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Rockwell Automation Trusted TMR Manual

Pulse generator and monitoring module
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PD-T8444
Trusted TMR Pulse Generator and Monitoring
Module
Product Overview
The Trusted® Triple Modular Redundant (TMR) Pulse Generator and Monitoring Module interfaces
through special Thyristor Drivers, to two Stepper Motors, which form an integral part of a damper
rod control system. The Module is based upon the Trusted T8461 Digital Output Module. Feedback
of Thyristor activation and rod position is provided by the Module as a % movement figure and a
series of fault signals. Triplicated diagnostic tests are performed throughout the Module in order to
locate and annunciate hardware failures. Inputs are treated as analogues and are fully tested by the
nature of their operation. Fault tolerance is achieved through a TMR architecture within the
Module.
The Module has been configured to provide the control and interlock requirements for a high
power stepper motor control system which is used to position Damper Rods in a Nuclear reactor.
The functionality of this Module is highly specialised and is detailed later in this Product Description
(PD).
Features:
• Two Stepper Motor controls.
• Special control algorithms and fault diagnostics resident within the Module.
• Bi-directional fast and slow movement.
• Emergency stop and hold facility.
• Rod position indication.
• Thyristor driver fault indications.
• ESD Rod release.
• 2500 V impulse withstand opto/galvanic isolation barrier.
• Automatic over-current protection (per channel), no fuses required (outputs).
Rockwell Automation Publication PD-T8444
Issue 10
Trusted

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  • Page 1 PD-T8444 Trusted Trusted TMR Pulse Generator and Monitoring Module Product Overview The Trusted® Triple Modular Redundant (TMR) Pulse Generator and Monitoring Module interfaces through special Thyristor Drivers, to two Stepper Motors, which form an integral part of a damper rod control system. The Module is based upon the Trusted T8461 Digital Output Module. Feedback of Thyristor activation and rod position is provided by the Module as a % movement figure and a series of fault signals.
  • Page 2 Trusted PD-T8444 • Front Panel status Light Emitting Diodes (LEDs) for each point indicate status and field wiring faults. • Front Panel Module status LEDs indicate Module health and operational mode (Active, Standby, Educated). Rockwell Automation Publication PD-T8444 Issue 10...
  • 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 TMR Pulse Generator and Monitoring 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.
  • Page 5 Trusted TMR Pulse Generator and Monitoring 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 TMR Pulse Generator and Monitoring 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 TMR Pulse Generator and Monitoring Module PREFACE ISSUE RECORD Issue Date Comments July 05 Formatting Dec 06 Weights and Dims Sep 07 Tbl16 Chns rotated Nov 09 Table 5 change Apr 10 Rack 7 change Aug 15 Rebranded and reformatted with correction to Relative Humidity Range...
  • Page 8 PREFACE Trusted TMR Pulse Generator and Monitoring Module Page intentionally left blank Issue 10 Rockwell Automation Publication PD-T8444...

  • Page 9: Table Of Contents

    Trusted TMR Pulse Generator and Monitoring Module Table of Contents Table of Contents Description ......................3 1.1. Field Termination Unit (FTU) ....................... 4 1.2. Field Interface Unit (FIU) ......................4 1.3. Host Interface Unit (HIU) ......................5 1.4. Front Panel Unit (FPU) ........................ 6 1.5.
  • Page 10 Table of Contents Trusted TMR Pulse Generator and Monitoring Module 4.4. Output and Input Separation/Channel Allocation ..............31 Fault Finding and Maintenance ................34 5.1. Fault Reporting .......................... 34 5.2. Field Wiring Faults ........................34 5.3. Module Faults ........................... 34 5.4.

  • Page 11: Description

    Trusted TMR Pulse Generator and Monitoring Module 1. Description 1. Description The TMR Pulse Generator and Monitoring (PG/M) Module is a member of the Trusted range of Input/Output (I/O) Modules. All Trusted I/O Modules share common functionality and form. At the most general level, all I/O Modules interface to the Inter-Module Bus (IMB) which provides power and allows communication with the TMR Processor.

