Rockwell Automation Trusted CS300 Manual
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Rockwell Automation Trusted CS300 Manual

Rockwell Automation Trusted CS300 Manual

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PD-8162
Trusted CS300 Bridge Module
Product Overview
The CS300 Bridge Module presents a new opportunity to combine the CS300 Input / Output (I/O)
structure with the latest processing and communications features of Trusted
Combining the two products will enable CS300 users to benefit from features such as 3-3-2-0
Processor fault tolerance, IEC 61131 programming suite, Ethernet networks, OPC, Ethernet peer to
peer and remote diagnostics. The CS300 Bridge Module replaces the CS300 ICCB in the CS300
Primary chassis.
Any system using the CS300 Bridge Module and Trusted Triple Modular Redundancy (TMR)
Processor can also include Trusted Expanders and I/O modules forming a Hybrid system. To the
Trusted TMR Processor, the Trusted and CS300 chassis appear in the same system map. All systems
using Trusted TMR Processors can be seamlessly integrated together.
Features:
• TMR fault tolerant (3-3-2-0) operation
• Dedicated hardware and software test regimes which provide very fast fault recognition and
response times
• Automatic fault handling without nuisance alarming
• Hot replacement, self-configuration.
• Interfaces to Trusted TMR Expander Bus
• Front panel indicators that show module health data transmission status
• Certified as non-interfering for use in IEC 61508 SIL 3 systems
• Retains DIN 19250/AK6 certification of the original CS300 system
Rockwell Automation Publication PD-8162
®
.
Issue 4
Trusted

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Summary of Contents for Rockwell Automation Trusted CS300

  • Page 1 PD-8162 Trusted Trusted CS300 Bridge Module Product Overview The CS300 Bridge Module presents a new opportunity to combine the CS300 Input / Output (I/O) structure with the latest processing and communications features of Trusted ® Combining the two products will enable CS300 users to benefit from features such as 3-3-2-0 Processor fault tolerance, IEC 61131 programming suite, Ethernet networks, OPC, Ethernet peer to peer and remote diagnostics.
  • Page 2 Trusted PD-8162 Page intentionally left blank Rockwell Automation Publication PD-8162 Issue 4...
  • Page 3 PREFACE PREFACE In no event will Rockwell Automation be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment. The examples given in this manual are included solely for illustrative purposes. Because of the many variables and requirements related to any particular installation, Rockwell Automation does not assume responsibility or reliability for actual use based on the examples and diagrams.
  • Page 4 PREFACE Trusted CS300 Bridge Module IMPORTANT A login is required to access the link. If you do not have an account then you can create one using the "Sign Up" link at the top right of the web page. DOCUMENTATION FEEDBACK Your comments help us to write better user documentation.
  • Page 5 Trusted CS300 Bridge Module PREFACE SCOPE This manual specifies the maintenance requirements and describes the procedures to assist troubleshooting and maintenance of a Trusted system. WHO SHOULD USE THIS MANUAL This manual is for plant maintenance personnel who are experienced in the operation and maintenance of electronic equipment and are trained to work with safety systems.
  • Page 6 PREFACE Trusted CS300 Bridge Module WARNINGS AND CAUTIONS WARNING: EXPLOSION RISK Do not connect or disconnect equipment while the circuit is live or unless the area is known to be free of ignitable concentrations or equivalent AVERTISSEMENT - RISQUE D’EXPLOSION Ne pas connecter ou déconnecter l’équipement alors qu’il est sous tension, sauf si...
  • Page 7 Trusted CS300 Bridge Module PREFACE ISSUE RECORD Issue Date Comments Apr 2008 First Issue Feb 2010 TC-322 details Jul 2015 Converted document to Rockwell branding layout Clarified certification status and corrected Operating Humidity range Jun 2016 Correction of Operating Temperature specification, typographical errors and updated to incorporate IEEE standards.
  • Page 8 PREFACE Trusted CS300 Bridge Module Page intentionally left blank Issue 4 Rockwell Automation Publication PD-8162...

  • Page 9: Table Of Contents

    Trusted CS300 Bridge Module Table of Contents Table of Contents Description ......................3 1.1. Overview ............................ 3 1.2. Power Distribution ........................4 1.3. Communication Buses ........................ 4 1.3.1. The Trusted to CS300 Primary Chassis ................4 1.3.2. Inter-Module Link (IML) ..................... 4 1.4.
  • Page 10 Table of Contents Trusted CS300 Bridge Module Page intentionally left blank Issue 4 Rockwell Automation Publication PD-8162...

