B0400DV

REV D

I/A Series®
Control Network User’s Guide
August 17, 2007

MONITORING, REPORTING, AND INFORMATION MANAGEMENT STATIONS

INFORMATION
NETWORK
(ETHERNET)
I/A Series HOST
AND APPLICATIONS
STATIONS

I/A Series CONTROL

NETWORK

I/A Series
CONTROL
STATIONS

I/A Series I/O AND FIELD INTERFACE DEVICES

Invensys, Foxboro, I/A Series, and Micro-I/A are trademarks of Invensys plc, its subsidiaries and affiliates.
All other brand names may be trademarks of their respective owners.

Copyright 2002-2007 Invensys Systems, Inc.

All rights reserved

SOFTWARE LICENSE AND COPYRIGHT INFORMATION

Before using the Invensys Systems, Inc. supplied software supported by this documentation, you
should read and understand the following information concerning copyrighted software.
1. The license provisions in the software license for your system govern your obligations
and usage rights to the software described in this documentation. If any portion of
those license provisions is violated, Invensys Systems, Inc. will no longer provide you
with support services and assumes no further responsibilities for your system or its
operation.
2. All software issued by Invensys Systems, Inc. and copies of the software that you are
specifically permitted to make, are protected in accordance with Federal copyright
laws. It is illegal to make copies of any software media provided to you by
Invensys Systems, Inc. for any purpose other than those purposes mentioned in the
software license.
Contents
Figures................................................................................................................................... vii

Tables..................................................................................................................................... ix

Preface.................................................................................................................................... xi
Purpose .................................................................................................................................... xi
Audience .................................................................................................................................. xi
Revision Information ............................................................................................................... xi
Reference Documents .............................................................................................................. xi

1. Introduction ...................................................................................................................... 1
Network Configurations ........................................................................................................... 2
Workstations ............................................................................................................................. 9
RCNI Module .......................................................................................................................... 9
NCNI Module ........................................................................................................................ 10
Ethernet Switches .................................................................................................................... 12
Cabling ................................................................................................................................... 12
Category 5 Cabling ............................................................................................................ 13
Fiber Optic Cabling ........................................................................................................... 13
Single Mode Cable ........................................................................................................ 14
Multimode Cable .......................................................................................................... 14
Media Converters ............................................................................................................... 14

2. Site Planning ................................................................................................................... 15

Site Planning Overview ........................................................................................................... 15
Physical Considerations ...................................................................................................... 15
Organizational Considerations ........................................................................................... 17
Network Design ...................................................................................................................... 17
Network Design Rules ........................................................................................................ 17
Carrierband LANs (CBLAN) ........................................................................................ 17
Control Network ........................................................................................................... 17
Control Segments .......................................................................................................... 18
Optical Budget (100Base-FX connections) .................................................................... 18
Non I/A Series Equipment ............................................................................................ 19
Workstations as Routers ................................................................................................ 19
Ethernet Switches with Short Aging Timers .................................................................. 19
Network Topology ............................................................................................................. 19
Network Devices ................................................................................................................ 21

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B0400DV – Rev D Contents

Network Cabling ................................................................................................................ 22

Fiber Optic Cabling ...................................................................................................... 22
Twisted-Pair Cabling ......................................................................................................... 24
Null Hub ...................................................................................................................... 25

3. Installation ...................................................................................................................... 27
Installing Network Components ............................................................................................. 27
Ethernet Switch Installation ............................................................................................... 27
Switch Configuration ......................................................................................................... 27
RCNI Module Installation ................................................................................................. 28
Module Identifier (Letterbug) Installation ..................................................................... 28
RCNI Mounting ........................................................................................................... 30
NCNI Module Installation ................................................................................................. 32
Media Converter Installation .............................................................................................. 34
Media Converter Configuration .................................................................................... 34
Connecting Network Components ......................................................................................... 34
Fiber Optic Cabling Guidelines .......................................................................................... 34
Connecting the NCNI Module .......................................................................................... 34
Connecting the RCNI Module .......................................................................................... 35
RCNI Connection to Ethernet Switch .......................................................................... 35
RCNI Connection to Workstation ................................................................................ 36
Interconnecting Ethernet Switches ..................................................................................... 37

4. Maintenance.................................................................................................................... 39
General Troubleshooting Guidelines ....................................................................................... 39
Characterize the Problem ................................................................................................... 39
Determine Which Devices are Affected .............................................................................. 39
Troubleshoot the Affected Devices ..................................................................................... 40
Indicators ................................................................................................................................ 41
RCNI Module .................................................................................................................... 41
NCNI Module ................................................................................................................... 42
Ethernet Switches ............................................................................................................... 43
Media Converters ............................................................................................................... 43

Appendix A. I/A Series Control Network Legacy Ethernet Switches.................................... 45

Introduction ............................................................................................................................ 45
8-Port Unmanaged Switch ................................................................................................. 45
8-Port Managed Switch ...................................................................................................... 46
24-Port Managed 10Base-T/100Base-TX Switch (P0972MH) ........................................... 47
8-Port Fiber/ 8-Port Copper Managed Switch (P0972WG) ............................................... 48
Legacy Ethernet Switch Configuration .................................................................................... 48
8-Port Unmanaged Switch Configuration .......................................................................... 48
8-Port Managed Switch Configuration ............................................................................... 49
24-Port Managed 10Base-T/100Base-TX Switch (P0972MH) Configuration .................... 49
8-Port Fiber/ 8-Port Copper Managed Switch (P0972WG) Configuration ........................ 51

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Contents B0400DV – Rev D

Legacy Ethernet Switches Connection ..................................................................................... 54

Fiber Optic Port to Fiber Optic Port ............................................................................. 54
Fiber Optic Port to RJ-45 Port ...................................................................................... 54
RJ-45 Port to RJ-45 Port ............................................................................................... 55
Ethernet Switch Interconnection Diagrams ............................................................................. 56

Appendix B. Natural Limitations in Communication Networks.......................................... 59

Summary ................................................................................................................................ 59
Introduction ............................................................................................................................ 59
Communication Protocols ...................................................................................................... 60
IEEE 802.3 ........................................................................................................................ 60
IEEE 802.4 ........................................................................................................................ 61
Optimum Protocol ............................................................................................................. 61
IEEE 802.3 Collisions ........................................................................................................ 61
Moore's Law ........................................................................................................................... 61
Bottleneck Effects .................................................................................................................... 61
I/A Series Loading Capabilities ................................................................................................ 62
Monitoring Bus Load ......................................................................................................... 62
System Diagnostics ............................................................................................................. 62
Overloading Effects ............................................................................................................ 63
Preventive Measures ........................................................................................................... 63
Conclusion .............................................................................................................................. 64

Index .................................................................................................................................... 65

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B0400DV – Rev D Contents

vi
Figures
1-1. I/A Series Control Network Block Diagram .................................................................. 1
1-2. Network Configuration Example #1 ............................................................................. 2
1-3. Network Configuration Example #2a ............................................................................ 3
1-4. Network Configuration Example #2b ........................................................................... 4
1-5. Network Configuration Example #3 ............................................................................. 4
1-6. Network Configuration Example #4 ............................................................................. 5
1-7. Network Configuration Example #5 ............................................................................. 6
1-8. Network Configuration Example #6 ............................................................................. 7
1-9. Network Configuration Example #7 ............................................................................. 8
1-10. Front View of RCNI Module ........................................................................................ 9
1-11. MAU Mode Letterbug Options .................................................................................. 10
1-12. Front Panel of NCNI Module .................................................................................... 11
2-1. Three-Tier Star Topology ........................................................................................... 21
3-1. RCNI Module Identifier ............................................................................................. 29
3-2. RCNI Rail Clamp and Mounting Bracket Assembly ................................................... 30
3-3. Slide RCNI onto Bracket Assembly ............................................................................. 31
3-4. DIN Rail Mounting Bracket Orientation .................................................................... 32
3-5. NCNI Nodebus Select Switch ..................................................................................... 33
3-6. NCNI Module Connection (Fiber Port) ..................................................................... 35
3-7. NCNI Module Connection (RJ-45 Port) .................................................................... 35
3-8. RCNI to Ethernet Switch (Fiber Port) ........................................................................ 36
3-9. RCNI to Ethernet Switch (RJ-45 Port) ....................................................................... 36
3-10. RCNI Connection to Workstation .............................................................................. 37
4-1. RCNI Indicators ......................................................................................................... 41
4-2. NCNI Indicators ......................................................................................................... 42
A-1. 8-Port Unmanaged Ethernet Switch (Typical) ............................................................ 46
A-2. 8-Port Managed Ethernet Switch (Typical) ................................................................. 46
A-3. 24-Port Managed 10Base-T/100Base-TX Switch (P0972MH) ................................... 47
A-4. 8-Port Fiber/ 8-Port Copper Managed Switch (P0972WG) ........................................ 48
A-5. 8-Port to 8-Port Connection via Fiber Optic Port ....................................................... 54
A-6. 16-Port to 8-port via Media Converter ........................................................................ 55
A-7. Connecting Switches via RJ-45 Ports (MDI Port) ....................................................... 55
A-8. Connecting Switches via RJ-45 Ports (Null Hub) ....................................................... 56
A-9. 8-Port Uplink Cabling Options .................................................................................. 57
A-10. Media Converter to Extend Transmission Distance .................................................... 58
B-1. I/A Series Communication Model ............................................................................... 59
B-2. The Perception of Ethernet ......................................................................................... 60
B-3. Health Concerns of the I/A Series Control Network ................................................... 64

vii
B0400DV – Rev D Figures

viii
Tables
2-1. Multimode Fiber Cable - Maximum Transmission ..................................................... 23
2-2. Fiber Optic Patch Cables with SC-type Connectors .................................................... 23
2-3. Fiber Optic Patch Cables with MT-RJ Connectors ..................................................... 23
2-4. Fiber Optic Conversion Cables (ST to MT-RJ) .......................................................... 24
2-5. Single Mode Fiber Optic Cable - Maximum Transmission ......................................... 24
2-6. CAT5 Cable - Maximum Transmission Distance ........................................................ 25
2-7. Prefabricated CAT5 STP Cables with RJ-45 Connectors ............................................ 25
2-8. Null Hub .................................................................................................................... 26
2-9. Grounded Null Hub ................................................................................................... 26
3-1. Switch Configuration Documentation ........................................................................ 27
3-2. Methods of Connecting Ethernet Switches ................................................................. 37
4-1. RCNI Indicators ......................................................................................................... 41
4-2. NCNI Indicators ......................................................................................................... 42
A-1. I/A Series Control Network Legacy Ethernet Switch Part Numbers ............................ 45
A-2. Configuration Settings - 8-Port Switch ....................................................................... 49

ix
B0400DV – Rev D Tables

x
Preface

Purpose
This document provides general guidelines and specific requirements for designing, installing,
and maintaining an I/A Series® control network. Topics include:
♦ Site Planning
♦ Installation
♦ Maintenance.
For detailed and specific information on the Ethernet switches, refer to the documentation sup-
plied by the switch vendor with the switch.

Audience
This book is intended for use by process engineering, operations, installation, and maintenance
personnel. They are expected to have a working knowledge of Ethernet LANs and I/A Series
configurations.

Revision Information
For this revision of the document (B0400DV-D), the following items were modified:
Chapter 3 “Installation”
♦ Added “Switch Configuration” on page 27.
Appendix B “Natural Limitations in Communication Networks”
♦ Added this appendix.

Reference Documents
The following documents provide additional or related information:
♦ Field Automation Subsystem Micro-I/A® Station User’s Guide (B0193VJ)
♦ Nodebus/Control Network Interface (PSS 21H-7B5 B4)
♦ Redundant Control Network Interface (PSS 21H-7B6 B4)
♦ Network Cable Systems Installation and Maintenance (B0193UW)
♦ Network Cable Systems Planning (B0193UX).
For information on configuring switches for the I/A Series control network, refer to the appendi-
ces in the following documents:
♦ A-Series (P0973BH/P0973BJ/P0973BK) Switches, Hardware and Software Configura-
tion Instructions (B0700CH)
♦ V-Series (P0972WP/P0972YC) Switches, Hardware and Software Configuration
Instructions (B0700CL)

xi
B0400DV – Rev D Preface

♦ E7 Chassis and 16-port Fiber (P0972MK/P0972MJ) Switches, Hardware and Software

Configuration Instructions (B0700CM)
For information on configuring media converters for the I/A Series control network, refer to the
following document:
♦ Media Converter Installation and Configuration Guide for Control Networks
(B0700CP)

xii
1. Introduction
This chapter provides an introduction to the concepts and equipment used in an I/A Series control net-
work.
The I/A Series control network is a switched Ethernet network based on IEEE 802.3u and IEEE
802.3z standards. The control network consists of a backbone of optionally redundant Ethernet
switches, which is connected to:
♦ Workstations
♦ Control Segments - control segments are similar to I/A Series node segments. The
connection to the backbone is made through NCNI modules.
The flexibility of the architecture allows users to design a network configuration that fits their
needs exactly. Configurations can be as simple as a Windows® host workstation connected
directly to a Micro-I/A station, or as complex as redundant Ethernet networks communicating at
up to gigabit speeds and interfaced with a control network.

Switch Switch Switch Switch Switch Redundant

Backbone

Control
NCNI Segment
Nodebus RCNI Workstation

NCNI Workstation

Switch Switch Switch Switch Switch Redundant

Backbone

Figure 1-1. I/A Series Control Network Block Diagram

1
B0400DV – Rev D 1. Introduction

Network Configurations
The following examples illustrate all of the network configurations that have been tested and
qualified. If you would like to implement other configurations, you are encouraged to contact the
Invensys Foxboro IPS Global Product Support.
Example #1
Figure 1-2 illustrates how a Micro-I/A station and a workstation can be connected using an Ether-
net switch with RJ-45 ports. Each device is connected to the switch by Category 5 (CAT5®),
shielded twisted-pair copper cable. A separation of up to 200 meters between the Micro-I/A sta-
tion and the workstation is possible with this configuration.

