Rockwell Automation T71xx User Manual

ICS Regent +Plus
PD-7000
Processor Modules
(128K: T7110, T7111 and T7112) (512K: T7120, T7121 and T7122)
The controller assembly's three processor modules store and execute application programs, scan and update the I/O modules, process communications, and detect system faults. Each of the processor modules executes the application programs independently, but in lock-step synchronization with the other two. And each processor module independently communicates in lock­step synchronization with the I/O assembly over its own dedicated I/O Safetybus link.
®
Issue 1, September, 04
Features
Triple modular redundant, fault tolerant (3-2-0) operation.
Two-out-three hardware voting of all internal operations.
Automatic fault handling without nuisance alarming.
Time-stamped fault historian.
Hot replacement with pushbutton education of new module
(no need to re-load programs).
Battery-backed program storage for power outage protection.
Structured function block programming.
Multiple program execution.
Front panel indicators on each module show processor,
communications, I/O, program, battery, memory lock, and power status.
TÜV certified for safety, Risk Class 5.
The processor modules use a two-out-of-three voting scheme to detect faults in the system. The Regent identifies, isolates, and records transient and permanent faults as they occur. All faults are recorded in the system's fault history. Permanent faults are also
Industrial Control Services (Issue 1) 1
Processor Mo dules (T7110, 11, 12, 20, 21, and 2 2)
annunciated by an LED on the front of the processor module. In addition, redundant fault contacts are activated to signal an external device to alert operators to any permanent fault.
Module Operation
A block diagram of a typical processor module is shown in Figure
1. Inside each processor module is a main processor, an I/O proc-
essor, and a power supply. A battery inside each of the processor module maintains user application programs and the downloadable portions of the system's RAMcode if there is a power failure. Each processor module has interfaces to the processor Safetybus and the I/O Safetybus. These interfaces consist of an input voter, discrepancy detector logic, and an output driver.
Figure 1. Block Diagram of a Processor Module.
The voting and fault detection circuits allow the processor modules to identify and isolate transient, intermittent, and permanent faults as they occur. All faults are recorded in the system's fault history.
Each processor module contains its own power supply that converts input power to the logic power levels used by the internal processor circuits. The failure of one power supply will only effect
2 (Issue 1) Industrial Control Services
Processor Mod ules (T7110, 11, 12, 20, 21, and 22 )
one processor module — allowing the other two modules to continue operating — thus keeping the Regent on-line by virtue of its majority two-out-of-three voting architecture.
Programs are stored in on-board battery-backed RAM. Program instructions are fetched from each processor’s memory and executed by the processors. Data from inputs are read from the I/O modules in the I/O assembly. The main processor coordinates the Regent’s activities and solves the application algorithms programmed by the user. Outputs are driven by transmitting data through the processor module’s I/O processor to the I/O assembly.
Communications between the main processor and the I/O processor are maintained through shared RAM that is used as a “mail box” for data transfers between the two processors.
All three processor modules operate independently in lock-step synchronization with the other two modules, continuously repeating a scan cycle (Figure 2).
Figure 2. The Regent’s Scan Cycle.
The main processors in each of the three processor modules run programs and process communications synchronously, while the I/O processors in each module read and write I/O synchronously.
During these synchronous operations, all instructions and data are distributed across the Safetybus where automatic voting and fault detection occur.
Main Processor
During each scan cycle, the main processor executes application programs, reading inputs from the shared RAM and writing outputs to the shared RAM.
PD-7000 Sep-04 (Issue 1) 3
Processor Mo dules (T7110, 11, 12, 20, 21, and 2 2)
In addition to running application programs, the main processor takes care of system overhead, such as:
Background diagnostics including voter tests, read tests of the
EPROMs, and read-write tests of the RAM (this automatic test is also what re-educates a new processor).
Communications processing including reading from and
writing to the communications modules every one millisecond and checking the communications messages at the end of each scan.
Fault filtering and reporting (which are available through
W
INTERPRET’s fault status and fault history features).
Reading the communications module’s real-time clock (if a
real-time clock communications module is installed).
I/O Processor
During each scan cycle the I/O processor receives voted input data into its local RAM and transfers it to the shared RAM — making it available to the main processor. After being processed by the main processor, output data are placed into the shared RAM and read by the I/O processor into its local RAM and written to the outputs.