  • Page 12: Field Termination Unit (Ftu)

    1. Description Trusted TMR Pulse Generator and Monitoring Module Figure 2 shows a simplified block diagram of the Trusted PG/M Module. Figure 2 Functional Block Diagram 1.1. Field Termination Unit (FTU) The Field Termination Unit (FTU) is the section of the I/O Module that connects all three FIUs to a single field interface.

  • Page 13: Host Interface Unit (Hiu)

    Trusted TMR Pulse Generator and Monitoring Module 1. Description The FIU also measures a range of on-board “housekeeping” signals that assist in monitoring the performance and operating conditions of the Module. These signals include power supply voltages, current consumption, on-board reference voltages, board temperature, and condensation 1.3.

  • Page 14: Front Panel Unit (Fpu)

    1. Description Trusted TMR Pulse Generator and Monitoring Module 1.4. Front Panel Unit (FPU) The Front Panel Unit (FPU) contains the necessary connectors, switches, logic, and LED indicators for the Front Panel. For every Module, the FPU contains the Slice Healthy, Active/Standby, the Educated indicators (LEDs), and the module removal switches.

  • Page 15: Sequence Of Events Characteristics

    Trusted TMR Pulse Generator and Monitoring Module 1. Description Processor its ability to process data with integrity. In addition, the DSP uses Cyclical Redundancy Checks (CRC) to verify the variables and configuration stored in flash memory. Between the HIU and FIU are a series of optically isolated links for data and power. The data link is synchronised and monitored for variance.
  • Page 16 1. Description Trusted TMR Pulse Generator and Monitoring Module Figure 3 Output Switch Structure The upper switches as shown in Figure 3 are denoted as N.O. (Normally Open), and are controlled by the FIU on which they are physically resident.

  • Page 17: Switch Diagnostics

    Trusted TMR Pulse Generator and Monitoring Module 1. Description Figure 4 Simplified Switch Circuit Diagram A resistor provides a means of continuously monitoring the switch current. A signal transistor is used to drive the gate of Switch 2. It provides Switch 2 with a negative gate voltage, to minimise it’s on resistance, and serves to hold Switch 2 on in the event that the...

  • Page 18: Short Circuit Protection Issues

    1. Description Trusted TMR Pulse Generator and Monitoring Module 1.9.2. Short Circuit Protection Issues In a fuse-free design such as in the Trusted System, the Module is required to respond rapidly in the event of an over-current or over-power situation. In fact, this protection scheme offers advantages to fuses in both automatic recovery and speed of action.

  • Page 19: Input Interfaces

    Trusted TMR Pulse Generator and Monitoring Module 1. Description 1.10. Input Interfaces Each input channel is provided with three analogue to digital converters (ADCs) which monitor the voltage at the input connection. Each input is a high impedance channel which measures from 0 V to 30 V.

  • Page 20: Installation

    If the pins have not been damaged, try reinstalling the module. 2.2. Field Cable Selection I/O cables suitable for use with the Trusted TMR Pulse Generator and Monitoring Module are detailed in the following Product Descriptions. • PD-TC200 – Trusted I/O Companion Slot Cables •...

  • Page 21: Module Pin-Out Connections

    Trusted TMR Pulse Generator and Monitoring Module 2. Installation The Product Descriptions detailed above also detail the types of Field Termination Assembly (FTA) or Versatile Field Termination Assembly (VFTA) which may be used with this type of Module. 2.3. Module Pin-out Connections...