  • Page 11: Description

    Trusted CS300 Bridge Module 1. Description 1. Description 1.1. Overview The CS300 Bridge Module enables connection between a CS300 I/O sub system and the Trusted TMR Processor. Three CS300 Bridge modules replace the three ICCB modules in a CS300 primary chassis.

  • Page 12: Power Distribution

    1. Description Trusted CS300 Bridge Module 1.2. Power Distribution Each of the Bridge modules is powered from triple redundant PSUs (situated in a separate chassis) that support the main I/O chassis with 5 V, 12 V & ±20 Vdc supplies and up to three CS300 extension chassis with 12 V and ±20 Vdc only.

  • Page 13: Installation

    Trusted CS300 Bridge Module 2. Installation 2. Installation 2.1. Module Each of the three Bridge modules replaces one of the CS300 ICCB modules. Figure 2 shows the module. The replacement must be carried out with the system offline. The modules consist of a single Printed Circuit Board (PCB) assembly.

  • Page 14: Tc-322-02 Interface Cable Assembly

    2. Installation Trusted CS300 Bridge Module 2.2. TC-322-02 Interface Cable Assembly The interface cable connects from the Trusted Interface Adapter T8312 to an identical 12 way socket on the interface cable connector card. Figure 3 TC-322-02 Interface Cable Assembly Figure 4 CS300 Main Chassis Rear View...
  • Page 15 Trusted CS300 Bridge Module 2. Installation Figure 5 Trusted Controller Chassis Rear View Figure 5 shows a four socket version of the T8312 Expander Interface Adapter with a TC-301-01 cable attached, which connects to a Trusted expander chassis. The Expander Interface Adapter has four or seven connections available to individual Trusted Expander chassis or to the CS300 controller chassis using the TC-322-02 Interface Cable Assembly.

  • Page 16: Module Configuration

    2. Installation Trusted CS300 Bridge Module 2.3. Module Configuration Figure 6 CS300 Chassis Backplane The Bridge module requires minimum configuration, namely the setting of three sets of jumpers 0 to 3 to define the chassis address to Trusted. These are situated on the CS300 chassis backplane as shown here.

  • Page 17: Application

    Trusted CS300 Bridge Module 3. Application 3. Application All CS300 I/O modules are configured using the IEC 61131 application Toolset provided with Trusted. This configuration requires entries in the System Configuration (System.INI) for the chassis and modules and their hardware operational parameters, and also in the workbench I/O connection table, for software settings and data connection.
  • Page 18 3. Application Trusted CS300 Bridge Module Figure 8 Insert New Chassis The first chassis to be created is a CS300 8162. This includes the bridge modules in place of the CS300 processors. Choose typeCS300 8162 and select a logical chassis number. This chassis number will define the switch configuration described in Section 2.3.
  • Page 19 Trusted CS300 Bridge Module 3. Application Figure 10 Chassis Connection On closing this dialog, the CS300 8162 chassis should have a blue flash symbol on the left. The right hand side shows the chassis address as: < Trusted expander Interface slot> - <Expander socket number> - <CS300 chassis number>...
  • Page 20 3. Application Trusted CS300 Bridge Module Figure 12 Jumper Setting This chassis then links into the extension chassis BIC, which is linked to the main CS300 8162 chassis by ribbon cables. To add a BIC chassis, right click again on the background and select CS300 BIC. The switch settings on these chassis should not be changed from their old configuration in the CS300 system.
  • Page 21 Trusted CS300 Bridge Module 3. Application Having added all the chassis in the system, the next step is to insert modules. For each module, right-click on the appropriate chassis slot. Select the module from the list. Figure 14 CS300 Modules On left-clicking the module, the module options are displayed.

  • Page 22: Board Definitions

    3. Application Trusted CS300 Bridge Module The ‘Mode’ is included for PI727 modules which can be set to 3-2-1 or 3-2-0 operation. For output modules, an input module may be configured to monitor the outputs as a diagnostic feedback. Where this is required, check the Enable Monitor option and select the chassis and slot of the input module.

