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Rockwell Automation Trusted TMR Manual

Rockwell Automation Trusted TMR Manual

Analogue output module – 40 channel
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Trusted TMR Analogue Output Module – 40 Channel
Trusted TMR Analogue Output Module – 40
Channel
Product Overview
The Trusted® TMR Analogue Output Module interfaces to 40 field devices. Triplicated
diagnostic tests are performed throughout the Module including measurements for current,
and voltage on each portion of the voted output channel. Tests are also performed for stuck
on and stuck off failures. Fault tolerance is achieved through a Triple Modular Redundant
(TMR) architecture within the Module for each of the 40 output channels.
Automatic line-monitoring of the field device is provided. This feature enables the Module
to detect both open and short circuit failures in field wiring and load devices.
The Module provides on-board Sequence of Events (SOE) reporting with a resolution of 1
ms. An output change of state triggers an SOE entry. Output states are automatically
determined by voltage and current measurements on-board the Module.
This Module is not approved for direct connection to hazardous areas and should be used in
conjunction with Intrinsic Safety Barrier devices.
Features:
• 40 Triple Modular Redundant (TMR) output channels per Module.
• Comprehensive, automatic diagnostics and self-test.
• Automatic line monitoring per point to detect open circuit and short circuit field
wiring and load faults.
• 2500 V impulse withstand opto/galvanic isolation barrier.
• Automatic over-current protection (per channel), no external fuses required.
• On-board Sequence of Events (SOE) reporting with 1 ms resolution.
• Module can be hot-replaced on-line using dedicated Companion (adjacent) Slot or
SmartSlot (one spare slot for many Modules) configurations.
• Front Panel output status Light Emitting Diodes (LEDs) for each point indicate output
status and field wiring faults.
Rockwell Automation Publication ICSTT-RM284O-EN-P
Issue 15
Product Overview
i

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  • Page 1 Trusted TMR Analogue Output Module – 40 Channel Product Overview Trusted TMR Analogue Output Module – 40 Channel Product Overview The Trusted® TMR Analogue Output Module interfaces to 40 field devices. Triplicated diagnostic tests are performed throughout the Module including measurements for current, and voltage on each portion of the voted output channel.
  • Page 2 Features: Trusted TMR Analogue Output Module – 40 Channel • Front Panel Module status LEDs indicate Module health and operational mode (Active, Standby, Educated). • TϋV Certified for non-interfering applications, refer to the safety manual T8094. • Outputs are powered in isolated groups of eight. Each such group is a Power Group (PG).
  • 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 Analogue Output Module – 40 Channel 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 Analogue Output Module – 40 Channel 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 Analogue Output Module – 40 Channel 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...
  • Page 7 Trusted TMR Analogue Output Module – 40 Channel PREFACE ISSUE RECORD Issue Date Comments Aug 05 Format /Text editing Dec 06 Weights & Dims Jul 07 Certification Sep 07 Specification Nov 07 STATE descriptions Feb 08 Channel LED colours Apr 10...
  • Page 8 PREFACE Trusted TMR Analogue Output Module – 40 Channel Page intentionally left blank viii Issue 15 Rockwell Automation Publication ICSTT-RM284O-EN-P...

  • Page 9: Table Of Contents

    Trusted TMR Analogue Output Module – 40 Channel Table of Contents Table of Contents Description ......................3 1.1. Output Field Termination Unit (OFTU)..................5 1.2. Analogue Output Field Interface Unit (AOFIU) ................5 1.3. Host Interface Unit (HIU) ......................5 1.4.
  • Page 10 Table of Contents Trusted TMR Analogue Output Module – 40 Channel Fault Finding and Maintenance ................31 5.1. Fault Reporting ......................... 31 5.2. Field Wiring Faults ........................31 5.3. Module Faults .......................... 31 5.4. Companion Slot ........................32 5.5. SmartSlot ..........................32 5.6.

  • Page 11: Description

    Trusted TMR Analogue Output Module – 40 Channel 1. Description 1. Description The TMR 4-20 mA Analogue Output 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 1. Description Trusted TMR Analogue Output Module – 40 Channel Figure 2 shows a simplified block diagram of the Trusted 24 Vdc Analogue Output Module. OFTU_LV ISOL FIELD OFIA GFSS OFIU_LV & A/Ds ISOL OFIU_LV & A/Ds ISOL OFIU_LV &...

  • Page 13: Output Field Termination Unit (Oftu)

    Trusted TMR Analogue Output Module – 40 Channel 1. Description 1.1. Output Field Termination Unit (OFTU) The Output Field Termination Unit (OFTU) is the section of the I/O Module that connects all three AOFIUs to a single field interface. The OFTU provides the Group Fail Safe Switches and passive components necessary for signal conditioning, over-voltage protection, and EMI/RFI filtering.