  • Page 22: Trusted Module Polarisation/Keying

    2. Installation Trusted TMR Pulse Generator and Monitoring Module 18 Mon Rod 2 Phase B power Pwr Group 3 (+) Mon Rod 1 Phase C power supply B supply A 19 Mon Rod 2 Phase BB power Pwr Group 3 (+) Mon Rod 1 Phase AA power supply B...
  • Page 23 Trusted TMR Pulse Generator and Monitoring Module 2. Installation the cable so that they correspond with the bungs fitted to the associated Module prior to fitting. Cable Exit Polarising/Keying Smart Pins. Trusted Cable Swap (Remove using hood Connector side cutters where...

  • Page 24: Application

    Trusted TMR Pulse Generator and Monitoring Module 3. Application 3. Application 3.1. Module Configuration There is no configuration required to the physical Module. All configurable characteristics of the Module are performed using tools on the Engineering Workstation (EWS) and become part of the application or System.INI file that is loaded into the TMR Processor.

  • Page 25: Rack 1: Pg_Ctrl

    Trusted TMR Pulse Generator and Monitoring Module 3. Application Rack I/O Board Description Data Direction No. of Channels Type OEM Parameters PG_CTRL Pulse Generator controls Boolean FIELD Field State Integer PI_CTRL Position Indicator controls Integer PG_FAULT Pulse Generator faults Boolean...

  • Page 26: Rack 2: Field

    3. Application Trusted TMR Pulse Generator and Monitoring Module Channel Description ROD_TRIP control signal for Rod 2 PG_INHIBIT_RESET control signal for Rod 2 GD_A_INHIBIT_RESET control signal for Rod 2 GD_A_INHIBIT_RESET control signal for Rod 2 GD_A_INHIBIT_RESET control signal for Rod 2...

  • Page 27: Rack 3: Pi_Ctrl

    Trusted TMR Pulse Generator and Monitoring Module 3. Application Channel Description Phase A voltage feedback on Motor A of Rod 2 Phase B voltage feedback on Motor A of Rod 2 Phase C voltage feedback on Motor A of Rod 2...

  • Page 28: Rack 4: Pg_Fault

    3. Application Trusted TMR Pulse Generator and Monitoring Module Channel Description COUNT_UP control signal for PI for Rod 2 COUNT_DOWN control signal for PI for Rod 2 LOAD control signal for PI for Rod 2 NewPosition integer value for PI for Rod 2 Table 6 Rack 3: PI_CTRL Descriptions 3.2.4.
  • Page 29 Trusted TMR Pulse Generator and Monitoring Module 3. Application Rockwell Automation Publication PD-T8444 Issue 10...

  • Page 30: Rack 5: Line_Flt

    3. Application Trusted TMR Pulse Generator and Monitoring Module 3.2.5. Rack 5: Line_Flt Channel Description Field output channel 1 line fault Field output channel 2 line fault Field output channel 40 line fault Table 8 Rack 5: Line_Flt Descriptions The line fault input state is reported as true (logic ‘1’) for a line fault condition (open circuit, short circuit, and no field supply voltage).
  • Page 31 Trusted TMR Pulse Generator and Monitoring Module 3. Application Description Channel Units (Full Scale Range) Output voltage (post isolation) -32768 32767 24V1 Output Voltage -32768 32767 HIU Board Temperature -32768 32767 (Note: Temperature, °C = input value / 256) Front Panel Load Current...

  • Page 32: Rack 8: Info

    3. Application Trusted TMR Pulse Generator and Monitoring Module Description Channel Units (Full Scale Range) (Note: Temperature, °C = input value / 256) FIU Output Group 4 Field Supply Voltage -32768 32767 FIU Board Temperature, Output Group 4 -32768 32767 (Note: Temperature, °C = input value / 256)

  • Page 33: System.ini File Configuration

    Trusted TMR Pulse Generator and Monitoring Module 3. Application Channel Description Standby Module Healthy Standby Module mode FCR Status Primary module is Active Active Module is simulated Table 11 Rack 8: INFO Descriptions The Active Module chassis and slot numbers indicate the position of the currently Active Module.
  • Page 34 3. Application Trusted TMR Pulse Generator and Monitoring Module Page intentionally left blank Issue 10 Rockwell Automation Publication PD-T8444...

