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Rockwell Automation
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SC300E
User Manual
43 pgs3.02 Mb2

Rockwell Automation SC300E User Manual

Trusted™
PD-8161
Trusted™ / SC300E Bridge Module
Introduction
The SC300E Bridge presents a new opportunity to combine the SC300E Triguard I/O structure with the latest processing and communications features of Trusted™.
Combining the two products will enable Triguard users to benefit from features such as 3-3-2-0 Processor fault tolerance, IEC 1131 programming suite, Ethernet networks, OPC, Ethernet peer to peer and remote diagnostics. The SC300E Bridge replaces the Triguard MPP in the Triguard Primary chassis.
Any system using the SC300E Bridge and Trusted™ TMR Processor can also include Trusted™ Expanders and I/O modules forming a Hybrid system. To the Trusted™ TMR Processor, the Trusted™ and SC300E chassis appear in the same system map. All systems using Trusted™ TMR Processors can be seamlessly integrated together.
Features
• Triple Modular Redundant (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
• TÜV certification and IEC61508 SIL3
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Trusted™ Bridge Module 8161
Issue Record
Issue Number Date Revised by Technical CheckAuthorised by Modification
1 Apr 08 A Holgate N Owens P Stock Initial Issue
2 Feb 10 A Holgate N Owens P Stock TC-322 details
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Trusted™ Bridge Module 8161
Table of Contents
1. Description......................................................................................................................................7
1.1 Overview.........................................................................................................................................7
1.2 Power Distribution ..........................................................................................................................8
1.3 Communication Busses..................................................................................................................8
1.3.1 The Trusted™ to SC300E Primary Chassis...................................................................................8
1.3.2 Inter-Module Link (IML) ..................................................................................................................8
1.4 Function..........................................................................................................................................8
2. Installation ......................................................................................................................................9
2.1 Module............................................................................................................................................9
2.2 TC-322-02 Interface Cable assembly...........................................................................................10
2.3 Module Configuration ...................................................................................................................11
3. Application ....................................................................................................................................12
3.1 System Configuration ...................................................................................................................12
3.2 Board Definitions ..........................................................................................................................16
3.2.1 Module – 8161 (Bridge Module) ...................................................................................................17
3.2.2 Module – MBB (Bus interface Module).........................................................................................18
3.2.3 Module – mai32lad (0-5V; analogue input Module)......................................................................19
3.2.4 Module – mai32mad (0-10V; analogue input Module) .................................................................20
3.2.5 Module – mai32nad (0-20Ma; analogue input Module)................................................................21
3.2.6 Module – mai32pad (0-40Ma; analogue input Module)................................................................22
3.2.7 Module – mao04nnd (0-22Ma; analogue output Module) ............................................................23
3.2.8 Module – mdi32bis (24v; digital input Module) .............................................................................25
3.2.9 Module – mdi32fis (120v; digital input Module) ............................................................................26
3.2.10 Module – mdi32gis (48v; digital input Module) .............................................................................27
3.2.11 Module – mdi64bns (24v simplex; digital input Module)...............................................................28
3.2.12 Module – mdo16fns (120v; digital output Module) .......................................................................30
3.2.13 Module – mdo16gns (48v; digital output Module).........................................................................32
3.2.14 Module – mdo32bns (24v; digital output Module).........................................................................34
3.2.15 Module – mhb44ind (Pulse-in/analogue output Module) ..............................................................36
3.2.16 Module – mrb01xs (remote slave Module)...................................................................................38
3.2.17 Module – mrb04xm (remote master Module)...............................................................................39
4. Operation......................................................................................................................................40
4.1 Front Panel Indicators and Controls.............................................................................................41
4.1.1 Tx & Rx Indicators ........................................................................................................................41
4.1.2 Health Indicator ............................................................................................................................41
4.1.3 On-Line Indicator and Switch .......................................................................................................41
5. Fault Finding and Maintenance ....................................................................................................42
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Trusted™ Bridge Module 8161
6. Specifications ...............................................................................................................................43
Figures
Figure 1 Block Diagram showing interface between Trusted™ system and Triguard I/O...................... 7
Figure 2 8161 Bridge Module ................................................................................................................. 9
Figure 3 TC-322-02 Interface Cable assembly..................................................................................... 10
Figure 4 Triguard main chassis rear view............................................................................................. 10
Figure 5 Trusted™ controller chassis rear view ................................................................................... 11
Figure 6 Chassis Address Jumpers...................................................................................................... 11
Figure 7 Trusted™ Processor Chassis with Expander Interface.......................................................... 12
Figure 8 Insert New Chassis................................................................................................................. 12
Figure 9 Triguard main chassis ............................................................................................................ 13
Figure 10 Chassis Connection.............................................................................................................. 13
Figure 11 Connected Chassis .............................................................................................................. 13
Figure 12 Jumper Setting ..................................................................................................................... 14
Figure 13 MBB and MRB04XM Chassis Addressing ........................................................................... 14
Figure 14 Triguard Modules.................................................................................................................. 15
Figure 15 Module Options .................................................................................................................... 15
Figure 16 Front Panel Layout ............................................................................................................... 40
Tab le s
Table 1 Bridge Module Associated Equipment....................................................................................... 6
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Trusted™ Bridge Module 8161
Precautionary Information
WARNING
Warning notices call attention to the use of materials, processes, methods, procedures or limits which must be followed precisely to avoid personal injury or death.