The I/O processor also shares in managing system overhead. This overhead includes:
Background I/O processor tests (voter tests, read EPROM tests,
and read-write local RAM tests).
I/O module tests (I/O module voter tests, logic loopback tests,
and coordinating other I/O module tests).
Fault filtering and reporting (which are available through
W
INTERPRET’s fault status and fault history features).
Testing and Diagnostics
Each processor module’s error detection logic is periodically tested to ensure its continued correct operation. Testing is done using self-tests that are automatically scheduled by each processor module’s real-time operating system.
Front Panel Indicators and Controls
Figure 3 shows the physical features of the processor modules. The front panel of each module contains status indicators as well as a reset button and a memory lock keyswitch.
4 (Issue 1) Industrial Control Services
Processor Mod ules (T7110, 11, 12, 20, 21, and 22 )
Figure 3. Processor Module.
PD-7000 Sep-04 (Issue 1) 5
Processor Mo dules (T7110, 11, 12, 20, 21, and 2 2)
Processor Indicator
This red and green LED pair indicates the overall health of the processor module. During normal operation the green PROC indicator is on. If a module fault occurs the red indicator turns on and the green indicator turns off.
Communications Indicator
This red and green LED pair indicates the overall health of the system’s communications. During normal operation the green COMM indicator is on. If a communications fault occurs the red COMM indicator turns on and the green COMM indicator turns off.
I/O Indicator
This red and green LED pair indicates the overall health of the system’s I/O. During normal operation the green I/O indicator is on. If an I/O fault occurs the red I/O indicator turns on and the green indicator turns off.
An I/O module failure causes all of the processor modules to indicate an I/O fault. An I/O transceiver module, I/O power supply module, or I/O Safetybus cable fault causes only the associated processor module to indicate an I/O fault.
Run Indicator
This green LED is off if the Regent has cold-started (system power­up without 2oo3 validated programs). After the RAMcode is loaded the Run LED flashes slowly (about ½ Hertz). With at least one program loaded and running this indicator will flash faster (about 2 Hertz).
The RUN indicator will be on steadily when an application program scan exceeds the maximum allowable scan time (approximately 200 milliseconds for the 128 kbyte modules, and 400 milliseconds for the 512 kbyte modules).
Battery Indicator
The green BATT OK indicator shows whether the module’s battery has sufficient power to maintain the programs in the processor. If the battery has adequate power, this LED will be on. If the battery needs to be replaced this LED will be off .
Memory Lock Indicator
This green LED indicates whether the module’s memory lock keyswitch is in the on or off position. The MEMLK indicator will be green when the keyswitch is in the on position.
6 (Issue 1) Industrial Control Services
Processor Mod ules (T7110, 11, 12, 20, 21, and 22 )
The system’s memory lock status is voted: If at least two processor modules are locked, the system is memory locked, if at least two processor modules are unlocked, the system memory is unlocked.
Power Indicator
The green POWER indicator is on when the module is receiving adequate power and its internal power supply is healthy.
Reset Button
A reset button is used to initiate the voted reset function. A voted reset clears system fault indicators after a fault has been detected and a module has been removed and replaced.
Pressing the reset buttons on two operating modules performs a voted reset. During a voted reset, the processors continue to execute the application programs and fault reporting is temporarily suspended. If a new processor module has been inserted it is synchronized and automatically educated by standard diagnostic tests performed by the system. At the end of the voted reset all of the internal fault status bits are reset and normal fault reporting is enabled.
Note:
The time it takes the system to complete a voted reset may range from a couple seconds to a few minutes. Larger processor memory sizes and application program scan times will result in longer voted reset times. However, during the voted reset, the system always continues to read and write I/O, solve application programs and perform communications functions normally.
Memory Lock Keyswitch
The memory lock keyswitch is used to prevent changes or modifications to the system’s application programs. When the memory lock keyswitch is in the off position, programs can be modified.
The system’s memory lock status is voted: If at least two processor modules are locked the system is memory locked, if at least two processor modules are unlocked, the system memory is unlocked.
In WINTERPRET developed systems, changing the memory lock status from off (unlocked) to on (locked) automatically disables all input and output forcing. Forcing can be restored only by unlocking the system memory and enabling the force tables again using WINTERPRET.