Workstation Micro-I/A
Copper Switch Station
X To PC = To HUB

CAT5 Cable CAT5 Cable

100 m (Max) 100 m (Max)

Figure 1-2. Network Configuration Example #1

2
1. Introduction B0400DV – Rev D

Example #2
Multiple existing node segments (control segments) can connect to the control network through
pairs of NCNI modules. Figure 1-3 illustrates a control network, divided into eight control seg-
ments and arranged in a star configuration. Note that FONBE (Fiber Optic Nodebus Extender)
modules are not allowed in any of the control segments. Additional devices may be connected to
the Ethernet switches.

NOTE
No more than eight pairs of NCNI modules may be used in this star configuration.

Gigabit Ethernet over

Fiber Uplink Ports
FAST ETHERNET WORKGROUP SWITCH FAST ETHERNET WORKGROUP SWITCH

RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

PWR PWR
RESET
CPU RESET
CPU
COM COM

Workstation Workstation

RCNI

RCNI

FAST ETHERNET WORKGROUP SWITCH FAST ETHERNET WORKGROUP SWITCH

RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

PWR PWR
RESET
CPU RESET
CPU
COM COM

Fiber Switch

A A A A

B B B B

NCNI NCNI NCNI NCNI

(Control Segment
CP CP #3 through #6 CP CP
omitted for clarity)
B A B A B A B A
Control Control Control Control
Segment #1 Segment #2 Segment #7 Segment #8

Figure 1-3. Network Configuration Example #2a

3
B0400DV – Rev D 1. Introduction

Figure 1-4 shows a single workstation using an RCNI module connected directly to the NCNI
modules on the Nodebus. Connections between the RCNI module and the NCNI modules use
multimode fiber optic cable terminated with MT-RJ connectors. The workstation is connected to
the RCNI module with CAT5 copper cable.

A
B A

Nodebus
RCNI
CP
Workstation NCNI
B
Figure 1-4. Network Configuration Example #2b

Example #3
The configuration in Figure 1-5 shows how a high speed Ethernet network can be connected to
an I/A Series Nodebus network by using a DNBT module to provide the interface between the
networks. Designing the network in this way allows workstations and Micro-I/A stations that are
connected to the Ethernet to access the I/A Series Nodebus network. By using optional fiber optic
uplink modules in the Ethernet switches, inter-switch communication at gigabit speeds is possi-
ble. Distances of 10 km between switches are possible if single mode fiber optic uplink
modules and cable are used.

Gigabit Ethernet over

Fiber Uplink Ports

Fiber Switch
FAST ETHERNET WORKGROUP SWITCH FAST ETHERNET WORKGROUP SWITCH

RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

PWR PWR
RESET
CPU RESET
CPU
COM COM

Copper Switch

Media
Media Converter
Converter

DNBT
MAU Mode

Workstation Workstation

Workstation Micro-I/A
Station
CP
A B
Nodebus
Figure 1-5. Network Configuration Example #3

4
1. Introduction B0400DV – Rev D

Example #4
The network configuration illustrated in Figure 1-6 includes redundant Ethernet networks for
improved reliability. Workstations are connected to both Ethernet networks through a Redundant
Control Network Interface (RCNI) module. One Ethernet network is connected to Nodebus A
through a Nodebus/Control Network Interface (NCNI) module, while the second Ethernet net-
work is connected to Nodebus B via another NCNI module. In the event that one Ethernet net-
work or one half of the Nodebus should fail, the workstation still has access to the devices on the
Nodebus. As in the previous example, communication between Ethernet switches can be at giga-
bit speeds. Depending on the uplink modules installed, CAT5 copper cable or fiber optic cable
can be used to connect the switches’ uplink ports.

Gigabit Ethernet over

Fiber Uplink Ports

Fiber Switch
FAST ETHERNET WORKGROUP SWITCH FAST ETHERNET WORKGROUP SWITCH

RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

PWR PWR
RESET
CPU RESET
CPU
COM COM

Copper Switch
Media
Converter
100Base-FX

RCNI RCNI RCNI

Workstation Workstation

Workstation
Media
Converter

FAST ETHERNET WORKGROUP SWITCH FAST ETHERNET WORKGROUP SWITCH

RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

PWR PWR
RESET
CPU RESET
CPU
COM COM

Note: Additional workstations may A

be connected to the switches. A B
For clarity, these have been
omitted from this diagram. Nodebus

CP NCNI
B

Figure 1-6. Network Configuration Example #4

5
B0400DV – Rev D 1. Introduction

Example #5
The configuration in Figure 1-7 shows how Micro-I/A stations can be connected to an I/A Series
Nodebus network by using NBI modules to provide the interface between the Nodebus and exist-
ing Micro-I/A stations.

Workstation

NBI NBI
NCNI 100Base-TX
A
A B

Nodebus
Media Micro-I/A
Converter Station
RCNI
B
“CB” “CA”

Copper Switch

AUI Port Hub

Legacy
Workstation
Micro-I/A
Station

AUI port
Hub
Figure 1-7. Network Configuration Example #5

6
1. Introduction B0400DV – Rev D

Example #6
Figure 1-8 illustrates how NCNI modules can be used to extend a node’s Nodebus. Connections
between NCNI modules can be made using either CAT5 copper cable, or multimode fiber cable.
Fiber optic cable allows for distances of up to two kilometers between Cellbus structures, while
CAT5 allows for 100 m. In addition, fiber optic cable is immune to electrical interference.

NOTE
When control segments are joined, as in this example, a maximum of two (2) fiber
optic control segments are allowed. These segments are not allowed to contain Fiber
Optic Nodebus Extender (FONBE) modules. Copper Nodebus extenders are
allowed.

NOTE
Distances between control segments greater than 2 km are possible using single
mode fiber. Contact the Invensys Foxboro Customer Service Center for assistance.

Cellbus Cellbus

A A

B B

Fiber
NCNI NCNI

CP CP

B A B A

Control Control
Segment #1 Segment #2

Figure 1-8. Network Configuration Example #6

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B0400DV – Rev D 1. Introduction

Example #7
Figure 1-9 illustrates how an extended Nodebus can be connected to the control network. In this
example, connections to the switches in the control network are made through fiber optic cable.
Connections between NCNI modules use both multimode fiber optic cable and CAT5 copper
cable. As in the example above, no more than two (2) control segments are allowed to be con-
nected together in this manner.

100Base-FX
A A
FAST ETHERNET WORKGROUP SWITCH

RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

PWR
RESET
CPU
COM

Workstation Workstation
B B
RCNI RCNI

NCNI

Fiber Switch FAST ETHERNET WORKGROUP SWITCH

RX

1
TX RX

2
TX RX

3
TX RX

4
TX RX

5
TX RX

6
TX RX

7
TX RX TX

8
RX

9
TX RX TX

10
RX TX

11
RX TX

12
RX TX

13
RX TX

14
RX TX

15
RX TX

16

PWR
RESET
CPU
COM

CP CP

B A B A
100Base-FX
Control Control
Segment #1 Segment #2

A A A A A A

CAT5 CAT5 CAT5

B B B B B B

NCNI NCNI NCNI NCNI NCNI NCNI

CP CP CP CP CP CP

B A B A B A B A B A B A

Control Control Control Control Control Control

Segment #3 Segment #4 Segment #5 Segment #6 Segment #7 Segment #8

Note: For NCNI-to-NCNI connections, a special crossover cable is used (P0972MQ). In addition to the
signal crossover, this cable provides a necessary connection between the cable shield and the
grounded DIN rail. See “Category 5 Cabling” on page 13

Figure 1-9. Network Configuration Example #7

8
1. Introduction B0400DV – Rev D

NOTE
Also refer to Appendix B “Natural Limitations in Communication Networks” on
page 59 for additional detail on planning an I/A Series control network.

Workstations
The following I/A Series stations can be connected to the control network:
♦ P92 Windows Host Workstation
♦ P79 UNIX® Host Workstation
♦ P80 UNIX® Host Workstation
♦ P81 UNIX® Host Workstation.
These workstations provide host services to Micro-I/A stations, fault-tolerant control processors,
Integrator 30s, and so forth. In addition, the workstations provide the operator interface for the
display of graphic and textual information.
Each workstation connects to the dual 100Base-FX networks by way of a RCNI module. The
workstation connection to the RCNI module is made through a cable adapter and Invensys
Foxboro Category 5 (CAT5) cabling.

RCNI Module
The Redundant Control Network Interface (RCNI) module is designed to act as a communica-
tions network interface between an I/A Series workstation and the Ethernet switches and NCNI
modules used in the control network. Figure 1-10 shows the front and side of the module.

Figure 1-10. Front View of RCNI Module

The module is designed as a stand-alone unit (P0972QM - RCNI only) and is equipped with
four rubber feet for placement on a tabletop or other flat surface. Alternatively, the module can be
mounted to a DIN rail through the use of a separate mounting adapter (P0972PF - RCNI
w/adapter). Power to the unit is supplied through an IEC-320 power connector on the side of the
unit. Six I/A Series letterbug sockets contain the station identity which can be communicated via
RS-423/232 to the attached workstation upon request. Five LEDs provide module and commu-
nication line status.

9
B0400DV – Rev D 1. Introduction

Ethernet communication between the RCNI module and the workstation is by either 10Base-T
or 100Base-TX protocol through the module’s RJ-45 connector. Two MT-RJ connectors allow
communication with two separate Ethernet switches via 100Base-FX multimode fiber optic
connections.
RCNI control information is communicated via RS-423/232 lines which share the CAT5 cable
with the Ethernet communication lines.
For more information on the RCNI module, including device specifications, refer to I/A Series
Hardware Redundant Control Network Interface (PSS 21H-7B6 B4).
MAU Mode
The RCNI module has an alternate fixed mode of operation in which it is not under control of
the workstation. In this mode network transmit and receive parameters are determined by the
characters installed in the front panel letterbug sockets. When the RCNI is in MAU mode the
workstation does not have the ability to receive the station identifier from the RCNI.

NOTE
MAU mode is not normally used. The RCNI module should be configured for its
default mode unless there is a specific reason for using MAU mode.

MAU mode is enabled when the four left-most letterbug sockets are either empty, or have null
code letterbugs installed. Anything other than null letterbugs or empty sockets in these four posi-
tions causes the RCNI to operate in its default mode and to interpret the characters in the six
letterbug sockets as the station identifier. When the RCNI module is in MAU mode, the two
right-most letterbug sockets determine the transmit and receive characteristics of the RCNI mod-
ule. Refer to Figure 1-11 for the valid letterbug characters and their meaning.

Letterbug Socket 1
Null letterbugs A = Transmit on Network A
(or empty) B = Transmit on Network B

C A
Letterbug Socket 2
A = Receive on Network A
B = Receive on Network B
C = Receive on Networks A & B

Figure 1-11. MAU Mode Letterbug Options

NCNI Module
The Nodebus/Control Network Interface (NCNI) module (P0972PP) is designed to enable com-
munication between a Nodebus and the control network. The NCNI module must be mounted
in a Cellbus structure in order to obtain power and connection to the Nodebus. Figure 1-12
shows the front panel of an NCNI module.

10
1. Introduction B0400DV – Rev D

Nodebus Switch
(A or B)

MT-RJ Port
Status

MT-RJ Port
Nodebus
Transmit

RJ-45 Port
Status
RJ-45 Port

Module Status
Green
Red

Figure 1-12. Front Panel of NCNI Module

The NCNI connects to the control network through the connectors on the front panel. Using the
MT-RJ connector, it can connect directly to a 100Base-FX Ethernet switch port using 62.5/125
micron multimode fiber. Alternatively, a 10Base-T/100Base-TX connection can be made using
the RJ-45 front panel connector and CAT5 cable.

NOTE
Only 62.5 micron multimode fiber optic cable is supported. Use of cable other than
62.5 micron multimode fiber optic cable could result in data loss or impaired
performance.

Two LEDs at the bottom of the front panel indicate the module’s power status. The red LED is
turned on if any of the module’s four power monitors (-12 V, 5 V, 3.3 V, 2.5 V) are not satisfied.
The green LED lights only if all four power monitors are satisfied.
Three yellow LEDs in the center of the front panel provide Nodebus and switch port status.
There is one LED each for the 10Base-T/100Base-TX port, the 100Base-FX port, and the Node-
bus status. The LEDs for the TX and FX ports light when the link connection is made, and blink
when there is transmit or receive activity on the associated port. The Nodebus LED lights when
data received by the switch port is being transmitted onto the Nodebus.
A two-position slide switch at the top of the front panel determines the module’s Nodebus selec-
tion (bus A or bus B).

11
B0400DV – Rev D 1. Introduction

NOTE
Two NCNI modules are required for the Nodebus interface. The “A” module trans-
fers data between Nodebus A and Network switch A. The “B” module transfers data
between Nodebus B and Network switch B. For proper operation of the network,
the data cable from the module’s switch port must be connected to the same Ether-
net network as the selected Nodebus (for example, Nodebus A to Ethernet A, Node-
bus B to Ethernet B).

! CAUTION
The Nodebus select switch on each of the two NCNI modules must be set to select
a different bus (A or B). If both NCNI modules are set for the same bus, the control
network does not operate correctly.

For more information on the NCNI module, including device specifications, refer to I/A Series
Hardware Nodebus/Control Network Interface (PSS 21H-7B5 B4).

Ethernet Switches
A switch is an active multiport communication device that provides a separate collision domain
for each port, and uses Media Access Control (MAC) layer to direct network packets to the appro-
priate station or switch. This allows multiple simultaneous communications among network
devices connected to the switch.
The current switches which support the I/A Series control network are discussed in the docu-
ments listed in “Reference Documents” on page xi. Legacy switches are discussed in Appendix A
“I/A Series Control Network Legacy Ethernet Switches” on page 45.

Cabling
Three different types of cabling are used:
♦ Shielded twisted-pair 10/100 BaseT CAT5 cabling - 100 m (328 ft.) maximum
♦ Multimode fiber optic cabling - 2 km (1.24 mi) maximum
♦ Single mode fiber optic cabling - 10 km (6.21 mi) maximum.