  • Page 14: Front Panel Unit (Fpu)

    1. Description Trusted TMR Analogue Output Module – 40 Channel The HIU provides the following services common to the Modules in the family: • High Speed Fault Tolerant Communications with the TMR Processor via the IMB interface. • FCR Interconnect Bus between slices to vote incoming IMB data and distribute outgoing I/O Module data to IMB.

  • Page 15: Line Monitoring And Output States

    Trusted TMR Analogue Output Module – 40 Channel 1. Description 1.5. Line Monitoring and Output States The Module automatically monitors the output channel current and voltage to determine the state of the output channel. The numerical output state and line fault status are reported back to the application and are represented below.

  • Page 16: Sequence Of Events Characteristics

    1. Description Trusted TMR Analogue Output Module – 40 Channel Module replacement activities depend on the type of spare Module configuration chosen when the system was configured and installed. The Module may be configured with a dedicated Companion Slot or with a SmartSlot for a spare replacement Module.
  • Page 17 Trusted TMR Analogue Output Module – 40 Channel 1. Description TOP_RAIL LOAD_A LOAD_B LOAD_C SENSE_A SENSE_B SENSE_C PRM_A PRM_B PRM_C ENABLE_C ENABLE_A ENABLE_B LOAD LOAD_A LOAD_B LOAD_C LOAD FIELD_RTN Figure 3 Output Driver Structure The upper transistors shown in Figure 3 operate in the linear mode, and are controlled by the AOFIU on which they are physically resident.

  • Page 18: Output Channel Diagnostics

    1. Description Trusted TMR Analogue Output Module – 40 Channel The structure of each OFIU output driver is shown below: 24V V GFSS FIELD TOP_RAIL POWER FPGA OPTO COMMAND FET 1 OPTO RESPONSE UPSTREAM ENABLE FET 2 DOWNSTREAM ENABLE Figure 4 Simplified Driver Circuit Diagram A sense resistor provides a means of continuously monitoring the output current, as measured with an analogue to digital converter (ADC) channel.

  • Page 19: Group Fail Safe Switches

    Trusted TMR Analogue Output Module – 40 Channel 1. Description Each channel is continuously monitored to determine the presence of field faults, such as an open circuit, or lack of field loop power. Note that short circuits are not considered to be a fault condition for an analogue current output channel such as provided by this Module.
  • Page 20 1. Description Trusted TMR Analogue Output Module – 40 Channel Page intentionally left blank Issue 15 Rockwell Automation Publication ICSTT-RM284O-EN-P...

  • Page 21: Installation

    If the pins have not been damaged, try reinstalling the Module. 2.2. Cable Selection I/O cables suitable for use with the Trusted TMR Analogue Output Module are detailed in the following Product Descriptions: • Trusted I/O Companion Slot Cables, publication...

  • Page 22: Termination

    2. Installation Trusted TMR Analogue Output Module – 40 Channel 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 type of Module. Custom length multi-core FTA cables are 0.5 mm with a resistance of 40 Ω/km.
  • Page 23 Trusted TMR Analogue Output Module – 40 Channel 2. Installation Chan 21 (+) Pwr Group 3 (+) Chan 17 (+) Chan 22 (+) Pwr Group 3 (+) Chan 18 (+) Pwr Group 3 Rtn Pwr Group 3 (+) Pwr Group 3 Rtn...

  • Page 24: Trusted Module Polarisation/Keying

    2. Installation Trusted TMR Analogue Output Module – 40 Channel 2.5. Trusted Module Polarisation/Keying. All Trusted Modules have been Keyed to help prevent insertion into the wrong position within a Chassis. The polarisation comprises two parts; the Module, and the associated field cable.

  • Page 25: Application

    Trusted TMR Analogue Output Module – 40 Channel 3. Application 3. Application 3.1. Module Configuration There is no configuration required to the physical Output 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 26: Rack 1: Ao

    3. Application Trusted TMR Analogue Output Module – 40 Channel Rack I/O Board Description Data Type Direction No. of Channels DISCREP Channel Discrepancy Integer HKEEPING Housekeeping Registers Integer INFO I/O Module Information Integer Table 3 Complex Equipment Definition There are two OEM parameters included in the first rack (AO Board). These OEM parameters define the primary Module position;...

  • Page 27: Rack 2: State

    Trusted TMR Analogue Output Module – 40 Channel 3. Application Table 5 Rack 1: AO Descriptions The output command scaling is designed to be consistent with the T8431 Analogue Input Module. This relationship is described by the table below: Command...

  • Page 28: Rack 3: Ai

    3. Application Trusted TMR Analogue Output Module – 40 Channel Value Description Unused Table 8 Rack 2: STATE value Descriptions 3.2.3. Rack 3: AI The AI board returns the field loop voltage at the output. Channel Description Field output channel 1 voltage...

