In order
to reduce the number of subscriptions to a DPU to the configured limits, the
existing subscriptions will have to be reduced below the configured limits.
Existing subscriptions can be shed (eliminated) by either resetting the DPU
or by forcing unsubscribe. Unsubscribes may be forced by closing the
application that is issuing them (e.g., close the maxVUE displays, close
maxSTORIAN, etc.). When those applications are restarted, they will have
to issue new subscriptions to the DPU. Thus, they will come under the limits
configured in the SBPLimits block.

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Model PDP Series 400 maxDPU4F

Copyright 2007 by Metso Automation MAX Controls Inc.

Metso Automation • 278705 •

CHAPTER 2 ...................................................................................................................... 2-1

DPU Front Panel Input/Output Connections ...........................................................................................................2-1

Metso Automation • 278705 •

DPU Switch Setting and Button Controls ................................................................................................................ 3-1

CHAPTER 4 ...................................................................................................................... 4-1

Interpreting Status LEDs........................................................................................................................................... 4-1

CHAPTER 5 ...................................................................................................................... 5-1

CHAPTER 6 ...................................................................................................................... 6-1

Redundant DPU Operation ....................................................................................................................................... 6-1

CHAPTER 7 ...................................................................................................................... 7-1

Configuring and Starting the DPU ........................................................................................................................... 7-1

CHAPTER 8 ..................................................................................................................... 8-1

IRIG-B Interface......................................................................................................................................................... 8-1

iv Metso Automation • 278705•

DPU-Specific Function Blocks....................................................................................................................................9-1

Distributed Processing Unit Functionality

The DPU, also known as maxDPU4F, is a self-contained microprocessor-

• Comprehensive alarming and calculations

• Logging of Sequence of Events (SOE) data at 1 millisecond resolution

• Acquisition of trend information and other data

• Continuous scanning of Model IOP I/O modules

• Execution of predefined algorithms, called Function Blocks, for process

Model PDP403 – DPU4F #181550, #181555, or #181580 and Backup Cable

Model PDP406 – DPU4F w/IRIG & Comm. #181551, #181555, or #181581

Metso Automation • 278705 •

Model PDP408 – DPU4F w/IRIG & Comm #181551, #181555, or #181581

Distributed Processing Unit Hardware

I/O Bus Interface

A configuration tool is available to help the user verify that a proposed

Fully Self Describing Object Oriented Database

1-2 Metso Automation • 278705 •

This means that there is no possibility that the configuration observed is

Fully Software Backplane Compliant

The Software Backplane uses subscription services where data is only

Distributed Processing Unit Specifications

Storage temperature range (-)25 to 70 degrees C

Relative humidity range 5 to 90% noncondensing

Power requirements 24 Vdc ±4 Vdc

Current: 0.9 A @ 24 Vdc

Powering the DPU

Metso Automation • 278705 • 1-3

Mounting the DPU

Positioning the DPU in a Standard maxPAC Chassis

When using a second DPU for backup, it should be mounted vertically

Positioning the DPU When Upgrading

If the previous DPU was a DPU3, DPU4A, or DPU4B; new Ethernet

1-4 Metso Automation • 278705 •

DPU Front Panel Controls and Features

maxNET Interface Ports

Network Status LEDs

Serial Port (Optional)

Metso Automation • 278705 • 1-5

IOM Status LED

I/O Status LED

IRIG-B Port (Optional)

1-6 Metso Automation • 278705 •