NOTE
Single mode fiber cable is used only for uplink connections between Ethernet
switches.

Depending on the number and the geographical distribution of the stations in the control net-
work, you can interconnect up to five switches in series.

12
1. Introduction B0400DV – Rev D

Category 5 Cabling
There are two basic configurations of Category 5 (CAT5) cables:
♦ Straight-through cables: cables used to connect workstations to RCNI modules,
NCNI modules to Ethernet switches, and media converters to Ethernet switches.
♦ Crossover cables (also called a null hub): cables used to interconnect Ethernet
switches. For NCNI-to-NCNI connections a special crossover cable is used
(P0972MQ). In addition to the signal crossover, this cable provides a necessary con-
nection between the cable shield and the grounded DIN rail.
When one switch is connected to another, the transmit and receive wires must be crossed over,
such that the transmit wire from switch #1 connects to the receive wire from switch #2, and vice
versa. Crossover cables are used much less frequently than straight-through cables. A straight-
through cable can be used as a crossover cable, by using a null hub cable (P0971PK).
A null hub is a very short cable that has a male connector on one end and a female connector on
the other. The transmit and receive wires are reversed, so when it is connected to the end of a
straight-through cable, the resulting cable system can act as a crossover cable. The null hub is used
to interconnect switches using straight-through CAT5 when neither switch is equipped with an
MDI-X port (crossover port).

Fiber Optic Cabling

Fiber optic cable is used to connect RCNI and NCNI modules to Ethernet switches and to make
connections between Ethernet switches. The fiber optic cable’s electrical isolation characteristics
provide protection from voltage differentials and ground loops and permit communication instal-
lations to pass through areas where intrinsically safe operation is required. The fiber optic cable is
unaffected by electrical noise such as EMI and RFI and can be installed even in the following
cases:
♦ Areas containing rotating machinery, arc welders, and so forth
♦ Cable trays containing high voltage power lines
♦ Outdoor areas exposed to lightning hazards
♦ Areas containing strong magnetic fields.
Two different types of fiber optic cable may be used in the I/A Series control network:
♦ Single mode cable (uplink only)
♦ Multimode cable (switch-to-device connections and uplink connections).

NOTE
Single mode and multimode fiber optical devices are not compatible. Both devices
being connected (and the cable) must be of the same type in order to ensure proper
operation. In certain limited cases (connecting Ethernet switch uplink ports, for
example), a conditioning cable may be employed so that multimode fiber cable can
be used with a single mode device. For specific information, refer to the diagrams in
the Appendix “Ethernet Switch Interconnection Diagrams” in the switch docu-
ments listed in “Reference Documents” on page xi, and in “Ethernet Switch Inter-
connection Diagrams” on page 56 for legacy switches.

13
B0400DV – Rev D 1. Introduction

Single Mode Cable

In the control network, single mode fiber optic cable can be used to connect Ethernet switches to
each other through each switch’s uplink port. The uplink ports of each of the switches being con-
nected must be designed for single mode operation. The cable should be terminated with SC-type
connectors.

Multimode Cable
Multimode fiber optic cable is employed in five different situations in an I/A Series control net-
work:
♦ RCNI to Ethernet Switch - The RCNI module is capable of connecting directly to an
Ethernet switch’s 100Base-FX port using a multimode fiber optic cable terminated
with MT-RJ connectors. If the Ethernet switch does not have fiber optic ports, a
media converter can be used between the RCNI and the switch to enable a connec-
tion. In this case, multimode fiber cable is used between the RCNI and the media
converter, while the connection between the media converter and the Ethernet switch
uses CAT5 copper cable.
♦ NCNI to Ethernet Switch - The NCNI module is also capable of connecting directly
to an Ethernet switch’s 100Base-FX port using a multimode fiber optic cable termi-
nated with MT-RJ connectors. In addition to its MT-RJ fiber optic connector, the
NCNI module has a standard RJ-45 port. This allows connection to 10Base-T or
100Base-TX Ethernet ports without the need for a media converter.
♦ Ethernet Switch to Ethernet Switch - Ethernet switches that are equipped with multi-
mode fiber uplink ports may be connected. The fiber optic cables should be
terminated with SC-type connectors.
♦ NCNI Module to NCNI Module - One pair of NCNI modules can be connected to
another pair in order to join two control segments. The fiber optic cable used to con-
nect the modules should be equipped with MT-RJ connectors.
♦ RCNI Module to NCNI Module - An RCNI module can be connected to a pair of
NCNI modules to enable a workstation to access devices on the Nodebus. Use fiber
optic cable terminated with MT-RJ connectors for this connection.

Media Converters
The media converter provides a means for connecting devices that use CAT5-STP copper cable
with RJ-45 connectors, to a device that uses multimode fiber optic cable. This allows you to con-
nect an RCNI module to Ethernet switches that are not equipped with fiber optic ports, while
gaining the benefits of extended range isolated fiber optic transmission.
For specific information on the media converters, refer to Media Converter Installation and Con-
figuration Guide for Control Networks (B0700CP), and in “Ethernet Switch Interconnection Dia-
grams” on page 56 for legacy switches.

14
2. Site Planning
This chapter describes the steps that should be taken and the options that should be considered
when planning an I/A Series control network.
The design of each control network is different, and depends on the needs and requirements of
the individual site. The following paragraphs provide the information necessary to help network
designers plan an I/A Series control network that meets the needs of their specific site.

Site Planning Overview

An I/A Series control network is designed to allow communication between the control stations
and workstations connected to the network. This network is formed by interconnecting the con-
trol stations and workstations using fiber optic or copper cable, Ethernet switches, interface
devices (RCNI and NCNI modules) and, if necessary, media converters. In a properly constructed
network, all the stations on the network are able to communicate with each other. If a higher
degree of reliability is required, the control network can be constructed of redundant networks,
providing two signal paths between each device on the control network.
The design of a control network is driven largely by the site’s physical environment, but must also
take into consideration organizational requirements. In addition, there are rules that must be fol-
lowed when connecting devices to form a control network. The following two sections explain the
factors affecting the physical and the organizational designs of the network.

Physical Considerations
The physical location of equipment at the site influences the network design. Use the answers to
the following questions, along with the network design guidelines and device and cable specifica-
tions in this chapter, to choose equipment and cabling appropriate to the requirements for the
specific site.
♦ What is the maximum end-to-end distance between devices in the network?
The distance between the ends of the network may determine what kind of Ether-
net switches are used and what kind of cabling is used between those switches. If
individual cable runs are greater than a hundred meters, it is necessary to use fiber
optic cable for at least one connection, due to its greater transmission distance.
♦ How many control stations and workstations will be connected to the network?
The number of control stations and workstations influences how many Ethernet
switches and separate cables are included in the network. It may be wise to plan
for expansion and growth when arriving at this number.

15
B0400DV – Rev D 2. Site Planning

♦ How are the control stations and workstations distributed?

The physical distribution of control stations and workstations could have a bear-
ing on the type and number of Ethernet switches, as well as the type of cabling
used. If the control stations and workstations are clustered together, a single larger
capacity switch may be able to accommodate them all. If they are dispersed, sev-
eral smaller switches may be a better solution. Large distances might require the
use of fiber optic cable between switches or between switches and control stations
or workstations. Cable routing between devices must also be considered.
♦ Will the network have redundant cabling?
Redundant networks require twice as many switches and cables. If they are being
used, more media converters may be required.
♦ If redundant cabling is used, will the redundant cables be routed together or
separately?
Separate routing makes it less likely that both network paths are affected by a
single damaging event. However, it also means the two different routing paths are
necessary.
♦ If redundant cabling is used, will the switches from each network path be connected
to the same power circuit or feed?
Using a separate power feed or circuit for each network path means that a power
outage in a single feed does not disable the entire network.
♦ Through what kind of physical environment will the cabling pass?
Fiber optic cable is immune to magnetic fields and electrical noise, so it can be
used in places where copper cable would be unreliable. If cabling must be routed
through areas subject to high EMI or RFI, fiber optic cable should be considered.
Due to its immunity to lightning, fiber optic cable should also be used for out-
door cable runs (rated for outdoor use).
♦ Where will the equipment be located?
Will switches be mounted in racks, in cabinets, or placed on shelves or tabletops?
RCNI modules can be mounted on DIN rails or panels if the module is ordered
with the mounting hardware (P0972PF). Take into consideration thermal require-
ments, especially if the equipment will be mounted in an enclosed cabinet or area.
♦ Have plans for future expansion been considered?
Consider installing Ethernet switches with additional ports so that control stations
or workstations can be easily added in the future. Running extra copper or fiber
optic cable will allow for network expansion later.
♦ Have maintenance and troubleshooting provisions been made?
Leaving at least one unused port on each Ethernet switch allows for maintenance
and troubleshooting of managed switches. Patch panels at the end of cable seg-
ments facilitate troubleshooting and network re-configuration.

16
2. Site Planning B0400DV – Rev D

Organizational Considerations
Specific organizational requirements should be considered when planning the network.
♦ Should certain control stations or workstations be connected to the same switch?
It may be advantageous to group control stations or workstations according to
department, process, or other criteria that is important to the site or organization.
♦ Should certain control stations or workstations not be connected to the same switch?
It may be disadvantageous to connect all the control stations or workstations from
a particular group to the same switch. If the switch were to fail, none of these con-
trol stations or workstations would be able to access the network through that
switch. Without a redundant network, none of the workstations from that group
would have network access.

Network Design
Once the general plan for the control network has been outlined, the physical design of the net-
work can be defined. The following two sections describe the rules concerning network topology
and list the specifications for the network devices (switches, converters, interface modules) and
cabling. Use these sections to choose the equipment that is needed to implement the plan that was
derived from the answers to the questions at the beginning of this chapter. When the physical
design has been finalized, make a drawing or map of the network topology and save it. The map
should be updated whenever a physical change is made to the network.

Network Design Rules

When designing the network, the following rules should be kept in mind.

Carrierband LANs (CBLAN)

The following rules apply with respect to Carrierband LANs:
1. Carrierband LAN design rules remain unchanged
2. Systems with more than 64 logical stations must use the Carrierband LAN to connect
the individual control networks.
3. Carrierband LAN I/F (CBLI) modules can be used to connect I/A Series control net-
works to the Carrierband LAN.
For more information on Carrierband LANs, refer to Network Cable Systems Installation and
Maintenance (B0193UW) and Network Cable Systems Planning (B0193UX).

Control Network
The following rules apply to the design of an I/A Series control network:
1. No more than 64 logical stations where
♦ Fault-tolerant stations count as one (1) logical station
♦ Workstations and other non fault-tolerant stations count as one (1) logical station
2. There should be no more than five switches in the path between any two devices in
the control network.

17
B0400DV – Rev D 2. Site Planning

3. Two types of connections to the Ethernet switches are allowed:

♦ Control segments - a maximum of eight control segments are allowed within the
control network.
♦ Workstations - one workstation is allowed for every free port on the switches.

NOTE
It is recommended that one port on each managed Ethernet switch be reserved for
testing and diagnostic purposes. No devices should be connected to this port.

Control Segments
If Release 7.x workstations are being added to an existing node, the following rules apply:
1. A maximum of two redundant switches may be added to the existing node, using a
pair of NCNI modules.
2. If switches are added to an existing node or nodes are being collapsed, a Release 7.x
application workstation running Release 7.x of Network Fault Detection (NFD) soft-
ware is required.
3. WP workstations can be added using NCNIs combined with RCNIs and no applica-
tion workstation is required. (See Figure 1-4)
4. The FONBE and NBE modules may be left in place, even if they are joining three
segments
5. Only workstations may connect to Ethernet switches.
6. As many workstations may be added as there are free ports on the switches (See
previous note).
If a control network has more than one control segment, the following rules apply:
1. A maximum of one (redundant) CBLAN in the entire control network.
2. A maximum of eight control segments per control network.
3. A maximum of two control segments per NCNI connection to the control network
backbone.
4. No FONBE or NBE modules used to connect control segments - the NCNI can be
used to replace these devices.
5. All other normal control segment rules apply, for example, no more than 32 physical
modules on the control segment.

Optical Budget (100Base-FX connections)

Optical signals begin to be attenuated as soon as they leave the transmitter in the originating
device. The signal strength decreases as the signal passes through the optical fiber and associated
passive devices such as patch panels, connectors, and splices. This attenuation must be managed
in order to ensure that the optical signal reaches its destination with sufficient strength. The fol-
lowing guidelines apply when planning fiber optic connections in the control network:
1. There is an 8dB signal loss budget for fiber optic connections between:
♦ NCNI module and another NCNI module
♦ NCNI module and a RCNI module

18
2. Site Planning B0400DV – Rev D

♦ NCNI module and an Ethernet switch

♦ RCNI module and an Ethernet switch
♦ RCNI module and a media converter
This means that the combined signal loss of all the passive devices (patch panels, con-
nectors, and splices) between the originating device and the receiving device must not
exceed 8dB. Attenuation due to aging and maximum cable length has already been
accounted for and does not have to be included in the budget.

NOTE
The signal loss budget specified here applies only to equipment supplied by
Invensys Foxboro. Refer to the manufacturer’s specifications for equipment not sup-
plied by Invensys Foxboro.

Non I/A Series Equipment

The following rules apply to non I/A Series equipment:
1. For Release 7.x, non I/A Series equipment is not allowed to be connected to the con-
trol network.

Workstations as Routers
The following rule applies to using workstations as routers:
Workstations should not be used as routers between a control network and another Ether-
net network. Separate Ethernet networks can be connected to a control network using
existing methods supported by Invensys Foxboro.