  • Page 35: Operation

    Trusted TMR Pulse Generator and Monitoring Module 4. Operation 4. Operation 4.1. Front Panel Status indicators on the Front Panel of the Module provide visual indications of the Module’s operational status and field status. Each indicator is a bi-colour LED. Located at the top and bottom of each Module is an ejector lever that is used to remove the Module from the Chassis.

  • Page 36: Module Status Leds

    4. Operation Trusted TMR Pulse Generator and Monitoring Module 4.2. Module Status LEDs There are six Module status indicators on the Module Front Panel: three Healthy, one Active, one Standby, and one Educated. The Healthy indicators are controlled directly by each Module slice.

  • Page 37: I/O Status Leds

    Trusted TMR Pulse Generator and Monitoring Module 4. Operation Table 12 Module Status Indicators 4.3. I/O Status LEDs There are 40 channel status indicators on the Module Front Panel, one for each field input/output. These indicators are controlled by the FPU. The FPU receives data from each of the Module slices.

  • Page 38: Feedback Inputs

    4. Operation Trusted TMR Pulse Generator and Monitoring Module 4.3.2. Feedback Inputs Function Green Green Red Flash Amber Amber Notes Steady Flash Steady Steady Flash Input off no Slice LEDs faults allowed allowed Green Input off with Slice LEDs Red...

  • Page 39: Output And Input Separation/Channel Allocation

    Trusted TMR Pulse Generator and Monitoring Module 4. Operation 4.4. Output and Input Separation/Channel Allocation The Module has 6 pulse outputs, 12 pulse inputs and 2 control signals per motor drive. The Output Module has 5 power groups protected by Group Fail Safe Switches. In order to minimise the effect of a single group failure the I/O is segregated as shown below.
  • Page 40 4. Operation Trusted TMR Pulse Generator and Monitoring Module Issue 10 Rockwell Automation Publication PD-T8444...
  • Page 41 Trusted TMR Pulse Generator and Monitoring Module 4. Operation Page intentionally left blank Rockwell Automation Publication PD-T8444 Issue 10...

  • Page 42: Fault Finding And Maintenance

    Trusted TMR Pulse Generator and Monitoring Module 5. Fault Finding and Maintenance 5. Fault Finding and Maintenance 5.1. Fault Reporting Module faults are reported to the user through visual indicators on the Front Panel of the Module and through status variables which may be automatically monitored in the application programs and external system communications interfaces.

  • Page 43: Smartslot

    Trusted TMR Pulse Generator and Monitoring Module 5. Fault Finding and Maintenance secondary (or spare) slot. The two slots are joined at the rear of the Trusted Chassis with a double-wide I/O Interface Cable that connects both slots to common field wiring terminations.

  • Page 44: Transfer Between Active And Standby Modules

    5. Fault Finding and Maintenance Trusted TMR Pulse Generator and Monitoring Module 5.7. Transfer between Active and Standby Modules The TMR Processor is responsible for managing a pair of I/O Modules through an Active/Standby changeover. The following rules apply to Active/Standby changeovers, though the TMR Processor and not the I/O Module enforces them: •...
  • Page 45 Trusted TMR Pulse Generator and Monitoring Module 5. Fault Finding and Maintenance Under normal conditions, an Active/Standby changeover will only occur if the new Active Module is fault free. Under some circumstances, it is desirable to be able to force a changeover to a known faulted Module.

  • Page 46: Technical Specifications

    Trusted TMR Pulse Generator and Monitoring Module 6. Technical Specifications 6. Technical Specifications 6.1. Introduction The Pulse Generator and Monitoring Module is required to be high integrity but it is not in itself intended to be a safety system. The design concept maintains the advantages of TMR Systems while retaining a simple implementation of a Damper Rod Control System by the use of redundant paths.