PD-7000 Sep-04 (Issue 1) 7
Processor Mo dules (T7110, 11, 12, 20, 21, and 2 2)
Application
Processor module type should be selected based on the main input power voltage (110 VAC, 220 VAC, or 24 VDC) and on memory requirements (128 kbytes or 512 kbytes). Each memory size supports all programming functions and up to 16 chassis of I/O. Typically, systems with more that 300 I/O points will require 512 kbytes of memory due the larger program size, increased data handling, etc.
Note:
In WINTERPRET developed systems, approximately 64K bytes of memory are used to store the RAMcode portion of the operating system (27K) and internal workspace memory (37K) required for miscellaneous system features.
Maintenance
Each of the Regent's processor modules has a replaceable lithium battery. These batteries provide sufficient backup power to prevent loss of memory during a power failure.
The batteries have a shelf life of approximately 10 years. When providing power to the module's memory during a power failure, the battery can provide backup power to a processor module's memory for approximately six months.
Battery Replacement
To replace the battery in a processor module, lift the cover at the bottom of the front panel,by easing the two retaining clips with a screwdriver. Carefully remove the battery clips from the battery. Fit a new battery, taking care to route the wires back inside the module. Close the cover.
Replacing the battery on a live module will not cause a shutdown.
8 (Issue 1) Industrial Control Services
Processor Mod ules (T7110, 11, 12, 20, 21, and 22 )
EPROM Replacement
EPROM replacement is necessary only when upgrading to a new version of the TRIOS operating system.
Important!
Important!
Because processor modules with different EPROM sets cannot operate together in the same system, replacing EPROMs in an installed system will require shutting down the entire Regent system.
To prevent damage to module components when replacing EPROMs always follow proper electrostatic discharge prevention procedures during disassembly and handling. This includes the use of ESD mats and wrist straps.
Module Removal
Loosen the retaining screw at the top of the module. Open the two module release levers by rotating them outward (toward you). Carefully pull the module out of the controller chassis.
Replacing EPROMs
The three EPROMs in each module are labeled U42 and U43 (main processor) and U19 (I/O processor). Figure 4 shows the locations of the EPROMs on each printed circuit board.
PD-7000 Sep-04 (Issue 1) 9
Processor Mo dules (T7110, 11, 12, 20, 21, and 2 2)
Figure 4. Processor Module EPROM locations.
Remove EPROM U42 from the main processor board by rotating the chip socket’s retaining clips outward. This will eject the chip from its socket. Remove the old EPROM and place it on antistatic foam off to one side.
10 (Issue 1) Industrial Control Services
Processor Mod ules (T7110, 11, 12, 20, 21, and 22 )
Remove the new U42 EPROM from its packaging and inspect its pins to make sure they are not bent.
Find the pin one index point (or notch) on the new EPROM. Position the new EPROM in the chip socket so that the pin one index point is facing the U42 label on the printed circuit board.
Carefully insert the new EPROM into the chip socket. It is often easiest to align and partially insert the pins on one side of the chip first, then align the other pins on the other side, and press the EPROM carefully into place.
Before pressing the chip into place, check that all pins are properly aligned in their respective holes. If the pins are not properly aligned, carefully remove the chip and repeat the previous step.
Gently press the EPROM into the chip socket. As the EPROM is pressed home the chip socket’s retaining clips will rotate inward to secure the EPROM.
After fully inserting the EPROM, make a final check to ensure that the pins are not bent, the pins are fully engaged and the EPROM orientation is correct. If any pins are bent or the EPROM is not oriented correctly, remove the EPROM and reinstall it.
Important!
If you install and apply power to a module with an EPROM installed backwards the EPROM may be damaged. When the EPROM is inserted backwards, power will be applied to incorrect pins of the EPROM. If this happens, do not remove and re-insert the same EPROM. Replace the incorrectly positioned EPROM with a new EPROM.
Repeat the above steps for the U43 EPROM. After installing the two new EPROMs in the main processor board,
rotate (or flip) the main processor board to one side to expose the I/O processor board.
Locate the U19 EPROM on the I/O processor board and use the steps described above to remove the old EPROM and install the new EPROM.
PD-7000 Sep-04 (Issue 1) 11
Processor Mo dules (T7110, 11, 12, 20, 21, and 2 2)
Reinstalling Modules
Reinstall the modules one at a time. To help make alignment easier, install the first processor module in the left-most position, the second module in the center position, and the third module in the right-most position.