Ethernet Switches with Short Aging Timers

When an Ethernet switch receives data that is addressed to a device that is unknown to the switch,
it will retransmit the data out all of its ports. In time, the switch learns of the address of each of
the I/A Series devices in the network and no longer has to retransmit the data out all of its ports.
This is normal when a new switch is added to the network, or when a switch has been taken off-
line for a period long enough to allow its aging timer to expire. Switches with maximum aging
timer values that are less than 65,000 seconds (approximately 18 hours) are most susceptible to
this condition. The 8-port managed switches can only support an aging timer value of 415 sec-
onds. The end result is increased network activity until the switch learns the addresses of the
I/A Series devices attached to the network. For this reason, it is not recommended that these
Ethernet switches be used for critical applications. Refer to the switch’s documentation to deter-
mine the maximum aging timer value for the switch.

Network Topology
A key feature of the I/A Series control network is that all the devices in the network should be able
to communicate with one another. However, the topology is restricted by the following rule:
A path between any two devices in the network should have no more than five switches
en route.
This is best achieved by connecting switches in a star topology with no more than three tiers of
switches (including the central switch). To accomplish this, designate one switch as the central

19
B0400DV – Rev D 2. Site Planning

switch (Tier 1) of the network. Other switches connect to the central switch to form a second tier
of switches. If additional capacity is required, a third tier of switches can be connected to the sec-
ond tier. No switches may be connected to the third tier switches. Figure 2-1 illustrates a three-tier
star topology.

NOTE
Figure 2-1 only shows half of a redundant network. A fully redundant network
would require additional switches and cabling.

NOTE
Hubs can not be connected to the switches in an I/A Series control network.

In the example in Figure 2-1, the central switch is a 24-port switch with two optional gigabit fiber
optic uplink ports. Each fiber optic uplink port can be connected to another 16-port or 24-port
switch equipped with a similar uplink port. The central switch’s RJ-45 ports can be connected in
turn to the following:
♦ 8-port switches - through an RJ-45 port
♦ 16-port switches - through a media converter and an MT-RJ port
♦ 24-port switches - through an RJ-45 port
♦ Host workstations (P79, P80, P92) - through an RCNI module (for redundant
networks)
♦ Nodebus - through an NCNI module
♦ Micro-I/A stations
♦ A combination of all the above.

20
2. Site Planning B0400DV – Rev D

Nodebus

FAST ETHERNET WORKGROUP SWITCH

RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

PWR
RESET
CPU
COM

Switch

Tier 3
Switches

Tier 2
Switches

Central Switch
(Tier 1)

FAST ETHERNET WORKGROUP SWITCH

RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

PWR
RESET
CPU
COM

FAST ETHERNET WORKGROUP SWITCH

RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Workstation
PWR
RESET
CPU
COM

Switch

Figure 2-1. Three-Tier Star Topology

Network Devices
For specific information on the switches and media converters used in the I/A Series control
network, refer to the switch and media converter documents listed in “Reference Documents”
on page xi and in Appendix A “I/A Series Control Network Legacy Ethernet Switches” on
page 45 for legacy switches.

21
B0400DV – Rev D 2. Site Planning

Network Cabling
The following sections provide the specifications and transmission distance capabilities for the
fiber optic, and twisted-pair cabling used in the control network.

Fiber Optic Cabling

Two types of fiber optic cable can be used to connect devices in a control network: multimode
fiber optic cable and single mode fiber optic cable. Each cable type is used in different applica-
tions and the devices that are connected must support the type of cable being used. The following
sections give the supported uses and maximum transmission distances for each type of fiber optic
cable.

Multimode Fiber Optic Cabling

Multimode fiber optic cable is always used to connect RCNI modules to Ethernet switches (a
media converter is necessary with RJ-45 port switches). Multimode fiber can be used to connect
NCNI modules to Ethernet switches, NCNI modules to other NCNI modules, media converters
to other devices, and with the appropriate uplink module, Ethernet switches to other Ethernet
switches.

NOTE
Conversion cables are available to connect NCNI modules to existing fiber optic
cable with ST connectors. The part numbers are given in Table 2-4 below.

NOTE
If multimode fiber optic cable is used with a single mode/multimode uplink module
(P0972LR), a conditioning cable (P0972SR or P0972SS) is required. An SC-to-SC
coupler (P0972TW) is also necessary if the distance exceeds 3 m (10 ft).

Invensys Foxboro recommends that the selected multimode fiber optic cabling have the following
characteristics:
♦ 62.5 micron core/125 micron cladding
♦ Maximum allowable signal loss = 1 dB/km at a wavelength of 1300 nm
♦ Maximum allowable signal loss = 3.5 dB/km at a wavelength of 850 nm.
Cables with different characteristics can be used, but maximum transmission distance may be
reduced. Cable requirements, such as flexibility, fire retardancy, and durability, depend on the par-
ticular application. Check with your cable installer/vendor for a list of application-specific cable
characteristics.
Transmission distances for multimode fiber cable are given in Table 2-1.
For detailed information on cabling, refer to the diagrams in the Appendix “Ethernet Switch
Interconnection Diagrams” in the switch documents listed in “Reference Documents” on
page xi, and in “Ethernet Switch Interconnection Diagrams” on page 56 for legacy switches.

22
2. Site Planning B0400DV – Rev D

Table 2-1. Multimode Fiber Cable - Maximum Transmission

Transmission Maximum Connector

Application Protocol Distance Type
RCNI to switch 100Base-FX 2000 m (6562 ft) MT-RJ
NCNI to switch 100Base-FX 2000 m (6562 ft) MT-RJ
NCNI to NCNI 100Base-FX 2000 m (6562 ft) MT-RJ
Media converter to multimode fiber 100Base-FX 2000 m (6562 ft) MT-RJ
optic port
Switch to Switch
port to port 100Base-FX 2000 m (6562 ft) MT-RJ
P0972LR uplink module 1000Base-LX 550 m (1804 ft) SC
P0972LQ uplink module 1000Base-SX 275 m (902 ft) SC
P0972ST uplink module 1000Base-SX 275 m (902 ft) SC

Multimode fiber optic cables offered by Invensys Foxboro are listed in Table 2-2, Table 2-3 and
Table 2-4 below.

Table 2-2. Fiber Optic Patch Cables with SC-type Connectors

Multimode Fiber Optic Minimum Bend

Cable Length Radius
P0972QP 3 m (10 ft)
P0972QQ 15 m (49 ft)
P0972QR 50 m (164 ft)
P0972SR 3 m (10 ft)
(62.5 micron conditioning 2 inches
cable)
P0972SS 3 m (10 ft)
(50 micron conditioning
cable)

Table 2-3. Fiber Optic Patch Cables with MT-RJ Connectors

Multimode Fiber Optic Minimum Bend

Cable Length Radius
P0972KV 3 m (10 ft)
P0972KW 15 m (49 ft) 2 inches
P0972KX 50 m (164 ft)

23
B0400DV – Rev D 2. Site Planning

Table 2-4. Fiber Optic Conversion Cables (ST to MT-RJ)

Multimode Fiber Optic Minimum Bend

Cable Length Radius
P0972VD 3 m (10 ft)
P0972VE 15 m (49 ft) 2 inches
P0972VF 50 m (164 ft)

NOTE
For the specifications of cables with LC-type connectors, refer to the documenta-
tion for the appropriate switch which receives this type of connector. These docu-
ments are listed in “Reference Documents” on page xi.

Single Mode Fiber Optic Cabling

Single mode fiber optic cable is used only for connecting one switch to another through their
uplink ports. Each switch must be equipped with an appropriate uplink module in order to use
single mode fiber optic cable. Invensys Foxboro recommends that the selected single mode fiber
optic cabling have the following characteristics:
♦ 8 micron core/125 micron cladding
♦ Maximum allowable signal loss = 0.5 dB/km at a wavelength of 1300 nm.
Cables with different characteristics can be used, but maximum transmission distance might be
reduced. Cable requirements, such as flexibility, fire retardancy, and durability, depend on the par-
ticular application. Check with your cable installer/vendor for a list of application-specific cable
characteristics. Invensys Foxboro does not offer single mode fiber optic cables.
Transmission distances for single mode fiber optic cable are given in Table 2-5.

Table 2-5. Single Mode Fiber Optic Cable - Maximum Transmission

Application Transmission Protocol Max. Distance

Switch to Switch
Legacy 8-port to 8-port 100Base-FX 10000 m (32808 ft)
P0972LR uplink module 1000Base-LX 10000 m (32808 ft)

Twisted-Pair Cabling
Category 5 (CAT5), shielded twisted-pair (STP) copper cable is always used in the control net-
work for connecting RCNI modules to workstations and for connecting unmanaged switches to
RJ-45 ports on other devices. CAT5 cable can be used to connect NCNI modules to switches,
NCNI modules to other NCNI modules (null hub required), and with the appropriate uplink
module (P0972SV), 24-port Ethernet switches to other 24-port Ethernet switches.

24
2. Site Planning B0400DV – Rev D

NOTE
Connections between RCNI modules and workstations should be made with
Invensys Foxboro CAT5 cables. Not all third-party cables have all the connections
needed to ensure proper operation.

Transmission distances for CAT5 copper cable are given in Table 2-6.

Table 2-6. CAT5 Cable - Maximum Transmission Distance

Application Transmission Protocol Max. Distance

RCNI to switch 100Base-TX
NCNI to switch 100Base-TX
NCNI to NCNI 100Base-TX
100 m (328 ft) for all
Media converter to RJ-45 port 100Base-TX applications
Switch to Switch
port to port 100Base-TX
P0972SV uplink module 1000Base-TX

Table 2-7 lists the prefabricated CAT5 STP cables with RJ-45 connectors that are offered by
Invensys Foxboro.

Table 2-7. Prefabricated CAT5 STP Cables with RJ-45 Connectors

CAT5 Cable Length

P0972UB 0.5 m (1.6 ft)
P0971XK 3 m (10 ft)
P0971XL 15 m (49 ft)
P0972MR 30 m (98 ft)
P0971XM 50 m (164 ft)
P0971XN 100 m (328 ft)

NOTE
Plenum grade jackets are supplied on cables over three meters in length that are
offered by Invensys Foxboro. This applies to both fiber optic and CAT5 copper
cables.

Null Hub
A null hub is a very short cable that has a male RJ-45 connector on one end and a female RJ-45
connector on the other. The transmit and receive wires are reversed, so when it is connected to the
end of a straight-through cable, the resulting cable acts as a crossover cable. The null hub is used
to connect switches that do not have an MDI crossover port. A null hub is also required when
using CAT5 cable to connect one NCNI module to another.

25
B0400DV – Rev D 2. Site Planning

Table 2-8. Null Hub

Null Hub Part Number Length

P0971PK 0.3 m (1 ft)

A special null hub cable is required when using CAT5 cable to connect NCNI modules to the
network. This cable provides a necessary connection between the shield in the CAT5 cable and a
grounded DIN rail. Table 2-9 gives the part number for this cable.

Table 2-9. Grounded Null Hub

Grounded Null Hub Part Number Length

P0972MQ 0.3 m (1 ft)

26
3. Installation
This chapter describes the steps necessary to install the equipment that comprises an I/A Series
Control Network.
Installation of an I/A Series control network consists of locating the individual components and
then making connections between them using fiber optic or copper cable. The following para-
graphs provide the information necessary for the installation of the control network.

Installing Network Components

The following paragraphs provide instructions for installing the Ethernet switches, RCNI mod-
ules, and NCNI modules that will comprise the I/A Series control network.

Ethernet Switch Installation

The Ethernet switches are designed to be placed on a flat, level surface. Alternatively, switches
may be mounted in a rack using the mounting brackets supplied by the switch vendor. Ensure
that the environment in which the switch is located meets the switch’s environmental operating
specifications, especially heat and humidity. Refer to the documentation included with the switch
for detailed installation instructions and operating specifications.
For information on configuring switches for the I/A Series control network, refer to the switch
documents listed in “Reference Documents” on page xi, and in “Legacy Ethernet Switch Config-
uration” on page 48 for legacy switches.

NOTE
The switch hardware shown in this chapter is intended for illustrative purposes
only. The actual hardware may differ from that shown in the figures below.

Switch Configuration
When configuring switches for the I/A Series Control Network, refer to Table 3-1.

Table 3-1. Switch Configuration Documentation

I/A Series System P/N Vendor P/N Support Documentation

P0972MZ AT-FS708-10 / Allied Telesyn Appendix A “I/A Series Control
Network Legacy Ethernet
Switches”
P0972MF VH_8TX1MF / Vertical Horizon Appendix A “I/A Series Control
Network Legacy Ethernet
Switches”
P0972MG VH_8TX1UM / Vertical Horizon Appendix A “I/A Series Control
Network Legacy Ethernet
Switches”

27
B0400DV – Rev D 3. Installation

Table 3-1. Switch Configuration Documentation (Continued)

I/A Series System P/N Vendor P/N Support Documentation

P0972MH VH-2402-L3 / Vertical Horizon Appendix A “I/A Series Control
Network Legacy Ethernet
Switches”
P0972WG 8088 / Allied Telesyn Appendix A “I/A Series Control
Network Legacy Ethernet
Switches”
P0972MJ 2H258-17R / Cabletron/Enterasys B0700CM, Appendix B
P0972WP V2H124-24 / Enterasys B0700CL, Appendix B
P0972YC V2H124-24FX / Enterasys B0700CL, Appendix B
P0973BH A2H124-24 / Enterasys B0700CH, Appendix B
P0973BJ A2H124-24FX / Enterasys B0700CH, Appendix B
P0973BK A2H254-16 / Enterasys B0700CH, Appendix B

The Enterasys I/A Series Control Network switches can also be configured using the I/A Series
Switch Configurator Application Software (K0173ZU). Refer to The MESH Control Network
Operation, and Switch Installation and Configuration Guide (B0700CA) and the documentation
included with your Invensys qualified Ethernet switches for instructions on configuring the
switches for the I/A Series Control Network.

RCNI Module Installation

Three steps are required to install the RCNI module. These steps are:
1. Install module identifier (letterbug) on the front of the RCNI module.
2. Mount the RCNI module in its final destination.
3. Plug one end of the power cable into the RCNI module and the other end into a
power outlet.