  • Page 47: Phase Rotation

    Trusted TMR Pulse Generator and Monitoring Module 6. Technical Specifications 6.2. Phase Rotation TIME T1 TIME T2 TIME T3 FREQ. 1 437.5 ms 312.5 ms 125.0 ms (1.33 Hz) FREQ. 2 43.75 ms 31.25 ms 12.5 ms (13.3 Hz) Note: Timing is shown for clockwise rotation of stepping motor.

  • Page 48: Internal Testing And Monitoring

    6. Technical Specifications Trusted TMR Pulse Generator and Monitoring Module 6.4. Internal Testing and Monitoring Maintaining control of the Damper Rods/Stepper Motors is the primary aim of this system. Fail danger faults detected by any diagnostics do not lead to the Module releasing the Damper Rods except in the manner specified in Framatome Spec 08-5011407-00.

  • Page 49: Operation With One Thyristor Driver Removed

    Trusted TMR Pulse Generator and Monitoring Module 6. Technical Specifications 6.6. Operation with one Thyristor Driver Removed The PG/M Module interfaces to two Thyristor Drivers from each channel. The design is such that each channel can operate with one Thyristor Driver removed. Loss of feedback from both Thyristor Drivers of one rod does not affect control of any other rods.

  • Page 50: Analogue Feedback Out Of Limits

    6. Technical Specifications Trusted TMR Pulse Generator and Monitoring Module Initiating Pulse Feedback Pulse Acceptable Acceptable window Window Input Removed 8 ms Output Normal Waveform The window for short and long pulse width is 15 ms. Under normal operation if the input is removed when an AC phase had just started, the SCR would continue to conduct until the AC phase crossed the 0 V line again.

  • Page 51: Synchronisation/External Timing

    Trusted TMR Pulse Generator and Monitoring Module 6. Technical Specifications from each output, therefore each output must pulse 192*2 times = 384. Therefore if all pulses are counted the total will be 384*6 = 2304 pulses. Because of potential position registration errors the Counter has been configured so that it can count above the expected maximum and below zero.

  • Page 52: Module Temperature Measurement

    6. Technical Specifications Trusted TMR Pulse Generator and Monitoring Module 6.18. Module Temperature Measurement Temperature measurements are made on the Module for general monitoring purposes. These are indicative only and are not intended to provide accurate temperature readings. 6.19. Diagnostics Wherever possible the Trusted standard diagnostics have been maintained.

  • Page 53: Fta Output Schematic

    Trusted TMR Pulse Generator and Monitoring Module 6. Technical Specifications 6.20. FTA Output Schematic Field Output Switch To Thyristor Output Unit Burden Resitor Feedback Monitoring Module Field Termination Assembly 0V Field Figure 8 Field Termination Output Schematic Rockwell Automation Publication PD-T8444...

  • Page 54: Fta Input Schematic

    6. Technical Specifications Trusted TMR Pulse Generator and Monitoring Module 6.21. FTA Input Schematic Field Supply Not Used Input From Scaling Thyristor Resitor Unit Feedback Monitoring Field Termination Assembly Module 0V Field Figure 9 Field Termination Input Schematic Issue 10...

  • Page 55: Specifications

    Trusted TMR Pulse Generator and Monitoring Module 7. Specifications 7. Specifications System Supply Voltage 20 Vdc - 32 Vdc Circuit Type Fault tolerant, fully triplicated with optional line monitoring Number of Channels 40 Channels Independent Power Groups 5 each of 8 outputs...
  • Page 56 7. Specifications Trusted TMR Pulse Generator and Monitoring Module System Supply (24 V) 22 W Dissipated in the Module Field Common Isolation Basic Insulation 250 Vdc/Vac Maximum Impulse Withstand 2.5 kV Output Turn-on/off Delay 1.0 ms Sample Update Time 1.0 ms...

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