CAUTION
Caution notices call attention to methods and procedures which must be followed to avoid damage to the equipment.
Notes:
Notes highlight procedures and contain information to assist the user in the understanding of the information contained in this document
Warning
RADIO FREQUENCY INTERFERENCE
MAINTENANCE
Maintenance must be performed only by qualified personnel, otherwise personal injury, death, or damage to the system may be caused.
Caution
HANDLING
Under no circumstances should the module housing be removed.
Associated Documents
Product Descriptions (PD) provide product specific information.
The Safety Manual contains the recommended safety requirements for the safety system design.
The PD-T8082 – Toolset Suite provides specific guidance on system configuration and application generation.
The Operator and Maintenance Manual contains general guidelines on maintenance and diagnostic procedures.
For technical support email: support@icstriplex.com
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Trusted™ Bridge Module 8161
Associated Equipment

Part Number Product Name Description

Adds equipment definitions for SC300E modules
o the Trusted™ Toolset
T8042 SC300E Toolset Library
CS300/SC300E Interface Cable
TC-322-02
TC-325-02
Assembly SC300E Interface Cable
Connector Card
Table 1 Bridge Module Associated Equipment
t To connect between Trusted™ Expander
nterface Adaptor and SC300E Controller
I Chassis
To attach TC-322-02 cable to SC300E Controller Chassis
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Trusted™ Bridge Module 8161
Module
Bridge Module (A)
Backplane
1. Description
1.1 Overview
The SC300E Bridge enables connection between a Triguard SC300E I/O sub system and the Trusted™ TMR Processor. Three SC300E Bridge modules replace the three MPP modules in a Triguard primary chassis.
The Bridge module has a fast serial ("Hotlink") interface that transfers command and response packets between the two product families via the Trusted™ Expander Bus. The module uses a Field Programmable Gate Array (FPGA) for decoding instructions from the Trusted™ TMR processor, accessing the specified Triguard I/O module and returning any data requested.
Command data received by the three Bridge modules and responses to the Trusted™ TMR Processor are synchronised in accordance with the Lock Step operational characteristics of the Trusted™ Expander Bus. For this reason, the three bridge modules share their data and arrange their response packets in the same order for simultaneous transmission. The clock signal received from the Expander Bus is used to ensure that data from all three Bridge modules is transmitted on the same clock edge.
The Trusted™ TMR processor stores and executes the application program, scans and updates the Triguard I/O modules and detects system faults. Each of the three slices of the TMR Processor executes the application program independently, but in lock-step synchronisation with the other two.
All Triguard I/O modules are supported. Triguard Serial Communication modules are not supported. All communications to workstations and DCS systems are enabled through the Trusted™ Communications Interfaces.
(B)
(A)
FCR A
Trusted™
Expander
Interface
Trusted™
Main Chassis
(C)
FCR A
Expansion Bus (T C-322-02 Cable)
transmitter
Main Chassis
(TC-325-02 Board)
Bridge Module (C)
Bridge Module (B)
hotlin k
receiver
hotlin k
Triguard
FPGA
Inter Mod ule
Link
Triguard
to T riguard I/O Modules
Figure 1 Block Diagram showing interface between Trusted™ system and Triguard I/O
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Trusted™ Bridge Module 8161
1.2 Power Distribution
Each of the Bridge modules is powered from dual redundant 5.4V dc via the backplane from the chassis PAC or PDC dual power supplies.
1.3 Communication Busses
1.3.1 The Trusted™ to SC300E Primary Chassis
Communication between the Trusted™ Expander Interface Module and the SC300E Primary Chassis is via one of a possible four or seven triplicated two-way interface cables. A single backplane connector card routes the individual links in the cable to the three Bridge modules. Data voting is provided at the Expander Module Interface to ensure that cable faults are detected.
The link handles the following triplicated signals:
Data - Serial bi-directional bus.
Control - Bus clocks, module-enables and bus direction control.
Slot - Indicating the SC300E I/O slot position to the Bridge.