NOTE
The module identifier should be installed before the RCNI module is plugged into
a power outlet. The identifier is read at power up and since the RCNI module has
no power switch, power is applied as soon as the module is plugged into a power
outlet.

Module Identifier (Letterbug) Installation

A module identifier, composed of six letterbugs, is used to provide physical, user-assigned label(s)
on the RCNI module(s). The six letterbugs (characters) installed must match those entered for the
workstation during System Configuration (or System Definition). The six letterbug characters
can be any user-selected characters.
Each letterbug is a small plastic device with a single character embossed on the front surface. The
rear surface of the letterbug contains two to eight pins that are electrically connected. These pins
are arranged in configurations corresponding to particular characters or symbols. The required
sets of letterbugs are shipped packaged inside the I/A Series enclosures.

28
3. Installation B0400DV – Rev D

The module identifiers are electrically readable either right-side-up or inverted. The six letterbugs
that form one module identifier plug into a 48-pin connector on the front of the RCNI module.
To assemble and install the module identifiers, refer to Figure 3-1 and proceed as follows:
1. Referring to the information developed during the site planning phase, gather the six
letterbugs that form the module identifier and assemble them by inserting the dovetail
end of one letterbug into the corresponding end of the next letterbug until all six let-
terbugs have been assembled in the proper order.

Module
Identifier

Figure 3-1. RCNI Module Identifier

2. Insert the assembled letterbug set into the receptacle on the front of the module, being
careful that the pins are properly aligned with the holes in the receptacle.

NOTE
In order for the identifier to be recognized, power to the RCNI module must be
cycled after the module identifier has been installed.

NOTE
To remove the module identifier (letterbug set) use the letterbug extractor tool,
Invensys Foxboro part number P0902HK.

29
B0400DV – Rev D 3. Installation

RCNI Mounting
The RCNI module can be mounted on a level surface, or, using an optional mounting adapter, on
a panel or a DIN rail within an enclosure or on a wall.

RCNI DIN Rail Mounting

The RCNI is capable of being mounted on a standard DIN rail using an optional mounting
bracket and rail clamp assembly. The bracket is designed to allow mounting on either vertical or
horizontal rails. Figure 3-2 shows the mounting bracket and rail clamp.

NOTE
The mounting bracket and clamp are included with the RCNI when ordering
Invensys Foxboro part number P0972PF. Part number P0972QM is for tabletop
mounting and contains the RCNI only.

Bracket

Locking
Screw Clamp

Figure 3-2. RCNI Rail Clamp and Mounting Bracket Assembly

The following steps guide you through the process of installing the RCNI on a DIN rail.
1. Turn the bracket and the clamp assembly so that the flat side of both items are facing
you as shown in Figure 3-2. The assembly should be oriented in the same position as
it will be when installed on the DIN rail (that is, horizontal or vertical).

30
3. Installation B0400DV – Rev D

2. Slide the RCNI module down over the bracket assembly, making sure that the bracket
is fully engaged in the slots on the rear of the RCNI case. Refer to Figure 3-3.

NOTE
It might be necessary to loosen the locking screw so that the RCNI module can slide
all the way down over the bracket assembly.

3. Tighten the locking screw on the mounting bracket assembly so that the RCNI mod-
ule is locked to the mounting bracket assembly.
.

Slide
module
down.

Locking
Screw

Figure 3-3. Slide RCNI onto Bracket Assembly

31
B0400DV – Rev D 3. Installation

4. Clip the bracket assembly to the DIN rail. The assembly may be mounted to a hori-
zontal or a vertical rail. Refer to Figure 3-4.

Note: RCNI module has

been omitted
for clarity.

Vertical Horizontal

Figure 3-4. DIN Rail Mounting Bracket Orientation

NCNI Module Installation

The NCNI module is designed to be installed in an enclosure containing an Cellbus structure.

NOTE
A single NCNI module provides communication between one Nodebus (for exam-
ple, Nodebus A) and one network (for example, Network A). Two NCNI modules
must be installed for proper operation of the I/A Series control network.

To physically install an NCNI module into a mounting structure, proceed as follows:

1. Referring to the information developed during the site planning phase, determine in
which Cellbus slots you must install the NCNI module.
2. Use the switch on the front of the module to select the Nodebus to which the module
will be connected. Refer to Figure 3-5 for the location of this switch.

32
3. Installation B0400DV – Rev D

! CAUTION
The Nodebus select switch on each of the two NCNI modules must be set to select
a different bus (A or B). If both NCNI modules are set for the same bus, the control
network does not operate correctly.

Mounting Nodebus Select Switch

Screws Up = Nodebus A
Down = Nodebus B

Grounded
P0972MQ DIN Rail
Adapter Cable

Figure 3-5. NCNI Nodebus Select Switch

3. Insert the NCNI module into its assigned slot and push it firmly in place until it
engages the rear section of the mounting structure.
4. Observing the following CAUTION statement, and using the hex driver tool, tighten
the two captive mounting screw(s) at the front of the module (see Figure 3-5). This
fastens the module to the mounting structure bus.

! CAUTION
When installing the NCNI module or any other hardware that screws into inserts
embedded in plastic, use the hex driver tool (X0179AZ). Make sure that you do not
generate more than 12 inch/pounds of torque, or you might strip the threaded
insert out of the plastic.

5. If the NCNI module is being connected to the network with CAT5 cable, you must
use a P0972MQ adapter cable at the NCNI module. To install the cable, snap the
large end of the cable onto a grounded DIN rail and connect the RJ-45 plug to the
RJ-45 port on the NCNI module. Refer to Figure 3-5.
You have completed NCNI module installation. You can now connect the Ethernet switch to the
NCNI module.

33
B0400DV – Rev D 3. Installation

Media Converter Installation

The media converters are designed for office and industrial environments. They should be located
away from equipment that generates high levels of electrical noise (copiers, electrostatic printers,
electric welders, heavy motorized equipment). The units may be oriented in any manner which
allows you to make physical connection to the power supply and leaves adequate space for proper
ventilation. For detailed specifications, see the documentation provided with the media converter.

Media Converter Configuration

The configuration settings for the media converters are read when the device is powered on. For
this reason, media converters should be configured before power is applied.

RJ-45 to SC (P0972ME)
The P0972ME media converter (no longer supplied by Invensys) can be configured to either
enable or disable the Link Loss Carry Forward (LLCF) function using a switch on the rear of the
device. LLCF should be disabled for normal use.
The media converter is equipped with an MDI switch on the bottom of the device. MDI capabil-
ity allows signal crossover which eliminates the need for crossover cables with the media converter.
The MDI switch setting depends on the equipment and the ports that are being connected.

RJ-45 to MT-RJ
Refer to Media Converter Installation and Configuration Guide for Control Networks (B0700CP)
for instructions on configuring the RJ-45 to MT-RJ media converters.

Connecting Network Components

Fiber Optic Cabling Guidelines
The following guidelines should be followed when making fiber optic connections between
devices in the network:
♦ Minimum bend radius - Fiber optic cable can be damaged if it is bent too sharply.
Maintain a minimum bend radius of two inches when using fiber optic cable supplied
by Invensys Foxboro. Follow the cable manufacturers guidelines if third-party fiber
optic cable is used.
♦ Cable straps - Cable straps, if used, should be designed for use with fiber optic cable.
Hard plastic cable ties can damage fiber optic cable and are not recommended.
♦ Dust caps - Dust caps should remain in place to protect the polished cable ends while
cables are being routed.

Connecting the NCNI Module

The NCNI module provides the interface between a Nodebus and a data network Ethernet
switch. The connection between the module and the Nodebus is made when the module is
installed in the Cellbus, and requires no further action. The connection between the NCNI mod-
ule and the Ethernet switch is made using either of the two connectors on the front panel of the
module. A MT-RJ connector is provided to enable connection to a switch with a multimode fiber
port, and a RJ-45 connector allows connection to a switch with RJ-45 ports.

34
3. Installation B0400DV – Rev D

Figure 3-6 illustrates a fiber optic connection, and Figure 3-7 shows a connection using copper
CAT5 cable and a P0972MQ adapter cable.

NOTE
Make sure that the Ethernet switch has been configured before making the connec-
tion to the NCNI module.

P0972PP
Switch with Fiber (MT-RJ) Ports NCNI Module

FAST ETHERNET WORKGROUP SWITCH

RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

PWR
RESET
CPU
COM

62.5/125 micron Multimode

Optical Cable
w/MT-RJ Connectors
2 km (max)

Figure 3-6. NCNI Module Connection (Fiber Port)

P0972PP
Switch with Copper (RJ-45) Ports NCNI Module

CAT5 Cable P0972MQ

100 m (max) Adapter Cable

Figure 3-7. NCNI Module Connection (RJ-45 Port)

Connecting the RCNI Module

Three connections are made between the RCNI module and other devices:
♦ RCNI to Network A Ethernet switch
♦ RCNI to Network B Ethernet switch
♦ RCNI to high performance network workstations.
The following paragraphs describe these connections.

RCNI Connection to Ethernet Switch

The RCNI module provides the interface between a workstation and two redundant data net-
works. In order to communicate with both networks, the RCNI module is connected to two dif-

35
B0400DV – Rev D 3. Installation

ferent Ethernet switches and directs its output between them. One of these switches must belong
to network A, and the other switch must belong to network B.
The module is equipped with two MT-RJ fiber optic jacks, which can be connected directly to a
copper Ethernet switch using multimode fiber optic cable with MT-RJ connectors. Figure 3-8
illustrates a connection between an RCNI module and a 16-port Ethernet switch. The module
can also be connected to a switch that has RJ-45 ports by using a media converter between the
RCNI module and the switch. Figure 3-9 illustrates a connection between an RCNI module and
a copper Ethernet switch.

Switch with Fiber (MT-RJ) Ports P0972PF/P0972QM

RCNI Module
FAST ETHERNET WORKGROUP SWITCH

RX

1
TX RX

2
TX RX

3
TX RX

4
TX RX

5
TX RX

6
TX RX

7
TX RX TX

8
RX

9
TX RX TX

10
RX TX

11
RX TX

12
RX TX

13
RX TX

14
RX TX

15
RX TX

16
Network A
PWR
RESET
CPU
COM

To
Workstation

62.5/125 micron Multimode

Fiber Optic Cable
w/MT-RJ Connectors To
2 km (max) Network B
Figure 3-8. RCNI to Ethernet Switch (Fiber Port)

P0972PF/P0972QM
Switch with Copper (RJ-45) Ports RCNI Module

To
Network A Workstation

62.5/125 micron Multimode

Media Converter Fiber Optic Cable
w/MT-RJ Connectors
2 km (max)
To
CAT5 Cable Network B
100 m (max)
Figure 3-9. RCNI to Ethernet Switch (RJ-45 Port)

RCNI Connection to Workstation

A connection between the RCNI module and the workstation is established by using CAT5 cop-
per cable to connect the module’s RJ-45 port to the workstation. The connection at the worksta-
tion requires a Y adapter cable to interface with the workstation. This adapter cable differs
depending on the model of the workstation. Figure 3-10 shows a typical connection between an
RCNI module and a workstation.

36
3. Installation B0400DV – Rev D

NOTE
Refer to the workstation documentation for detailed instructions on making the
connection to a specific workstation.

P0972PF/P0972QM
RCNI Module

To Workstation

CAT5 Cable Adapter

100 m (max) Cable

Figure 3-10. RCNI Connection to Workstation

Interconnecting Ethernet Switches

Depending on which switch model has been selected as the central network switch, additional
switches may be connected in one of several ways. They are summarized in Table 3-2 below.

Table 3-2. Methods of Connecting Ethernet Switches

Central Switch Port End Switch Port

Uplink port (Gigabit Ethernet) Uplink port (Gigabit Ethernet)
Fiber optic port (100Base-FX) Fiber optic port (100Base-FX)
Fiber optic port (100Base-FX) RJ-45 (100Base-TX)
RJ-45 (10Base-T/100Base-TX) RJ-45 (10Base-T/100Base-TX)
RJ-45 (10Base-T/100Base-TX) Fiber optic port (100Base-FX)

For information on interconnecting switches for the I/A Series control network, refer to the
switch documents listed in “Reference Documents” on page xi for current switches, and to “Leg-
acy Ethernet Switches Connection” on page 54 for legacy switches.

37
B0400DV – Rev D 3. Installation

38
4. Maintenance
This chapter provides information on identifying the cause of problems with an I/A Series
control network.

General Troubleshooting Guidelines

When a problem occurs with the network, it is usually best to take an organized approach to diag-
nosing the cause. A random or scattered approach generally takes longer and can make it more
difficult to track down the cause of the problem by introducing additional unknowns. The fol-
lowing sections will help to determine the cause of a network problem.

Characterize the Problem

The initial step in diagnosing network problems is to understand what kind of problem exists.
♦ Has the problem always existed or has it just started?
New problems are sometimes caused by a change in network configuration. Check to
see whether there have been recent changes to network hardware, software, or config-
uration files.
♦ Is the problem constant or intermittent?
Constant problems are often the result of a component failure or a change to the net-
work configuration. Intermittent problems can be caused by environmental factors
such as excess heat or electrical noise.
♦ What kind of error indication is occurring?
Device communication failure - inability to communicate with one or more devices
on the network. This happens when the information path has been broken or inter-
rupted. Possible causes are damaged or misconnected cabling, or a failure in a network
device.
Data Loss - incorrect data is arriving at one or more devices. The data path is intact,
but the data is being corrupted along the way. This can be caused by failing network
devices, environmental factors, or exceeding transmission distance limits.
Error message - software has detected a problem. This can be caused by any number
of things. The text of the error message indicates what kind of problem has been
detected.

Determine Which Devices are Affected

Identifying the devices that are affected helps to determine where the cause of the problem lies.
For example, if all the unreachable devices are connected to the same Ethernet switch, then you
should probably start troubleshooting at that switch.
Follow the steps below to identify which device or devices are affected.
1. Are the problems limited to specific devices (stations, switches), or are they general in
nature?
2. Are the problems constant or are they intermittent?

