Distributed Safety I/O Pack Work Around

Problem
An issue (SCR #15589) with the Safety System Branding function was discovered in the ControlST
V03.02.38C. It is not safety related, but may cause confusion if an I/O pack must be replaced.

The issue occurs under the following conditions:

 The Safety (SIL) System has been Branded and Locked.
 An I/O Pack (Y-Pack) fails and the hardware needs to be replaced.
 No other changes to the Safety System have been made.

What should happen is that once the I/O pack is replaced, the user should be able to build and download to the
I/O pack. The Brand value in the status window should remain the same value (green) after the new hardware
has been downloaded.

What actually happens is that once the I/O pack has been downloaded and rebooted, the I/O pack comes back
up and causes a mismatched Brand value (i.e. a different value shown in yellow). In reality the certified
software has not been modified as the changed brand mistakenly indicates.
Workaround
To prevent a Branding mismatch issue
The user can help prevent a branding mismatch issue by preparing the SIL MarkVIeS system before branding
and locking the system. This procedure must be done when the system is not running and it is safe to
perform a reboot of the system. The following steps should be performed:
1. Make sure that all parameter updates have been made to all SIL I/O packs.
2. Make sure that the MarkVIeS is Unlocked.
3. Select Device -> Compress… from the menu.
4. Select Compress Distributed I/O and click OK.
5. Perform a Build of the MarkVIeS controller by selecting the Build button from the toolbar.
6. Initiate a Download with the Download wizard, and download the MarkVIeS controller and all I/O
packs. (Note: This should only be done when the system is offline, as a reboot of the entire SIL system
will be required.)
7. Once the MarkVIeS and all packs are back online, then re-run the download wizard and verify that
everything is equal.
8. The user can now lock and brand the MarkVIeS system. If a pack has to be replaced, it should no longer
cause a branding mismatch.

To correct a Branding mismatch issue

To restore to the correct brand, assuming no other changes have been made, the user must unlock the system by
selecting the Unlock button from the toolbar, and then initiate a new revision scan by selecting a Download
with the Download wizard. The entire system should scan as equal, with no downloads required.

The user should then force a download of the Parameters of the I/O pack that was just replaced, even though it
shows as equal.
Once the download of the I/O pack has been completed, the Brand should return to its original value prior to
replacing the I/O pack and should be equal again. The user can then re-lock the system. No re-certification
steps are needed since only the indication was corrected.

Note: This workaround procedure is not guaranteed to restore the Brand Match in all instances of replacing an
I/O pack.