Rockwell Automation T80015 User Manual

TrustedTM

AN-T80015

Trusted

Application Note

/ SC300E Migration process

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Issue Number

1 Apr 08 Andy Holgate Nick Owens Pete Stock Initial Issue

Date Revised by Technical

Check

Authorised by Modification

Introduction

The aim of this document is to provide a guide to the process of upgrading a Triguard SC300E system to a Hybrid SC300E / Trusted 8161 Bridge Modules controlled by a Trusted

Starting with the initial understanding of the existing system hardware configuration and functionality, through to the hardware upgrade process, logic programming and system test, this document will provide the integrator with the questions that will need to be answered for a successful upgrade.

It is not intended as a step by step guide, rather information regarding the main issues to be addressed during the system migration process.

system by replacing the SC300E processors (MPPs) with TrustedTM

processor.

Contents

Upgrade Process...................................................................................................................... 3

1.1. Scope of supply ..................................................................................................................... 3

1.2. System layout......................................................................................................................... 3

1.3. Tags, Discretes, Registers..................................................................................................... 4

1.4. Application logic..................................................................................................................... 4

1.5. Mechanical upgrade............................................................................................................... 5

2. Case Study – 2 chassis ESD system ....................................................................................... 6

2.1. Scope of Supply..................................................................................................................... 6

2.2. System Layout ....................................................................................................................... 6

2.3. Tags, Discretes, Registers..................................................................................................... 6

2.4. Application logic..................................................................................................................... 7

2.5. Diagnostics .......................................................................................................................... 10

2.6. Mechanical upgrade............................................................................................................. 11

3. Reference Documentation...................................................................................................... 13

4. Sample logic comparisons ..................................................................................................... 14

5. Migration Process – Flow chart .............................................................................................. 16

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1. Upgrade Process

1.1. Scope of supply

The first step of the Trusted required by the customer.

• Is it a test/demo setup or is it an actual plant upgrade?

• Does the client want to replicate the current user interface of the system as closely

as possible so as not to confuse the operators.

It is important to have all the ‘As Operational’ information available, ie the ‘As Built’, but with any onsite modifications or upgrades taken into account. The application backups supplied must be representative of the running system to ensure a smooth migration. It is essential that the system configuration files and application logic in the backups are identical to that which is running in the system at the time of the upgrade.

Triguard Serial I/O modules (MSR04XI) will be removed as there is no facility to communicate with SC300E Peer links or other SC300E communications equivalents. These must be replaced with Trusted and Modbus links to DCS etc.

SC300E migration process is to understand just what is

equivalents, namely peer links to other TrustedTM systems

1.2. System layout

1.2.1. Hardware layout

• Where is the Trusted

• Is there room in an existing cabinet for the Trusted

chassis, power supplies and fan trays will need a space up to 10U high in a cabinet.

• Does it need a new cabinet of its own? If so, is there room in the control room for more cabinets?

The physical layout will determine such things as length of the interface cable, number of fan trays required, comms cabling etc.

1.2.2. Toolset layout

Use the system folder to define the shape of the system as TrustedTM will see it. Create the SYSTEM.INI file in Trusted

Care must be taken to choose the correct setup or the configuration will not run. For example, the MDO32BNS output modules can be configured as 3-2-0 or 3-2-1 using jumpers on the module, and it is also possible to set the MDO32BNS to ‘hold last value’ or ‘go to zero’ in the event of a trip.

chassis going to be installed?

chassis? The TrustedTM

Toolset with any partner slots and module setup.

Create the I/O wiring table and board definitions in the toolset. Remember that what was Triguard Chassis 1 in the original SC300E system will now become Logical Chassis 2 and so on since the Trusted

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chassis is now Chassis 1.

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1.3. Tags, Discretes, Registers

Create tags to get diagnostic data from modules and wire them to the appropriate board in the Toolset. Create logic programs to derive alarms from diagnostic data, for example processor temperature, processor voltage etc.

sing the information in the system folder create a spreadsheet of all the tag names,

U discretes and registers along with descriptions and any other relevant data. This spreadsheet can be easily manipulated into a format which can be imported into the Toolset.

The standard SC300E will print alarm and diagnostic data directly to a printer whereas Trusted

can not. You need to use SOE (Sequence of Events) to capture changes of Boolean variables, so duplicate any tags needing to be monitored with a different name (prefix with S for example) and wire them to SOE boards in the I/O wiring.

1.4. Application logic

Decide on the language to be used for the main application logic. It may be a good idea to use ladder logic to mirror the current system so as to minimise the change for the users. Trusted ladder logic although not all SC300E functions can be directly replicated.

Some logic uses registers instead of individual discretes, especially where data is gathered from a whole module or function block, eg GDIA or FALT

The application logic should include the safety ladders as described in SS728 Appendix 1

1.4.1. Execution Speed

TrustedTM operates the SC300E I/O scanning asynchronously from the application scan, since the I/O scanning is operated by the 8161 Bridge Modules and reported to the processor as requested. The Trusted milliseconds, which is due to the ‘sleep period’ set in the system INI configuration. The processor is only using about two thirds of the 32ms scan; the rest is free for diagnostics and background functions.

The faster application scan time in Trusted Trusted

ladder logic, using the FBD/LD editor, can be made to look very similar to SC300E

programs must account for the delays expected in the SC300E.

application scan was measured at the minimum 32

and the asynchronous I/O handling means that

1.4.2. Printed messages, reports and events

SC300E is able to print reports and events, controlled by the application. TrustedTM has no printer output. However, it has two event logs. The processor holds an event log with 200 entries, which automatically records all system faults and actions without any intervention from the application. This reports all module faults and swaps as well as program downloads and Reset pushbutton presses. There is also a Sequence of Events log (SOE) which records changes to Boolean (digital) variables, complete with timestamps. These timestamps are to the nearest millisecond but are not absolutely accurate due to the disconnection between the Trusted record SOE timestamps on arrival to the system.

There is also an analogue event logger called Process Historian if required, but usually analogues are trended on the DCS or other graphics station.

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application and the real I/O in a hybrid system. Native TrustedTM I/O modules can

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1.4.3. Firmware calls

The SC300E application has several calls to the system firmware such as USR3, USR4, FALT etc. These are user configured and may have bespoke code designed to execute away from the application ladder. This means that if some of the functions in SC300E systems may need redesigning and they cannot be translated easily into ladder, structured text etc. Some calls usually involve system diagnostic functions, and can be replaced by application logic diagnostics.

1.4.4. Diagnostics

I/O module and system diagnostics flags are listed in PD 8161 for the SC300E products.

With Trusted commands are available to extract information on SC300E module status and chassis configuration. Diagnostic data on module health, discrepancies and LFD errors is also available in the application through the I/O connection boards for each module.

a terminal program may be used to access a command line interface, where

1.5. Mechanical upgrade

Remove the SC300E MPPs and replace with the 3x Trusted

8161 Bridge Modules.

The Bridge module requires minimum configuration, namely the setting of Unit ID jumpers 0 to 3 to define the chassis address to Trusted™.

Clicking on a SC300E chassis in the Trusted

System Configuration tool and selecting

‘Jumper config’ will display the required jumper settings for that chassis.

Connectors J1-3 on the TC-325-02 card, plug into the three 26-way diagnostic headers on the SC300E backplane. The Hotlink cable from the Trusted

Expander Interface adapter

plugs into 12-way J4.

Due to the low current requirements of the 5v supply to the 8161 Bridge modules may be necessary to fit a MXD dummy load module in the chassis, if no I/O modules are installed. This is to provide a minimum load for the chassis 5Vdc power supplies.

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