Rockwell Automation MAI32AD User Manual

Triguard SC300E

MAI32*AD

32-Channel Analogue Input Module

Differential

Issue 4

INTRODUCTION

PURPOSE

The Analogue Input Module provides up to 32, low voltage or current analogue input signals. All
channel
from

inputs into the module are resistively isolated from each other and galvanically isolated

the system environment.

Input

(MAI32*AD

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The basic module can be configured to meet a range of input specifications, the different
configurations can be identified from the module type number (see Section 1.3, Specification)
Circuit triplication and voting procedures make the module single-fault tolerant. A front panel
Channel selector and test points enable the metering of any channel, and indicators show the
circuit on-line status and the health of the module.

The module, which is compatible with ‘hot repair’, can be fitted in any of the ten I/O slots in the
SC300E Chassis, ‘wrong slotting’ is prevented by physical coding. The SC300E system
software identifies the module via a built-in hardware identifier.

Channel inputs are wired to the module via the DIN 41612 ‘rear plug-up’ system on the chassis
backplane. This document is intended to provide a general understanding of the function of the
Analogue
field.

Input Module, sufficient to enable basic maintenance operations to be eff

ASSOCIATED DOCUMENTATION

Reference No Title

008-5097

Chassis User Manual

ected in the

.

008-5102

008-5155

008-5156

TAI16AEA Termination Card Analogue Input
DIN to screw User Manual

TAI16AIR Termination Card Analogue Input
DIN

to

screw, 250 Ohm terminated, Internal

power, User Manual

TAI16BIRTermination Card Analogue Input DIN

008-5103

2

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to DIN, 250 Ohm terminated, Internal power,
User Manual

Mechanicalcodin
gblock(Upper)

321/320 Link

321 320

ConnectorJ1

Common
Interface (CI)
( on dau g ht er board)

Connector J2

Figure 1-1 General view and front panel detail

Connector J3

Mechanical coding
block (Lower)

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SPECIFICATION

MAI32*AD

32-Channel A/I Module Differential Input

Input parameters

All models have 32 input channels configured as follows:

Model number

MAI32LAD

MAI32MAD

0 to 20mA. Use TAI16AIR (BIR) with MAI32LAD

0 to 40mA Use TAI16AIR (BIR) with MAI32MAD

Channels

Architecture

Indicators

Channel Input Test Ponts

Input range

Input overrange protection

Current input applications

Model

Voltage input applications

0 to 5Vdc

0 to 10Vdc

32

TMR

Health 3 x On Line

Switch selectable on front panel

MAI32LAD

MAI32MAD

±40Vdc

See under “input range”

: 0 to 5Vdc

: 0 to 10Vdc

Resolution

Accurancy @ 25°C

Stability (temperature coefficient)

Analogue to digital converter

Sample rate

Input impedance

Power off impedance

Common mode range

Isolation

Power consumption

By system

By input loads

Overall size (mm)

Overall size (inches)

Weight

12 bits

±

0.04% over full signal range

±20ppm/°C

SAR (monotonic)

40ms nominal

>20M ohm

>12k ohm

±11Vdc

1kVdc system/channel

±15Vdc channel to channel

7.5W excluding input loads

3.2W maximum for 20mA module

400(9U)H x 397L x 28W

15.75H x 15.63L x 1.1W

1.6kg

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32-Channel A/I Module Differential Input

NOTE

For voltage loop inputs TAI16AEA termination cards must be used

ENVIRONMENTAL SPECIF

The maximum ambient temperature measured at the hottest point within the Triguard system
shall

not be greater than 60 degrees centigrade.

Temperature operatin

Tem

perature storage

Humidity

EMC/RFI

Vibration/Shock

Certification:

General Certification: Ref. SC300E TMR Product Guide (ref 008-5209)

Immunity

g

ICATIONS

+5°C to +60°C

-

25°C to +70°C

5% to 95% non-condensing at ambient <40°C

Tested and certified to IEC 1131-Part 2 1994

Tested and certified to IEC 1131-Part 2 1994

TRANSPORT AND HANDLING

The MAI32*AD must be transported and stored in its original packing material which should be
retained

for this purpose.