39
B0400DV – Rev D 4. Maintenance

3. Can the devices be reached using the ping command?

4. Does the ping -s command report that packets are being dropped?
5. What does System Management Displays indicate?
6. Use a network topology map to determine the physical location of the affected
devices.

Troubleshoot the Affected Devices

1. Check activity and status indicators on the affected devices.
2. Verify that the devices are getting power (check Status LEDs).
3. Check that the devices are correctly cabled and that the cables are not damaged (swap
a suspect cable with a known good cable).
4. If you have redundant networks, verify that each network is separate from the other.
Each switch should be connected to only one network and no cables can be crossed
over between the two networks. All the RCNI modules should have their Network A
ports connected to the same network. All Network B ports should be connected to the
remaining network.
5. Verify that the limit on distance between devices has not been exceeded. Distance is
dependent on transmission mode and cable type.
6. If fiber optic cable is being used, verify that the optical budget (total signal loss - dB) is
within specification. Refer to “Optical Budget (100Base-FX connections)” on page 18
for more information on optical budgets.

NOTE
Foxboro Invensys document #HH984 contains detailed information on fiber optic
cabling specifications for I/A Series networks. Contact the Invensys Foxboro
Customer Service Center to obtain a copy of this document.

7. Verify that traffic rates to the affected devices are not excessive.
8. Check System Management error counters.
9. Verify that the devices are properly configured. Also check that the adjacent device in
the network is correctly configured as well.

NOTE
Before removing a switch from the network, be sure to record its existing configura-
tion. This information is necessary when the replacement switch is configured.

NOTE
Make sure a replacement switch is correctly configured before adding it to the net-
work. Any uplink ports should be installed before the switch is configured. Refer to
“Ethernet Switch Installation” on page 27 for more information.

40
4. Maintenance B0400DV – Rev D

Indicators
Each component that makes up the control network is equipped with one or more indicators that
can be used to help diagnose network problems.

RCNI Module
Figure 4-1 and Table 4-1 identify the location and describe the function of the indicators on the
RCNI module.

Module Status
Green
Red

Network B
Workstation Port Status
Port Status
Network A
Port Status
Figure 4-1. RCNI Indicators

Table 4-1. RCNI Indicators

Indicator Color Function

Module Status Green (Steady) Normal operation
Red (Steady) Module is off-line
Both Off No power to unit or failed power supply
Both On Device fault
Both Flashing Normal on power up; continued flashing indicates fault
Workstation Port Amber (Steady) Link is established, but no data traffic
Amber (Blinking) Link established; transferring data
Off No link established
Network Port A Amber (Steady) Link is established, but no data traffic
Amber (Blinking) Link established; transferring data
Off No link established
Network Port B Amber (Steady) Link is established, but no data traffic
Amber (Blinking) Link established; transferring data
Off No link established

41
B0400DV – Rev D 4. Maintenance

NCNI Module
Figure 4-2 and Table 4-2 identify the location and describe the function of the indicators on the
NCNI module.

Nodebus
Switch (A or B)

MT-RJ Port
Status

Nodebus
Transmit

RJ-45 Port
Status

Module Status
Green
Red

Figure 4-2. NCNI Indicators

Table 4-2. NCNI Indicators

Indicator Color Function

Module status Green (Steady) Normal operation
Red (Steady) One or more module voltages are absent or out of range
Both Off No power to module
Both On Device fault
Both Flashing Normal on power up. Continued flashing indicates
fault.
MT-RJ port Amber (Steady) Link is established, but no data traffic
Amber (Blinking) Link established; transferring data
Off No link established
RJ-45 port Amber (Steady) Link is established, but no data traffic
Amber (Blinking) Link established; transferring data
Off No link established

42
4. Maintenance B0400DV – Rev D

Table 4-2. NCNI Indicators (Continued)

Indicator Color Function

Nodebus Amber (Steady) Link is established; transmitting onto Nodebus segment
transmit A or B, depending on Nodebus switch setting
Off No link established

Ethernet Switches
For the location and meaning of the indicators on a particular Ethernet switch, refer to the docu-
mentation provided with the switch.

Media Converters
For the location and meaning of the indicators on a particular media converter, refer to the docu-
mentation provided with the device.

43
B0400DV – Rev D 4. Maintenance

44
Appendix A. I/A Series Control
Network Legacy Ethernet Switches
This appendix discusses the legacy managed and unmanaged Ethernet switches used with the
I/A Series control network.

Introduction
Table A-1 lists the Invensys Foxboro part numbers for the legacy managed switches used with the
I/A Series control network.

Table A-1. I/A Series Control Network Legacy Ethernet Switch Part Numbers

Invensys
Hardware Foxboro P/N
8-Port unmanaged 10/100 Mbps switch (no fiber optic port) P0972MZ
8-Port managed 10/100 Mbps switch with multimode fiber optic uplink port P0972MF
8-Port managed 10/100 Mbps switch with single mode fiber optic uplink port P0972MG
24-port managed 10Base-T/100Base-TX RJ-45 ports P0972MH
16-port managed switch with 8-port 100FX MMF with MT-RJ connectors and P0972WG
8-port 10/100TX RJ-45 connectors plus 2 expansion bays

The management module for the 8-port managed switches, the 16-port switch, and the 24-port
switch provides a menu-driven system configuration program with management capability. See
the vendor manual Fast Ethernet Switch Management Guide (supplied with the switch) for further
details.
The switches can be mounted on a flat table or shelf surface. Install the switch in a dry area with
adequate air circulation. Avoid placing the switch in direct sunlight or near other heat sources.

NOTE
Do not restrict airflow by covering or obstructing air inlets on the side of the
switch.

8-Port Unmanaged Switch

The 8-port unmanaged switch provides eight RJ-45 ports, each of which supports the
10Base-T/100Base-TX communication protocol. An autonegotiation function within the
switch automatically sets the speed of each port based on the speed capability of the device con-
nected to the port. The last port (port 8) has two separate connectors associated with it. One of
the connectors is an MDI crossover connector, while the other is a normal straight-through con-
nector. This allows the switch to be uplinked to another switch without the need for a crossover
cable. Only one of the connectors for this port can be used at one time. The switch automatically

45
B0400DV – Rev D Appendix A. I/A Series Control Network Legacy Ethernet

selects the operational speed of its RJ-45 ports and negotiates the best connection possible with
the attached device. A typical, 8-port, unmanaged switch is shown in Figure A-1.

X To PC = To HUB

Figure A-1. 8-Port Unmanaged Ethernet Switch (Typical)

There are no dedicated uplink provisions for fiber optic connection with this switch. It may be
connected to another switch by connecting one of the 10Base-T/100Base-TX RJ-45 ports to a
similar port on the other switch. The switches communicate with each other at the speed of the
ports (either 10Base-T or 100Base-TX). A media converter may be necessary, depending on the
ports on the other switch.
For installation, the switch can be placed on a flat table or shelf surface or, with the included
brackets, installed in a 19-inch rack. Install the switch in a dry area with adequate air circulation.
Avoid placing the switch in direct sunlight or near other heat sources, such as hot air vents.

8-Port Managed Switch

Two versions of the 8-port managed switches provide eight 10Base-T/100Base-TX RJ-45 ports.
An autonegotiation function within the switch automatically sets the speed of each RJ-45 port
based on the speed capability of the device connected to the port.
A typical 8-port managed switch is shown in Figure A-2.

Figure A-2. 8-Port Managed Ethernet Switch (Typical)

The last port (port 8) on this device can be switched to operate through either the RJ-45 connec-
tor (10Base-T/100Base-TX), or, for uplink purposes, through the SC-type fiber uplink connector
(100Base-FX). There are two models of this switch available: the first with a fiber optic uplink
port that supports multimode fiber optic connections, and the second equipped with a single-
mode fiber optic uplink port.

NOTE
The uplink port and the last port on these switches cannot be used simultaneously.
If the uplink port is selected, then the eighth RJ-45 copper connection port is dis-
abled. Conversely, the fiber optic uplink port is disabled if the eighth RJ-45 is used.

46
Appendix A. I/A Series Control Network Legacy Ethernet Switches B0400DV – Rev D

24-Port Managed 10Base-T/100Base-TX Switch (P0972MH)

This switch (P0972MH) provides 24 port dual-speed manageable ports. It can be installed as
standalone or rack-mountable. The switch provides twenty-four 10Base-T/100Base-TX ports,
plus one front-panel slot for optional slide-in, 1000Base-SX, 1000Base- T or 1000 Base XX
GBIC modules.
A typical P0972MH managed switch is shown in Figure A-3.

Figure A-3. 24-Port Managed 10Base-T/100Base-TX Switch (P0972MH)

This switch supports Layer 2 switching, which is the default mode of the switch when powered
on.
An imbedded Web agent also provides management capability to any computer on the network
via common web browsers such as Netscape Navigator® or Internet Explorer® (both browsers
should be Version 4.0 or above).
Local Console Management (LCM) allows the user to monitor and configure the switch from a
VT-type terminal. LCM can be used to configure features such as SNMP community names and
access rights, Port Enable/Disable, firmware downloads, and Device IP address as well as most
other parameters. LCM can also provide statistical and diagnostic information about the entire
device or an individual port. Management of the switch is password protected. The same pass-
word is used for LCM and for the Web browser interface. Prior to accessing the Management
Module via a network connection, a valid IP address, subnet mask, and in some cases a default
gateway must be configured using an out of band connection or the BootIP protocol. The man-
agement option provides SNMP, RMON (4 groups: 1, 2, 3, and 9), and web management for
system control and statistical monitoring.
This switch has been superseded by the:
♦ 24-Port Copper managed switch with two 1Gb copper uplinks or two optional 1 Gb
fiber uplinks (P0972WP), discussed in the B0700CL document
♦ 24-Port Copper managed switch with two RJ-45 stacking/uplink ports and two ports
for Mini-GBIC modules (P0973BH), discussed in the B0700CH document.

47
B0400DV – Rev D Appendix A. I/A Series Control Network Legacy Ethernet

8-Port Fiber/ 8-Port Copper Managed Switch (P0972WG)

The 8-Port Fiber/ 8-Port Copper managed switch (P0972WG) is a specialized product offering
media flexibility through 8-port 100FX MMF with MT-RJ connectors and 8-port 10/100TX RJ-
45 connectors, plus 2 expansion bays. This Fast Ethernet switch provides exceptional perfor-
mance, ease of use and flexibility. Designed to switch heavy multicast and broadcast traffic effort-
lessly, this switch supports:
♦ a 800K multicast or broadcast packet replication rate
♦ 50K multicast packet forwarding rate, and
♦ up to 10 IGMP leaves and joins per second.
A typical P0972WG managed switch is shown in Figure A-4.

Figure A-4. 8-Port Fiber/ 8-Port Copper Managed Switch (P0972WG)

This switch includes management features such as a web-based interface, command line interface,
and SNMP and Telnet support.
This switch has been superseded by the 8-Port Copper/ 8-Port Fiber managed switch with two
RJ-45 stacking/uplink ports and two ports for Mini-GBIC modules (P0973BK), discussed in the
B0700CH document.

Legacy Ethernet Switch Configuration

The Ethernet switches are designed to be placed on a flat, level surface. Alternatively, switches
may be mounted in a rack using the mounting brackets supplied by the switch vendor. Make sure
that the environment in which the switch is located meets the switch’s environmental operating
specifications, especially heat and humidity. Refer to the documentation included with the switch
for detailed installation instructions and operating specifications.
Some switch types require configuration before they are added to the network. The following sec-
tions list the parameters to be set and directions to the procedure for setting them.

! CAUTION
Switches must be configured off line, before they are connected to the network.

8-Port Unmanaged Switch Configuration

The 8-port unmanaged switch has no configurable parameters. No configuration is necessary.

48
Appendix A. I/A Series Control Network Legacy Ethernet Switches B0400DV – Rev D

8-Port Managed Switch Configuration

Configuration of managed switches is accomplished by connecting a terminal (or a computer run-
ning terminal emulation software) to the console port on the switch and using the switch’s resi-
dent management software to set the parameters. Refer to the documentation included with the
switch for instructions on configuring a specific switch model.
Table A-2 lists the parameters that should be set, along with the required values.

NOTE
Specific switches have been tested with these configuration parameters.

Table A-2. Configuration Settings - 8-Port Switch

Parameter Value
IP Address See “Selecting the IP Address” below
Duplex Mode Autonegotiate, Disable flow control
AgeTime Set to highest value that the switch will allow, with a maximum of 65000
(decimal). Current 8-port switches only allow a maximum value of
415 seconds.

Selecting the IP Address - In order to avoid the possibility of address conflicts, IP addresses for
managed switches should be assigned sequentially beginning with address 151.128.79.1 and con-
tinuing through 151.128.79.192. For example, the first switch configured should be assigned an
address of 151.128.79.1; the second switch configured should be 151.128.79.2, and so on. In the
event that more than 192 addresses are needed, the block of addresses from 151.128.80.1 through
151.128.80.192 can be used for additional switches.

24-Port Managed 10Base-T/100Base-TX Switch (P0972MH)

Configuration
To configure the 24-port managed 10Base-T/100Base-TX switch (P0972MH) for use with an
I/A Series control network with workstations running I/A Series software, Version 7.x, proceed as
follows:
1. Connect the workstation to the switch.
a. Connect the console cable to the serial port on a workstation (COM1 or COM2).
b. Connect the other end of the cable to the COM port on the switch.
c. On the XP/NT/2000 workstation: click Start, click Run, type “hypertrm”, then
press Enter.
d. In the name box, type: INVENSYS. Click OK.
e. Select the appropriate serial port the switch is connected to (COM1 or COM2).
f. The COM1/COM2 properties dialog opens, the settings should be:
Bits Per Second: 9600
Data Bits: 8
Parity: None
Stop Bits: 1

49
B0400DV – Rev D Appendix A. I/A Series Control Network Legacy Ethernet

Flow Control: None

g. Click OK
2. Log-in to the switch with the default user account.
a. User name, type: admin. Press <Enter>.
b. There is no factory default Password, leave the field blank. Press <Enter>.
3. Clear the current configuration.
a. Using the arrow keys navigate to Switch Information. Press <Enter>.
b. Use the arrow keys to navigate to Reboot & Load Factory Default Configura-
tion Except IP Address. Press <Enter>.
c. Highlight YES. Press <Enter>. The switch reboots.
4. Log-in to the switch again.
a. Repeat step 2, to log-in.
5. Enter IP address of the switch.