  • Page 23: Module - Bic (Bus Interface Controller)

    Trusted CS300 Bridge Module 3. Application RACK 2: [INFO] - 12 ANALOGUE Inputs Word 1: FCR-A fault code (see note 1) Word 2: FCR-B fault code (see note 1) Word 3: FCR-C fault code (see note 1) Word 4: FCR-A hot-link error count...

  • Page 24: Module - Pi632 / Pi732 (Analogue Input Module)

    3. Application Trusted CS300 Bridge Module PHYSICAL MODULE: RACK 1: [STATUS] - 10 BOOL Inputs Variable 1: FALSE (Not used) Variable 2: TRUE = FCR-A faulted Variable 3: TRUE = FCR-B faulted Variable 4: TRUE = FCR-C faulted Note: The status of BIC FCR's can only be determined by the discrepancy status of accesses performed to I/O modules within the chassis of the BIC.

  • Page 25: Module - Pi641 / Pi741 (Analogue Output Module)

    Trusted CS300 Bridge Module 3. Application bit 3 Module offline or missing offline or missing online bit 4 Single slot hot repair in progress not in progress bit 5 Discrepancy errors faults detected no faults detected Word 2 Slot number of active module...
  • Page 26 3. Application Trusted CS300 Bridge Module slice is responding bit 2 Slice C slice is not responding or there is an error slice is responding bit 3 Module offline or missing offline or missing online bit 4 Single slot hot repair...

  • Page 27: Module - Pi616_5 / Pi616_9 / Pi716 / Pi717 (Digital Input Module)

    Trusted CS300 Bridge Module 3. Application Output data used for Slice C on the AO module. Only used if the corresponding boolean output in RACK 4 (CALIB) is TRUE. Notes: Discrepancy errors will only be checked if the AO module has a configured AI monitor module. Discrepancy errors indicate a difference between the output value on an AO and the voted input value on the AI monitor.

  • Page 28: Module - Pi626 / Pi726 (Digital Output Module)

    3. Application Trusted CS300 Bridge Module online bit 4 Single slot hot repair in progress not in progress bit 5 Discrepancy errors faults detected no faults detected Word 2 Slot number of active module RACK 3: (FAULTS) 2 INTEGER inputs...

  • Page 29: Module - Dmx_M (De-Multiplexed Display Driver)

    Trusted CS300 Bridge Module 3. Application bit 2 Slice C slice is not responding or there is an error slice is responding bit 3 Module offline or missing offline or missing online bit 4 Single slot hot repair in progress...

  • Page 30: Module - Dmx_O (De-Multiplexed Display Driver Card)

    3. Application Trusted CS300 Bridge Module PORT_B 0 or 2/3 MP serial port number for the DMX chain secondary link (=0 disables the secondary link) PHYSICAL MODULE: RACK 1: (DMX) 1 BOOLEAN output not used Notes: The dmx_m module must be defined before the dmx_o modules.

  • Page 31: Operation

    Trusted CS300 Bridge Module 4. Operation 4. Operation Figure 16 Front Panel Layout Rockwell Automation Publication PD-8162 Issue 4...

  • Page 32: Front Panel Indicators And Controls

    4. Operation Trusted CS300 Bridge Module 4.1. Front Panel Indicators and Controls 4.1.1. Tx & Rx Indicators Flashing amber Light Emitting Diodes (LEDs) indicate active transmit and receive communications on the Expander Bus. 4.1.2. Health Indicator A steady green Light Emitting Diode (LED) indicates a fault-free Bridge module; an extinguished LED indicates a fault.

  • Page 33: Fault Finding And Maintenance

    Trusted CS300 Bridge Module 5. Fault Finding and Maintenance 5. Fault Finding and Maintenance The Trusted TMR Processor provides fault monitoring, self-test and diagnostics functions. Fault Detection within a Trusted / CS300 system can be categorized into four regions: •...
  • Page 34 5. Fault Finding and Maintenance Trusted CS300 Bridge Module Page intentionally left blank Issue 4 Rockwell Automation Publication PD-8162...

  • Page 35: Specifications

    Trusted CS300 Bridge Module 6. Specifications 6. Specifications Supply Voltage 5.4 Vdc ±5 % Heat Dissipation Operating Temperature (convection cooling) 0 °C to +60 °C (+32 °F to +140 °F) Storage Temperature -25 °C to +70 ºC (-13 °F to +158 °F) Relative Humidity range 10 % –...

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