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TECHNICAL DESCRIPTIO

N

PHYSICAL

The Analogue Input Module is a 9U high PCB with integral front panel and rear connectors; a
plug-in daughter board carries the Common Interface circuits.The general layout, location of the
connectors,

front panel components and the 321/320 configuration link is shown in Figure 1-1.

Mechanical coding blocks

All Input/Output modules carry two mechanical coding blocks equipped with pins which mate
with

holes in corresponding blocks in the chassis and prevent the module being inserted into
the wrong slot. The pins in the module blocks are factory installed in a pattern determined by
the module and corresponding set screws are removed from the chassis coding blocks to
enable
block configuration for thi

fitting. Unused holes are plugged with set screws. The chassis mechanical coding

s module is shown i

n Figure 2-1

.

Figure 2-1 Chassis mechanical coding block configurations

EXTERNAL CONNECTIONS

Field circuits

The field input loop shown in Figure 2-2 is the absolute minimum required for the safe
connection
Analogue Input termination cards TAI16*** which can offer field power supplies, remote and
local

alarm indication, transient suppression and signal and protective ground facilities.

Figure 2-3 shows a termination card for a current input module.

of

analogue inputs. We however, recommend the use of their 16 Channel

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Figure 2-2 Basic field input circuit

Figure 2-3 Field input using Termination Card

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Figure 2-4 Field input connectors J2 and J3 pinouts

Module connectors

The System bus connector is J1 and the Common Interface is connected vi
shown). In the external connection diagram Figure 2-4 the following symbols are used:

= First Mate (long pin)

x = Connector pin

0V

=Instrumentation Earth

a J4 and J5 (not

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THEORY OF OPERATION

Analogue input module

The first part of the block diagram in Figure 2-5 shows the circuit used to process one of the 32
analogue inputs. The field input is connected across a ranging resistor which is selected in
accordance with the type of field input to be processed (current or voltage). The channel signal
is then distributed along four paths (A to D); paths A, B and C are the triplicated signal
processing circuit and path D feeds the metering test point.

In each path the signal is first passed through RF and low-pass filters before being applied to
one channe
microcontroller in the Common Interface is isolated, decoded and used to select which input
channel
and sent to an analogue to digital (ADC) converter which produces a serial data output coded
to represent the amplitude of the channel input signal. Factory set links connected to the ADC
enable the basic module to be configured for different +5Vdc o
ADC

output is passed via an opto-isolator to the Common Interface for processing.

l of a 32 channel multiplexer. For paths A, B and C a command from the

will be switched to the output of the multiplexer. The multiplexer output is then buf

fered

r +10Vdc voltage ranges. The

There is no ADC in path D, the buffered signal is applied directly to the metering test point on
the front panel. Channel selection is by means of the adjacent channel selector switches.
Power to the module is 5.4Vdc and 12Vdc supplied by each of the dual redundant SC300E
power supply units. Each line is divided into four branches to provide a supply to each of the
four paths. The dual inputs for both supplies (12V and 5.4V) in each branch are ORed via
diodes to provide the dual redundancy. After filtering and surge limitation the output rails VEE*
(nominally12V)
C 5V rails
Each of the A, B and C path supplies is also continuously monitored and the monitor outputs
A/PSUOK, B/PSUOK and C/PSUOK are sent via the Common Interface to the MPPs for
d

iagnostic purposes.

An On/off Line Request switch on the front panel enables a request to be sent to the MPPs
that the module be taken off-line for maintenance purposes.

The module contains a hardware identity circuit that enables system identification o
module.

Links

Only user changeable link is identified as LK3 and located in the top right hand corner of the
module

(see Figure 1-1). The link (LK3) enables the module to be set for 321 or 320 mode.

and VCC* (nominally 5V) provide power to their respective paths. The A, B and

also supply power to the corresponding control circuits in the Common Interface.

f the

Modes of operation

The 321 or 320 mode sets the threshold that determines how much of the circuit can be
degraded while still preserving overall operation. Setting the 320 mode means that the system
will

continue to function with two out of three serviceable circuits; if the number falls to one out

of th

ree the last read data is maintained. In 321 mode the system will continue to function with
one out of three serviceable circuits; if that fails the last read data is maintained and the
module is taken off-line.

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Figure 2-5 Analogue input module-Block

diagram

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Common interface

The three discrete control circuits in the Common Interface (A, B, and C) are each responsible
for the control of the corresponding one third of the I/O module circuits. Each control circuit
comprises a microcontroller with a dedicated watchdog, data buffers and shared RAM. The
circuit is powered via the module and permits live insertion of replacement modules.