NOTE
When selecting the IP address, in order to avoid the possibility of address conflicts,
IP addresses for managed switches should be assigned sequentially beginning with
address 151.128.79.1 and continuing through 151.128.79.192. For example, the
first switch configured should be assigned an address of 151.128.79.1; the second
switch configured should be 151.128.79.2, and so on. In the event that more than
192 addresses are needed, the block of addresses from 151.128.80.1 through
151.128.80.192 can be used for additional switches.

a. Using the arrow keys navigate to IP Setup. Press <Enter>.

b. Navigate to Get IP From: field and select <MANUAL>.
c. Navigate to the IP Address field and enter the switch IP address defined by Sys-
tem Definition or IACC (for example, 151.128.79.xxx).
d. Navigate to Subnet Mask: field and set the Subnet Mask field to 255.255.0.0.
e. Navigate to Default Gateway: field and set the Gateway field to 0.0.0.0.
f. Navigate to APPLY. Press <Enter>.
6. Set up port configuration, as follows.
a. Using the arrow keys navigate to Configure Ports. Press <Enter>.
b. Navigate to Configure Port From [1] to [1] and select the port range to be
configured.
c. Navigate to the State field and select <enable>.
d. Navigate to the Speed/Duplex field and select <Auto>.
e. Navigate to APPLY. Press <Enter>.

50
Appendix A. I/A Series Control Network Legacy Ethernet Switches B0400DV – Rev D

! CAUTION
Leaving unused Ethernet ports enabled is a high security risk. It is recommended
that all unused Ethernet and uplink ports be disabled.

7. Disable unused ports as recommended above.

a. Using the arrow keys navigate to Configure Ports. Press <Enter>.
b. Navigate to Configure Port From [1] to [1] and select the ports to be dis-
abled.
c. Navigate to the State field and select <disable>.
d. Navigate to APPLY. Press <Enter>.
8. Disable port mirroring.
a. Using the arrow keys navigate to Mirroring, Press <Enter>.
b. Navigate to Port Mirroring Settings. Press <Enter>.
c. Insure no ports have been mirrored. If any are, remove these mirrors.
9. Using the arrow keys navigate to Save Changes.
Switch setup is complete.

8-Port Fiber/ 8-Port Copper Managed Switch (P0972WG)

Configuration
To configure the 8-Port Fiber/ 8-Port Copper managed switch (P0972WG) for use with an
I/A Series control network with workstations running I/A Series software, Version 7.x, proceed as
follows:
1. Connect the workstation to the switch.
a. Connect the console cable to the serial port on a workstation (COM1 or COM2).
b. Connect the other end of the cable to the COM port on the switch.
c. On the XP/NT/2000 workstation: click Start, click Run, type “hypertrm”, then
press Enter.
d. In the name box, type: INVENSYS SWITCHES. Click OK.
e. Select the appropriate serial port the switch is connected to (COM1 or COM2).
f. The COM1/COM2 properties dialog opens, the settings should be:
Bits Per Second: 9600
Data Bits: 8
Parity: None
Stop Bits: 1
g. Click OK

51
B0400DV – Rev D Appendix A. I/A Series Control Network Legacy Ethernet

NOTE
When using HyperTerminal® with Microsoft® Windows 2000®, ensure that you
have Windows 2000 Service Pack 2 or later installed. Windows 2000 Service Pack 2
fixes the problem of arrow keys not functioning in HyperTerminal’s VT100 emula-
tion. See www.microsoft.com for information on Windows 2000 service packs.

2. Log-in to the switch with the default user account.

a. When asked for your user name, type: manager. Press <Enter>.
b. When asked for your password, type: friend. Press <Enter>.
3. To provide better security to the switch, change the password and login functions:

NOTE
The password must be at least 8 characters long. In the following steps, ******** is
the user defined password for this switch. Passwords are not displayed on the con-
sole screen.

a. At main menu, select C. This will enable the Command Line Interface.
b. Type “set password manager”.
c. Enter the current Manager Password -> friend. Press <Enter>.
d. Enter the new Manger password-> ********. Press <Enter>.
e. Re-enter the Manager password-> ********. Press <Enter>.
The CLI responds with:
Saving password...
Password changed successfully!
Press any key to continue ...
4. To clear the switch configuration:

NOTE
The following command should be performed before configuring the switch to
ensure the switch is in a known state. This command resets the switch.

a. At the main menu select 5 “System Config Menu”.

b. At the System Config Menu, select 7 “Reset to Factory Default”.
c. When asked the following questions, type as indicated:
♦ Are you sure you want to reset to factory defaults? Yes/No….
Type Y.
♦ Do you want to reset static IP, Subnet and Gateway as well?
Yes/No…. Type N.
♦ Do you want to proceed with switch reboot? Yes/No…. Type Y.
d. Press <Enter>. The switch reboots.

52
Appendix A. I/A Series Control Network Legacy Ethernet Switches B0400DV – Rev D

5. Once the switch has booted, set up the IP address of the switch. Enter the IP address
(151.128.79.nnn) that was assigned to the switch defined by SysDef or IACC during
the I/A Series system configuration.

NOTE
When selecting the IP address, in order to avoid the possibility of address conflicts,
IP addresses for managed switches should be assigned sequentially beginning with
address 151.128.79.1 and continuing through 151.128.79.192. For example, the
first switch configured should be assigned an address of 151.128.79.1; the second
switch configured should be 151.128.79.2, and so on. In the event that more than
192 addresses are needed, the block of addresses from 151.128.80.1 through
151.128.80.192 can be used for additional switches.

a. At main menu, select C. This will enable the Command Line Interface.
b. At the command line interface, type:
♦ Manager->
set ip interface=1 ipaddress=151.128.79.nnn netmask=255.255.0.0
6. Set the switch’s ID. The name you assigned to the switch (for example, letterbug) dur-
ing system configuration should be assigned to the switch (for example, SW0001).
♦ Manager-> set system name=“SW0001”
♦ Manager-> set system location=“Bldg N32-049”
♦ Manager-> set system contact=“Joe Smith ext. 555”
7. Set up port configuration, as follows.
♦ Manager-> set switch port=1-8 flowcontrol=none
♦ Manager-> set switch port=9-16 flowcontrol=none
♦ Manager-> set switch port=1-8 renegotiation=auto
♦ Manager-> set switch port=1-8 speed=autonegotiate
♦ Manager-> set switch port=9-16 speed 100mfull
♦ Manager-> destroy switch mirror
♦ Manager-> set switch agingtimer 65000

! CAUTION
Leaving unused Ethernet ports enabled is a high security risk. It is recommended
that all unused Ethernet and uplink ports be disabled.

8. Disable unused ports as recommended above.

♦ Manager-> set switch port=# status=disabled
# denotes the port to be disabled
9. Save the current configuration file.
♦ Manager-> save configuration
Switch setup is complete.

53
B0400DV – Rev D Appendix A. I/A Series Control Network Legacy Ethernet

Legacy Ethernet Switches Connection

Fiber Optic Port to Fiber Optic Port
Managed, 8-port switches can be connected directly to other 8-port managed switches connecting
each switch’s fiber optic ports with fiber optic cable. The fiber optic cable should be terminated
with SC-type connectors and the Ethernet switch’s fiber optic port must be selected with the slide
switch on the front panel of the device. When the fiber optic port is used in this manner, the last
RJ-45 port on the switch cannot be used. Figure A-5 gives an example of an 8-port to 8-port con-
nection via fiber optic cable.

P0972MF P0972MF
8-Port Switch 8-Port Switch

100Base-FX

62.5/125 micron Multimode

Fiber Optic Cable
w/SC-type Connectors
2 km (max)

Figure A-5. 8-Port to 8-Port Connection via Fiber Optic Port

NOTE
Make sure that the transmit (TX) port of one switch is connected to the receive
(RX) port of the other switch.

Fiber Optic Port to RJ-45 Port

An Ethernet switch with fiber optic ports can be connected to a switch with copper RJ-45 ports
by connecting a media converter between the two switches. Figure A-6 illustrates this connection
method.

54
Appendix A. I/A Series Control Network Legacy Ethernet Switches B0400DV – Rev D

P0972MZ
Example Switch with Fiber (MT-RJ) Ports 8-Port Switch

FAST ETHERNET WORKGROUP SWITCH

X To PC = To HUB
RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

PWR
RESET
CPU
COM

100Base-TX
CAT5 Cable
100 m (max)

Media Converter
100Base-FX
62.5/125 micron Multimode
Fiber Optic Cable
w/MT-RJ Connectors
2 km (max)
Figure A-6. 16-Port to 8-port via Media Converter

RJ-45 Port to RJ-45 Port

Switches can be connected to other switches through an RJ-45 port on each switch. It is necessary
that the first switch’s transmit signal is connected to the second switch’s receive line. The same is
true for the second switch’s transmit and receive signals. In order to accomplish this, some
switches (such as the 8-port managed switch) have an MDI port which allows the receive and
transmit signals on the MDI ports to be switched with each other. Figure A-7 shows a connection
between an 8-port switch and a switch with an MDI port.

P0972MZ Example Switch with

8-Port Switch Copper (RJ-45) Ports
X To PC = To HUB

MDI Port
(MDI-X)

10Base-T/100Base-TX
CAT5 Cable
100 m (max)

Figure A-7. Connecting Switches via RJ-45 Ports (MDI Port)

In the event that neither switch has an MDI port, a separate crossover cable, called a null hub,
must be used between the switches. Figure A-8 shows a connection between two 8-port switches
using a null hub.

55
B0400DV – Rev D Appendix A. I/A Series Control Network Legacy Ethernet

P0972MF P0972MF
8-Port Switch 8-Port Switch

P0971PK
Null Hub
(1 ft)

10Base-T/100Base-TX
CAT5 Cable
100 m (max)
Figure A-8. Connecting Switches via RJ-45 Ports (Null Hub)

Ethernet Switch Interconnection Diagrams

Multiple options are available for connecting Ethernet switches to each other. The figures in this
chapter illustrate the way in which the legacy switches can be connected and list the parts and
cables necessary. In addition, Figure A-10 shows how media converters can be used with fiber
optic cable to extend the distance between devices.

56
 P0972MF 100Base-FX, MMF Fiber P0972MF
8-Port Cat 5 2 Km (max) w/SC connectors 8-Port Cat 5

PORT
PORT
Ethernet Switch Cable Group A Ethernet Switch

UPLINK
UPLINK
See Note 3

10/100Base-TX 10/100Base-TX
Cat 5, w/RJ-45 Connectors Cat 5, w/RJ-45 Connectors
Cable Group B Cable Group B
Alternative Uplink Configurations

P0972MF See Note 3 P0972MF P0972MF

8-Port Cat 5 P0971PK
8-Port Cat 5 P0971PK
8-Port Cat 5

PORT
PORT
PORT

Ethernet Switch Ethernet Switch Ethernet Switch

UPLINK
UPLINK
UPLINK

NULL HUB ADAPTER NULL HUB ADAPTER

10/100Base-TX, Twisted Pair 10/100Base-TX, Twisted Pair

100 m (max) w/RJ-45 connectors 100 m (max) w/RJ-45 connectors
Cable Group B Cable Group B

10/100Base-TX 10/100Base-TX
Cat 5, w/RJ-45 Connectors Cat 5, w/RJ-45 Connectors
Cable Group B Cable Group B

P0972MG 100Base-FX, SMF P0972MG

8-Port Cat 5 10 Km (max) w/SC connectors 8-Port Cat 5

PORT
PORT

Ethernet Switch customer supplied Ethernet Switch

UPLINK
UPLINK

See Note 3
Appendix A. I/A Series Control Network Legacy Ethernet Switches

10/100Base-TX 10/100Base-TX
Cat 5, w/RJ-45 Connectors Cat 5, w/RJ-45 Connectors
Cable Group B Cable Group B

P0972MZ P0972MZ P0972MZ

Unmanaged, 8-Port, Cat 5 8MDI PORT Unmanaged, 8-Port, Cat 5 8MDI PORT Unmanaged, 8-Port, Cat 5
Ethernet Switch Ethernet Switch Ethernet Switch

Figure A-9. 8-Port Uplink Cabling Options

10/100Base-TX, Twisted Pair 10/100Base-TX, Twisted Pair
100 m (max) w/RJ-45 connectors 100 m (max) w/RJ-45 connectors
Cable Group B Cable Group B

10/100Base-TX 10/100Base-TX
Cat 5, w/RJ-45 Connectors Cat 5, w/RJ-45 Connectors
Cable Group B Cable Group B

Cable Group A (Fiber) Cable Group B (Cu ) Note 3: Ethernet port 8 and the uplink port
(w/SC connectors) (w/RJ-45 connectors) cannot be used simultaneously.
P0972QP = 3 meters P0971XK = 3 meters
P0972QQ = 15 m P0971XL = 15 m
P0972QR = 50 m P0972MR = 30 m
User supplied if > 50 m P0971XM = 50 m
P0971XN = 100 m
B0400DV – Rev D

57
58
B0400DV – Rev D

P0972MZ P0972MZ
8MDI PORT
Unmanaged, 8-Port, Cat 5 (w/X-over)
Unmanaged, 8-Port, Cat 5
Ethernet Switch MTRJ/MTRJ FIBER Ethernet Switch
Media Converter* 2 Km (max) Media Converter*
Cu to MTRJ ADAPTER Cu to MTRJ ADAPTER
Cable Group C 10/100Base-TX, Twisted Pair
RJ45/RJ45 Cu (100 Mbps, no X-over) (100 Mbps, X-cross)
100 m (max) w/RJ-45 connectors
100 m (max)
OR OR
Cable Group B SC/SC FIBER Cable Group B
P0972ME 2 Km (max) P0972ME
10/100Base-TX Cu to SC ADAPTER Cu to SC ADAPTER 10/100Base-TX
Cat 5, w/RJ-45 Connectors (100 Mbps, no X-over) (100 Mbps, no X-over)
Cable Group A Cat 5, w/RJ-45 Connectors
Cable Group B Cable Group B