Open the two module release levers by pulling them toward you. Carefully slide the module into the chassis. Be careful to keep the
module aligned while sliding it straight into the chassis. The module should mount into the chassis with a minimum of
resistance. If the module does not mount easily, do not force it. Remove it and check it for bent or damaged pins. If the pins look okay, try reinstalling the module.
When the module is almost fully into the chassis, the release levers will contact the chassis and begin to rotate closed. Press the levers closed to seat the module in the chassis.
If the module does not seem to have seated correctly, open the release levers and gently pull it back off the seat and out of the chassis. Check for bent or damaged pins. If any pins are bent or damaged do not install the module. Do not try to straighten bent pins. Instead return the module to ICS for repair or replacement. If the pins look okay, try reinstalling the module. You may need to remove the board assembly and realign the CPU boards in the assembly. See the tip, above.
After the module is properly seated, tighten the retaining screw at the top of the module.
12 (Issue 1) Industrial Control Services
Processor Mod ules (T7110, 11, 12, 20, 21, and 22 )
Safety Considerations
Processor module catalog numbers T7110, T7112, T7120 and
T7122 are TÜV certified for Risk Class 5 safety critical applications. Catalog numbers T7111 and T7121 (220 VAC powered modules) have not been certified as they do not meet the DIN VDE 0110 requirements for creepage and clearances.
Specifications
Voltage Range
T7110/T7120: T7111/T7121: T7112/T7122:
Frequency Range
T7110/T7120: T7111/T7121: T7112/T7122:
Maximum Load Fusing
Use with Chassis
T7110/T7120: T7111/T7121: T7112/T7122:
Power Hold-Up Time Heat Dissipation Fault Contact Rating
(Class II Connection Only) Load Current (max.): Load (min.): Voltage (max.): Switching Capacity (max.):
85 to 132 VAC 170 to 263 VAC 20 to 30 VDC
47 to 63 Hz 47 to 63 Hz —
100 VA 2 A, 250 V, slo blo (3AG),
(located on controller chassis)
T7100 T7101 T7102
10 msec, minimum 46 Watts, 156 BTUs/hour
1 amp 10 mV, 0.1 mA 30 VAC, 42.5 VDC
30 VA, 42.5 VAC (resistive)
Memory Size
128K: 512K:
Memory Type
PD-7000 Sep-04 (Issue 1) 13
T7110, T7111, T7112 T7120, T7121, T7122
Battery-backed CMOS RAM
Processor Mo dules (T7110, 11, 12, 20, 21, and 2 2)
Battery Type Battery Life
Under Load: Shelf Life:
I/O Interface
Cable Length: I/O Chassis:
Operating Temperature
Storage Temperature
Operating Humidity
Vibration
10 to 55 Hz:
Shock
Operating:
Li/SO2
6 months 10 years
Triple redundant I/O Safetybus 150 cable feet (45 m), maximum 16 chassis, maximum
0° to 60° C (32° to 140° F)
-40° to 85° C (-40° to 185° F)
0 to 95% relative humidity, non-condensing
±0.15mm
15 g, ½ sine wave, 11 msec
Electromagnetic Interference
IEC 801 Part 2 - Electrostatic
Discharges
IEC 801 Part 3 - Radiated
Electromagnetic Fields
IEC 801 Part 4 - Transients
and Bursts
IEC 801 Part 5 - Surge
Immunity
ANSI/IEEE C37.90 - Surge
Withstand Capability
Safety
Dimensions
Height: Width: Depth:
Level 3: Contact discharge of 6 kV Level 3: 10 V/M, 27 MHz ­500 MHz
Level 4: 2 kV, 2.5 kHz for t = 60 sec
Level 3: 2 kV
2.5 kV damped 1 MHz sine wave
4 kV bi-directional impulse, 10 nsec rise time, fast transient
Designed to meet UL 508 and CSA 22.2, No. 142-M1981
12.6" (320 mm)
1.27" (32 mm)
10.125" (257 mm)
14 (Issue 1) Industrial Control Services
Processor Mod ules (T7110, 11, 12, 20, 21, and 22 )
Weight
7.5 lbs (3.4 kg)
PD-7000 Sep-04 (Issue 1) 15
Loading...