  • Page 29: Rack 5: Line_Flt

    Trusted TMR Analogue Output Module – 40 Channel 3. Application The current is the sum value taken from the triplicated Module. The current level is reported as an integer, with the units being A. This may be used directly, scaled 1000 arithmetically or scaled using the IEC 61131 TOOLSET conversion tables.

  • Page 30: Rack 7: Hkeeping

    3. Application Trusted TMR Analogue Output Module – 40 Channel 3.2.7. Rack 7: HKEEPING Description Channel Units (Full Scale Range) 24V2 Output Voltage -32768 32767 Internal supply voltage (post regulator) -32768 32767 Internal supply current (post regulator) 65535 Output voltage (post isolation)
  • Page 31 Trusted TMR Analogue Output Module – 40 Channel 3. Application Description Channel Units (Full Scale Range) FIU Output Group 2 Field Supply Voltage -32768 32767 FIU Board Temperature, Output Group 2 -32768 32767 (Note: Temperature, °C = input value / 256)

  • Page 32: Rack 8: Info

    3. Application Trusted TMR Analogue Output Module – 40 Channel finding and diagnosis and may be used for reporting and display purposes. If a slice is Fatal, then all reported housekeeping inputs are set to zero. Each input within the housekeeping rack is reported as an integer. In general, the application engineer will not normally require these inputs.
  • Page 33 Trusted TMR Analogue Output Module – 40 Channel 3. Application The Active and Standby Module Mode is an integer indicating the current operating mode of the associated Module. The value indicates the current internal operating mode of the Module. Value...

  • Page 34: Sequence Of Events Configuration

    3. Application Trusted TMR Analogue Output Module – 40 Channel 3.3. Sequence of Events Configuration Each Boolean Output Variable can be configured for automatic Sequence of Events (SOE) logging. This applies to the Output Status and Line Fault Status variables. A Boolean variable is configured for SOE during the variable definition in the Data Dictionary Editor.

  • Page 35: Operation

    Trusted TMR Analogue Output Module – 40 Channel 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 output status. Each indicator is a bi-colour LED.

  • Page 36: Module Status Leds

    4. Operation Trusted TMR Analogue Output Module – 40 Channel 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 Analogue Output Module – 40 Channel 4. Operation Educated Module is not educated. Green Module is educated. Green – flashing Module is recognised by the Processor but education is not complete. Amber - Flashing Active/Standby changeover in progress.
  • Page 38 4. Operation Trusted TMR Analogue Output Module – 40 Channel Page intentionally left blank Issue 15 Rockwell Automation Publication ICSTT-RM284O-EN-P...

  • Page 39: Fault Finding And Maintenance

    Trusted TMR Analogue Output Module – 40 Channel 5. Fault Finding and Maintenance 5. Fault Finding and Maintenance 5.1. Fault Reporting Output 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 40: Companion Slot

    5. Fault Finding and Maintenance Trusted TMR Analogue Output Module – 40 Channel 5.4. Companion Slot For a Companion Slot configuration, two adjacent slots in a Trusted Chassis are configured for the same Module function. One slot is the primary slot and the other a unique secondary (or spare) slot.

  • Page 41: Transfer Between Active And Standby Modules

    Trusted TMR Analogue Output Module – 40 Channel 5. Fault Finding and Maintenance Module once it has booted. Once educated, the Educated LED will be steady green and the Active LED will be red flashing. Input Modules will now be reading and reporting their inputs. Output Modules have not yet energised their outputs.
  • Page 42 5. Fault Finding and Maintenance Trusted TMR Analogue Output Module – 40 Channel using the SmartSlot link. At this point, the TMR Processor will configure the Standby I/O Module with the same configuration information as the currently Active I/O Module and place the Standby I/O Module into the Standby state. The Active Module is then placed in the Maintain state (which suspends field loop testing), and any Module specific changeover data is transferred.

  • Page 43: Specifications

    Trusted TMR Analogue Output Module – 40 Channel 6. Specifications 6. Specifications Backplane (IMB) Supply Voltage 20 Vdc to 32 Vdc Power 22 W Field Supply Voltage 18 Vdc to 32 Vdc Maximum Current 0.9 A Power Dissipation Field Supply at maximum channel...
  • Page 44 6. Specifications Trusted TMR Analogue Output Module – 40 Channel Output Off State Leakage Current @ 24 V 350 µA max. Current Rating (Continuous) 1 mA to 22 mA Recommended Output Current 4 mA to 20 mA Accuracy @ +25 °C ±0.1 % of Full Scale...
  • Page 45 Trusted TMR Analogue Output Module – 40 Channel 6. Specifications Note 1) 50 Vrms Secondary circuit derived from Mains, OVC II up to 300V. Note 2) 250 Vrms Mains circuit, OVC II up to 300V. Exposure to voltages at these levels shall be temporally constrained consistent with the system MTTR.

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