Safety Report

Safety Report
Safety Report - Controlway A02 Daughtercard

Products Concerned:
INNPM12
IMMFP12
IMCPM02
PHCBRC10000000
PHCBRC20000000
PHCBRC30000000
PHCBRC40000000
Important Information:
In the first version of this Safety Report, ABB acted immediately to notify our customer base about the
conditions described in this document. After detailed evaluation, ABB has determined that this condition
does not represent or indicate a safety problem with our products.
Customers who have the products described in this Safety Report are directed to refer to Product Bulletin
3BUA000863 for the most current information about this issue.
Background Information and Purpose of this Document:

A problem has been identified with the Harmony Controlway communication bus interface design, and a
specific limited set of Harmony modules is capable of experiencing this problem. The purpose of this
notification is as follows:
· Provide awareness of the problem to the Harmony customer installed base
· Provide a description of the problem symptoms and a description of how this problem can affect
system operation
· Explain how to identify if a specific Harmony system is susceptible to experiencing this problem
· Provide the recommended resolution to the problem.
Problem Description:
The symptom of the problem is that some IMMFP12 or some PHCBRC100/200/300/400 modules may,
in isolated cases, experience a sudden but brief Controlway bus input value change. The bus input value,
when affected, may change to an incorrect value for ONE bus scan cycle (FC82 S13 scan cycle, or scan
cycle time of each bus input function code). This condition applies to bus input points (FC25 AI/B, and
FC41 DI/B) and bus input lists (FC63 AIL/B, and FC64 DIL/B). The receipt of an unexpected incorrect
bus input value into a controller module for one scan cycle could negatively affect system operation,
possibly resulting in a plant trip or other system mis-operation, if the application control logic within the
receiving controller uses bus points for this interlock purpose.
Module Identification:
ABB Inc.
Doc. Id. 3CUS000077 Rev. C Date. 2007-10-04 1 (4)

A Harmony Process Control Unit (PCU) may be susceptible to experience this problem if one (or more)
modules communicating on a specific Controlway bus within that PCU is of a specific nomenclature type
AND if one or more of these module nomenclature types has a specific version of the Controlway design
installed. It is possible to determine if a given Harmony PCU is susceptible to experience this problem by
visual inspection of the module types and the Controlway version of each module type within that PCU.
The specific module types affected are listed below. Furthermore, listed with each module type is the
potentially problematic Controlway version for that module type. If any one single module within a
Harmony PCU contains the problematic version of the Controlway design, the bus input problem can
potentially be experienced by any controller module within that PCU.
The problematic version of the Controlway design has been in existence and included in Harmony
products since August 2004. Any Harmony system assembled and delivered prior to this date will not
contain the problematic version of Controlway, unless newer expansion or replacement modules have
been added to the system. If any newer expansion or replacement modules have been added to an older
system, the system should be inspected for this potential problem.
The Controlway interface design has been recently enhanced to resolve and eliminate this problem within
the products identified in items 2, 3, and 4 below. The enhanced design is now included with all newly
manufactured products of these specific module types.
1. PHCBRC10000000 and PHCBRC20000000:
Inspect location U42 (lower-right corner of the board assembly). If this location contains a daughterboard
within a socket, and the daughterboard part number is 6644789A1, this module can cause or experience
the problem. The daughterboard part number will be either silk-screened on the surface of the circuit
board, or contain an adhesive label with the part number printed on the surface of the label.
2. PHCBRC30000000 and PHCBRC40000000:
Inspect location XU15 (top-center of the board assembly). If the socket contains a daughterboard AND
the daughterboard is part number 6644789A1, this module can cause or experience the problem. The
daughterboard part number will be either silk-screened on the surface of the circuit board, or contain an
adhesive label with the part number printed on the surface of the label. If XU15 does NOT contain a
daughterboard, inspect the label contained on either U26 (middle-left on the board assembly) or U71 (also
middle-left on the board assembly). If this label contains the checksum E19B, this module can cause or
experience the problem.
3. INNPM12:
Inspect location U27 (middle center of the board assembly). If this location contains a daughterboard
AND the daughterboard is part number 6644789A1, this module can cause controller modules within the
PCU where the INNPM12 module is installed to experience the problem. The daughterboard part number
will be either silk-screened on the surface of the circuit board, or contain an adhesive label with the part
number printed on the surface of the label.
4. IMCPM02:
Inspect locations XU18 and XU19 (middle-right on the board assembly). If these locations contain a
daughterboard AND the daughterboard is part number 6644789A1, this module can cause controller
ABB Inc.

modules within the PCU where the IMCPM02 module is installed to experience the problem. The
daughterboard part number will be either silk-screened on the surface of the circuit board, or contain an
adhesive label with the part number printed on the surface of the label.
5. IMMFP12:
Inspect location U27 (middle center of the board assembly). If this location contains a daughterboard
AND the daughterboard is part number 6644789A1, this module can cause or experience the problem.
The daughterboard part number will be either silk-screened on the surface of the circuit board, or contain
an adhesive label with the part number printed on the surface of the label.
Problem Resolution Options:

If a Harmony PCU contains one or more modules containing the problematic version of the Controlway
design, there are a couple methods to prevent the problem from affecting system operation in a negative
way. It is recommended that one of the following options be selected and implemented:
1. Hard-wire system-critical bus points (instead of sending any critical signals across the Controlway
bus).
2. Time delay filter on all critical Controlway bus inputs:

Because the bus input value change is only momentarily observed by the receiving module, as described
in the problem description section above, it is possible to time delay (or filter) the bus input within the
receiving module such that the logic does not respond to the momentary value change. To completely
eliminate a momentary digital bus point change, the required time delay must be greater than or equal to
the configured module bus scan rate + one controller module execution cycle time. For bus points, this is
S2 of FC82 + S13 of FC82. For bus lists, this is S1 of FC63 or FC64 + S2 of FC82.
The longterm resolution for these problems will be released in the form of an updated daughtercard,
revision A02. This resolution will become available for all modules listed above (with the exception of
the BRC100 and BRC200) beginning November 16, 2007.
Please contact ABB Technical Support at 1-800-HELP-365 (International = +1-440-585-7804) or

[email protected] for any questions regarding this product bulletin.
ABB Inc.

REVISION
Rev. ind.: Page (P) Description Date

Chapt. (C) Dept./Init.
New All New 200907
QA
C Page 1 Added reference to Product Bulletin 3BUA000863 03-OCT-07

PLM
ABB Inc.

Safety Report - Controlway A02 Daughtercard

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Background Information and Purpose of this Document:

· Provide awareness of the problem to the Harmony customer installed base

· Provide the recommended resolution to the problem.

Doc. Id. 3CUS000077 Rev. C Date. 2007-10-04 1 (4)

Doc. Id. 3CUS000077 Rev. C Date. 2007-10-04 2 (4)

Problem Resolution Options:

2. Time delay filter on all critical Controlway bus inputs:

Please contact ABB Technical Support at 1-800-HELP-365 (International = +1-440-585-7804) or

Doc. Id. 3CUS000077 Rev. C Date. 2007-10-04 3 (4)

Rev. ind.: Page (P) Description Date

C Page 1 Added reference to Product Bulletin 3BUA000863 03-OCT-07

Doc. Id. 3CUS000077 Rev. C Date. 2007-10-04 4 (4)

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