RJ45/RJ45 Cu MTRJ/MTRJ FIBER

100 m (max) Media Converter* 2 Km (max) 10/100Base-TX, Twisted Pair
Cu to MTRJ ADAPTER A
100 m (max) w/RJ-45 connectors
Cable Group B (100 Mbps, no X-over) Cable Group C RCNI TO WORKSTATION
P0972QM Cable Group B
MTRJ/MTRJ FIBER
B
Media Converter* Cable Group C
TO "B" NETWORK Cu to MTRJ ADAPTER
SWITCH (100 Mbps, no X-over)

RJ45/RJ45 Cu MTRJ/MTRJ FIBER

100 m (max) Media Converter* 2 Km (max)
Cu to MTRJ ADAPTER Cable Group C
Cable Group B (100 Mbps, no X-over)

SSB-A
NCNI

Cable Group A (Fiber) Cable Group B (Cu ) Cable Group C (Fiber)

(w/SC connectors) (w/RJ-45 connectors) (w/MTRJ connectors)
P0972QP = 3 meters P0971XK = 3 meters P0972KV = 3 meters * Note: Refer to B0700CP for the part numbers of the latest media converters.
P0972QQ = 15 m P0971XL = 15 m P0972KW = 15 m
P0972QR = 50 m P0972MR = 30 m P0972KX = 50 m
User supplied if > 50 m P0971XM = 50 m User supplied if > 50 m
P0971XN = 100 m

Figure A-10. Media Converter to Extend Transmission Distance

Appendix A. I/A Series Control Network Legacy Ethernet
Appendix B. Natural Limitations in
Communication Networks
This appendix discusses the natural limitations of the IEEE 802 communication networks used
in I/A Series systems, and some of the unwanted effects of violating the underlying design limits
and specifications.

Summary
The communication infrastructure is one of the important design criteria for the I/A Series sys-
tem that was introduced in 1987 as the first industrial architecture fully based on open ISO and
IEEE standards. The ISO and IEEE specifications and the successful I/A Series system evolved
continuously with the introduction of later hardware and software development.
Introducing faster technologies on an existing topology may impose additional demand on the
existing infrastructure. This must be managed to ensure that sufficient bandwidth remains avail-
able for flawless operation of the backbones and critical system functions.

Introduction
At its introduction, the I/A Series system was a revolutionary advancement from traditional
Distributed Control Systems. It was designed from the ground up to include integration of hard-
ware, software and communications networks. Lessons learned from the previous generation of
SPECTRUM™ DCS systems were applied to the newly developed systems. Some of the key
design criteria are the long-lived extensible architecture and the application of globally accepted
open communication standards based on ISO and IEEE protocols.

Figure B-1. I/A Series Communication Model

59
B0400DV – Rev D Appendix B. Natural Limitations in Communication

Communication Protocols
I/A Series systems, Version 7.x or earlier, utilize the following communication standards between
stations:
♦ IEEE 802.3 for Nodebus
♦ IEEE 802.4 Carrierband LAN for Tokenbus

NOTE
Newer I/A Series systems, Version 8.x or later, use The MESH control network,
which does not use these protocols. This network is discussed in The MESH Control
Network Architecture Guide (B0700AZ, Rev D or later).

Early IEEE standards did not address redundancy requirements for control systems. Foxboro has
successfully integrated redundant communication for the new process control systems based on
the mentioned standards.

IEEE 802.3
IEEE 802.3 CSMA/CD is a further development of the Ethernet system designed at XEROX®
PARC®.

Figure B-2. The Perception of Ethernet

The meaning of CSMA/CD is that stations will probe bus activity before accessing it (Carrier
Sense); that stations do this autonomously without a bus master (Multiple Access); and that trans-
mitting stations sense if other stations are accessing the bus simultaneously (Collision Detection).
The latter is unavoidable due to the (short) time required for the signal to cross the cable.
Notes:
1. This is a statistical rather than a deterministic protocol.
2. The Foxboro design applies limitations to promote a more deterministic behavior.
3. This appendix will mainly focus on this protocol because Nodebus traffic is the dom-
inant communication.

60
Appendix B. Natural Limitations in Communication Networks B0400DV – Rev D

IEEE 802.4
This standard is largely influenced by the Manufacturing Automation Protocol (MAP) originat-
ing from General Motors. The design uses the deterministic token passing method. This implies
some overhead due to token passing, initialization and error recovery.

Optimum Protocol
Deterministic communication is a must in process control, i.e. many processes require a finite
time to react on changes in that process.
Foxboro's implementation is based on in-depth data topology studies for typical control systems
accounting for potentially long distances between process locations (distributed control and or
I/O).
The determination was that IEEE 802.3 is the optimum for Nodebus (bandwidth) and that IEEE
802.4 is the best for the Carrierband LAN (distance).
However, be aware that the ongoing technological developments and system growth are demand-
ing a shift in communication concepts. Hence, the introduction of switching technology (the
I/A Series control network) with I/A Series systems with Version 7.x software, and The MESH
control network with I/A Series systems with Version 8.x software is to satisfy the demand for
more bandwidth.

IEEE 802.3 Collisions

The passive Nodebus consists of up to three segments interconnected with fiber optic or copper
cables via (Fiber Optic) Nodebus Extenders acting as signal repeaters. The Nodebus with up to
three segments forms a single collision domain, i.e. the CSMA/CD concept applies to all stations
in the three segments. Collision detection within a segment is very fast; collision detection
between the other segments takes longer due to signal- and repeater-delays.
All stations involved in a collision detect this condition and will automatically retry access after a
back off time. The number of retries is limited. Excessive retries are statistically reported and the
packet will be dropped. Further action / detection depend on the higher ISO layers.

Moore's Law
In 1965, Gordon Moore, then head of Research and Development at Fairchild Semiconductor,
prepared an article for the 35th anniversary of Electronics Magazine. He discovered that over the
period 1959-65, the number of components (e.g., transistors) on a chip roughly doubled every
year. This phenomenon is somehow present for all IT components, i.e. for computers and com-
munication bandwidth, and so forth.

Bottleneck Effects
Bottlenecks are natural stress manifestations unveiling the weakest point in a flow. Examples
include road traffic, capacity limitations, and so forth. Slowdowns are usually attributed to one or
more bottlenecks, which are caused when (part of ) the system is not running fast enough to keep
up with the demands placed on it.
The most common bottlenecks in computer networks occur for the following reasons:

61
B0400DV – Rev D Appendix B. Natural Limitations in Communication

♦ The system is starved for memory, so applications are forced to swap to disk, which
can slow response.
♦ The system is out of processor power.
♦ The network is overloaded

I/A Series Loading Capabilities

Generic capabilities are specified in the IEEE standards. The loading of ordinary Ethernet IT net-
works should not exceed 50%. Further increases are possible for short periods, but sustained over-
loading can cause excessive collisions, buffer overruns, time-outs and so forth. This will result in a
dramatic throughput drop due to the exponential increase in collisions.
Defining system capabilities is more complicated. Static capabilities are defined in the Product
Specification Sheets for the I/A Series system components. Dynamic capabilities depend strongly
on topology/size; module quantity; software packages running; configured scan rates; the con-
trolled process; number of alarms; startup / shutdown criteria and so forth. This differs consider-
ably from system to system, but also from moment to moment within a system. Loading
guidelines provide are a fairly good estimation tool, but the actual loading is more significant.
A good rule of thumb for deterministic communications is to limit Nodebus loading to 10%.
In- and out-bound traffic to and from the Carrierband LAN (IEEE 802.4) should be limited to
300 packets/second under worst case conditions. Hence the advised limit of 220 packets/second
under steady state conditions.

Monitoring Bus Load

Counters are available within SMDH to monitor the data communication of individual modules
at 4 different levels:
♦ MAC layer (closest to hardware).
♦ Network layer.
♦ Transport layer.
♦ Application layer (closest to application software).
Details are found in the System Management Displays document (B0193JC).
Diagnostic programs, e.g., remd/remv and pc/frev are available to collect the station information
to support the maintenance engineer and for remote analysis by product specialists.
Dedicated protocol analyzers can be used for the rare cases requiring further in depth analyses.
For example, Ethereal or EtherPeek for Nodebus and Mesh traffic can be used, and tokenbus
scope for the Token Bus.

System Diagnostics
Integrated diagnostic tools are the System Monitor and Network Fault Detection (NFD). The
System Monitor (SM) supervises and alarms the health status of system components. NFD super-
vises the health of the communication infrastructure.
Stations report their health and presence via regular heartbeats to SM. NFD monitors the redun-
dant network infrastructure and informs all stations and SM about the current network status.

62
Appendix B. Natural Limitations in Communication Networks B0400DV – Rev D

Communication networks have a low but real Bit Error Rate (fundamental electrical property)
necessitating an efficient method for error detection and recovery. This is one of the tasks of the
mentioned ISO layers.
Individual stations inform NFD about unacceptable error rates. NFD compares the problem
reports from stations, initiates appropriate testing, makes decisions about defects (reduced redun-
dancy) and informs SM and stations about defects. These defects are next diagnosed, fixed and
recovered by a maintenance specialist.
A prime task for the communication infrastructure is to provide efficient data exchange between
stations with minimal overhead. Hence, NFD must operate without adding significant loading
effects, even under abnormal conditions.

Overloading Effects
The previous section defined that all networks have a finite throughput. Exceeding this may cause
relative minor complaints (e.g. display slow down), but more severe cases will cause the loss of
data or even totally obstruct the data path.
Losing small amounts of data is recovered via the retry mechanisms of the ISO layers. Losing too
many sequential heart beats is a serious attack on system robustness. The system will report this as
a station and/or network failure. The operator/maintenance engineer may be confronted with
misleading or false error messages, questionable system information and so forth. Needless to say
that overloads must be prevented by proper management of the system, just like in any other
technical situation.

Preventive Measures
Recommended preventive measures are:
1. Actively manage the system. Preventive monitoring is a must for all (IT) networks.
Corrective maintenance is often too late.
2. Do not permit any non-I/A Series communications or any non-control related trans-
fers across Nodebus or Carrierband LAN.
3. Monitor system loading at regular intervals especially before and after making changes
to hardware and applications.
4. Use communication alternatives. For example, use a dedicated information network
or portable external memory for ad hoc file transfers between stations to satisfy the
needs during engineering activities, specifically during on line upgrade activities.
5. Disable unused ports to prevent accidental errors.
6. All external communication should run via this information network and a Firewall.
7. Eliminate any unnecessary traffic. Example: Scanning a tank temperature at 50 ms
interval is rather overdone because it takes minutes for such measurements to change.
8. If possible and efficient: Split the collision domain in two domains by replacing NBE
or FONBE with NCNI. Note that the positive effect may be reduced by traffic
between the separated collision domains.
9. Timely updated communication capabilities to keep up with increasing traffic
demands. I.e. include I/A Series system with Version 7.x Switching Technology.
10. Timely upgrade to The MESH (in an I/A Series system with Version 8.x software).
Note the fundamental improvements provided by The MESH; many collision

63
B0400DV – Rev D Appendix B. Natural Limitations in Communication

domains are eliminated, full-duplex connections more than double capacity, increased
bandwidth by a factor of ten, etc.
11. Include monitoring and alarming software for larger / more complex systems (i.e. The
MESH).
Figure B-3 depicts the two most important issues to remember to keep an I/A Series system net-
work running healthy.

REMEMBER
File Transfers
Here!

REMEMBER
Only Control
Data Here!

Figure B-3. Health Concerns of the I/A Series Control Network

Conclusion
The I/A Series system provides the long-lived extensible architecture promised two decades ago.
Learning lessons from previous generation systems was essential. Lifetime learning lessons from
this growth process, especially from the natural limitations opposing this growth, is crucial to
ensure that systems remain robust and are not crippled by unintended side effects of their growth.

64
Index
A
Aging timer 19

B
Bottlenecks in network 61
Bus load 62

C
Cable
fiber optic 22, 24
specifications 22
twisted-pair 24
Cellbus 10
Configuration
Ethernet switches 27, 48
media converter 34
CSMA(Carrier Sense, Multiple Access)/CD 60

D
diagnostic tools 62
DIN mounting 9
DIN rail 30
Distributed Control Systems - improvements on 59

E
Ethernet switches 12
8-port managed 46
8-port unmanaged 45
configuration 27, 48
connecting 37, 54
installation 27, 48
part numbers 45

F
Fiber optic cable 13, 22, 24

I
IEEE 802 protocols 60
Indicators
media converter 43

65
B0400DV – Rev D Index

NCNI module 42
RCNI module 41
Installation
Ethernet switches 27, 48
media converter 34
NCNI module 32
RCNI module 28
IP address 49

L
Letterbug 28

M
Media converter
configuration 34
indicators 43
installation 34
Module identifier 28
Moore's Law 61
Multimode fiber. See Fiber optic cable, multimode

N
NCNI module 10
connecting 34
indicators 42
installation 32
Network components
connecting 34
installing 27
Network topology 19
Nodebus/Control Network Interface module. See NCNI module
Null hub 13, 25

P
Part numbers
Ethernet switches 45
Prefabricated cables 25

R
RCNI module 9
connecting 35
indicators 41
installation 28
Redundant Control Network Interface module. See RCNI module

66
Index B0400DV – Rev D

S
Single mode fiber. See Fiber optic cable, single mode
Site planning 15
Specifications
cable 22
Star topology 19

T
Topology, network 19
Troubleshooting 39
Twisted-pair cable 24

U
Uplink module
Gigabit Ethernet 20

67
B0400DV – Rev D Index

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