Expander Chassis ID - 4 bit Trusted™ chassis address code.
1.3.2 Inter-Module Link (IML)
When returning data for Trusted™ Read requests, I/O Module data received by each Bridge module is shared with the other two using the serial IML via the backplane. The three sets of data are then arranged sequentially into the response packet for Trusted™. The IML is not used during Write requests.
1.4 Function
When an I/O access is to be performed, the Trusted™ TMR Processor issues a command packet to an Expander Interface module. The Expander Interface decodes the chassis address and transmits the packet through the Expander bus to receivers in the 8161 Bridge modules.
For short distances of a few metres, a twisted-pair copper cable is used, whilst on longer runs the copper cable is connected to three T8312 fibre optic units at each end of three pairs (Tx and Rx) of fibre optic cable. The Bridge modules, receiving the command signals, decode the packet.
The Bridge modules then implement the read or write access on the SC300E I/O module selected and return a response packet via the Expander Bus. The packet will contain both data and diagnostic information.
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Trusted™ Bridge Module 8161
2. Installation
2.1 Module
Each of the three Bridge modules replaces one of the Triguard MPP processors. Figure 2 shows the module. The replacement must be carried out with the system offline.
The modules consist of a single PCB assembly.
Figure 2 8161 Bridge Module
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Trusted™ Bridge Module 8161
2.2 TC-322-02 Interface Cable assembly
The interface cable connects from the Trusted™ Interface Adaptor T8312 to an identical 12 way socket on the interface cable connector card.
Figure 3 TC-322-02 Interface Cable assembly
Figure 4 Triguard main chassis rear view
Figure 4 shows the interface cable connector card (top left) fitted to three unused connectors on the rear of the Triguard controller chassis which is connected to the Trusted™ Expander Interface adaptor via the TC-322-02 interface cable (braided cable on left).
Connectors J1-3 on the TC-325-02 card plug into the three 26-way headers on the Triguard backplane. The expander cable, TC-322-02, from the Trusted™ Expander Interface plugs into 12-way socket J4.
Note that the chassis Unit ID jumpers will need setting before fitting the interface cable connector card (see section 2.3).
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Trusted™ Bridge Module 8161
Figure 5 Trusted™ controller chassis rear view
Figure 5 shows a four socket version of the T8312 Expander Interface Adaptor 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 Triguard controller chassis using the TC-322-02 Interface Cable Assembly.
2.3 Module Configuration
The Bridge module requires minimum configuration, namely the setting of Unit ID jumpers 0 to 3 to define the chassis address to Trusted™. These are situated on the Triguard chassis as shown here.
Figure 6 Chassis Address Jumpers
Unit ID jumpers 0,1,2,3 represent the binary address bits 1,2,4 & 8 respectively. A removed jumper signals a binary digit ‘1’. The address is set to between 2 and 8. On the first Triguard chassis (containing the SC300E Bridge Modules), remove jumper 1 to represent Trusted™ address '2' (as shown in the picture). The jumpers on all three sets must be set to the same address. Leave the jumpers as they were on the other Triguard chassis. It is usual to attach the chassis with address 2 to the first Expander Interface Adapter socket, for both Trusted™ chassis and Triguard chassis. This makes the software configuration easier.
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Trusted™ Bridge Module 8161
3. Application
All Triguard I/O modules are configured using the IEC1131 application Toolset provided with
rusted™. This configuration requires entries in the System Configuration (System.INI) for the chassis
T and modules and their hardware operational parameters, and also in the workbench I/O connection table, for software settings and data connection.
3.1 System Configuration
Figure 7 Trusted™ Processor Chassis with Expander Interface
The Triguard chassis are attached to the Expander Interface as if they were Trusted™ expander chassis, but the various chassis options for Triguard and CS300 are provided on the ‘Insert New Chassis’ dialog. Right-click on the grey background of the configurator window to insert a new chassis.
Figure 8 Insert New Chassis
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Trusted™ Bridge Module 8161
The first chassis to be created is a 8161. This includes the bridge modules in place of the Triguard processors. Choose type Triguard 8161 and select a logical chassis number. This chassis number will define the switch configuration described in section 2.3.
Figure 9 Triguard main chassis
The chassis should then be allocated to the Trusted™ Expander Interface module. Left-click on the left or right end of the Triguard 8161 chassis to open the Chassis Connection dialog. Select the slot number of the left-hand Expander Interface module.
Figure 10 Chassis Connection
On closing this dialog, the Triguard 8161 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> - <Triguard chassis number>
Figure 11 Connected Chassis
Left-click on the left or right end of the 8161 chassis to open the Chassis Connection dialog again. The ‘Jumper Config’ button now demonstrates how to set the Triguard backplane jumpers.
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