Figure 2-6 Common interface -

The microcontroller co-ordinates I/O signal processing, signal path diagnostics, on-line/off-line

status and signal status read/write cycles to and from the MPPs via an I/O communications

bus. All I/O modules have an identification code which is read by the Common Interface and

passed to the MPPs for verification. The on-line/

maintenance purposes, the On/off Line Request switch on the front of the module is

operated, the action is read by all three microcontrollers and the request passed to the MPPs

which may then grant the request. The watchdog extinguishes the Health LED on the I/O

module front panel in the event of a microcontroller failure, LFD action or a voting discrepancy.

off-

Block diagram

line status is determined by the MPPs. If,

for

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32-Channel A/I Module Differential Input

SERVICING

SCOPE

System repair is by module replacement. Faulty modules are not repairable in the fi
should be replaced by new modules and returned for repair.

CAUTION 1

Before fitting a new module ensure that the 321/320 link setting is the same as that on the old
module.

The module contains components that may be electrostatically sensitive, it should be
transported and stored in its original packaging material.

CAUTION 2

eld, they

DIAGNOSIS

The TriBuild workstation is used for fault diagnosis. In the case of an Input/Output fault the
Health LED on the faulty module will be extinguished.

CAUTI

ON 3

Do not use a mains-powered multimeter on the front panel test points.

CONFIGURATION

The only configuration necessary is the correct location of the 321/320 Link as shown in Figure
1-1 Ensure that the link configuration on the new module is identical to that on the old module.

REMOVAL AND REPLACEMENT

Preparation

Before removal /replacement ascertain if the module under consideration is used in the single
or dual hot repair configuration.

Failure to take the faulty module off-line before removing it from the chassis could trigger a fault
alarm

or

cause plant shutdown.

CAUTION 4

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When inserting a module ensure that it is aligned with the markings on the chassis rails and
that

it

module

SC300E

engages with the upper and lower guides. Improper insertion may cause damage to the

and/or chassis connectors.

CAUTION 5

Single-slot hot repair

Operate the On/Off Line Request switch on the faulty module, the three On Line LEDs should
all go out to indicate that the MPPs have recognised the request and taken the module off­The last read data input from the module will be maintained until the new module is on-line.
Slacken
draw

Insert the new module ensuring that it engages properly in the upper and lower guides in the
chassis, the top and bottom chassis rails carry alignment marks to assist. Pull out the
ejection levers and as the module is pushed back engage the levers on the chassis rails. The
levers
rear

Operate the On/Off Line Request switch and check that the three On Line LEDs illuminate for
one second, extinguish for one second and then illuminate permanently to indicate that the
module has been put on-line. If the LEDs do not illuminate either the first or second time or fail
to remain illuminated, then the module must be considered faulty.

the two module securing screws and use the black ejection levers (top and bottom) to

the module from its slot.

should then be used to draw the module into position, some resistance will be felt as the

connector pins engage. The module should be fixed in position with the securing screws.

Dual-slot hot repair

Insert the new module into the vacant hot repair slot ensuring that it engages properly in the
upper

and lower guides in the chassis, the top and bottom chassis rails carry alignment marks
to assist. Pull out the eject
the chassis rails. The levers should then be used to draw the module into position, some
resistance
position with the securing screws.

will be felt as the rear connector pins engage. The module should be fixed in

line.

ion levers and as the module is pushed back engage the levers on

Operate the On/Off Line Request switch on the new module. Ascertain that the three On Line
LEDs on the new module illuminate for one second, extinguish for one second and then
illuminate permanently as the LEDs on the old module extinguish. This sequence indicates
that the new module has been put on line and the old module taken off line. If the LEDs on the
new

module do not illuminate either the first or second time or fail to remain illuminated, the
new module must be regarded as faulty. The old module LEDs should remain illuminated
indicating

If the new module is serviceable slacken the screws on the old module and use its ejection
levers to remove it from the chassis.

PREVENTIVE MAINTENAN

No preventive maintenance is necessary.

that it is still on-line.

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SERVICE SUPPORT

SPARE PARTS

Spare parts and technical advice can be obtained from the your local area office.