Rockwell Automation T80017 User Manual
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Application Note
Regent to Trusted Migration
This document describes the steps needed to replace a Regent processor chassis with a Trusted
processor chassis. This replaces the Regent processor and communications modules and providing a
future path to expansion of the Trusted system side. It assumes a knowledge of Trusted application
design.
Issue Record
Issue
Number
1 June 08 Nick Owens Andy Holgate Pete Stock Initial Issue
2 June 08 Nick Owens Andy Holgate Pete Stock Corrections
Issue 2 June 08 AN-T80017 1
Date Revised by Technical
Check
Authorised by Modification
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AN-T80017 Regent to Trusted Migration
1. Hardware
The migration principles are identical for Regent (panel mount) and Regent +Plus (rack mount)
because the internal circuitry is the same, as is the software. In this document, the term ‘Regent’ is
used for both variants.
The Regent processor chassis with processor and communications modules is replaced by a Trusted
processor chassis with communications modules. The T8160 TMR Interface module (otherwise known
as the Regent interface module, or RIM) bridges the triplicated Regent Safetybus into the Trusted
Inter-Module Bus (IMB). The T8160 has a choice of two companion slot cables TC-320-01 and TC321-01. TC-320-01 ends in three connectors that fit the Regent chassis sockets. TC-321-01 ends in
three connectors that fit the existing Safetybus cables. This allows a choice of running new cables to
the first expander chassis or using the extra length of the existing cables.
The Trusted processor chassis is 6U high but also needs a 2U T8270 fan tray mounted above it. It
should not be located directly above bulk power supplies or other significant sources of heat, as air is
drawn from underneath the chassis.
A Trusted system requires one T8110B processor module (which contains three identical processors).
The chassis also has a companion processor slot to allow faulty processors to be replaced. For a
Trusted-Regent hybrid, one T8160 TMR interface module is required, and this is also fitted in a
companion slot, taking two of the eight single width slots. To replace the three Regent communications
modules, two Trusted T8151B communication interface modules are adequate. These each contain
four high speed serial ports and also two Ethernet ports. They support Modbus (master and slave) and
native Trusted peer networks, but will not support Regent Peer to Peer networks or the Regent
Guarded Peer link. Modbus Master requires a T8122 or T8123 Processor interface adapter.
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1.1. Parts List
T8100 1off Processor Chassis
T8270 1off Fan Tray
T8110B 1off Processor module (recommended spares holding of 1)
T8160 1off TMR Interface (recommended spares holding of 1)
T 8 1 5 1 B 2 o f f C o m m u n i c a t i o n s I n t e r f a c e
Optional T812x 1off Processor Interface Adaptor (T8120,1,2,3 as appropriate for IRIG and Modbus
Master licenses; see PD-T812X)
T8153 2off Communications Interface Adapter for serial and Ethernet connection
TC-320-01 1off Interface cable to plug into first Regent expander chassis OR:
TC-321-01 1off Interface cable to chain to existing cables
Recommended power supply for Trusted:
T8240 1off Power shelf for three Power Packs
T8231 2off 750W 24Vdc Power Pack
MCBs On AC (6A) and DC sides (20A)
Recommended replacement for Regent system power supplies is required (see PD-T8200 for options):
T8200 1off Power supply chassis (or T8201) (room for 6 modules)
T8220 3off Power supply module 15V (3off per 4 Regent chassis)
T8294 1off Supply adaptor board (1off per 4 Regent chassis)
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2. Electrical
The chassis and its modules are powered from a dual 24Vdc (nominal) supply, each supply providing
at least 250W through 20A MCBs.
If the Regent system power supplies are to be replaced, the T8200 range is recommended. These
have 250W units in sets of three to match the Regent power needs. Regent chassis require extra
diagnostic signals to start the system once the supply has settled and to warn it of impending loss of
power, and the T8200 range provides these signals. An interface board T8294 is available to provide
connections to four Regent chassis, including the diagnostic signals.
In the example shown in Figure 2, the Trusted chassis is powered by T8240 power shelves containing
T8231 supplies, which also replace existing bulk supplies powering the general 24V requirements in
the system and field.
2.1. Communications
The T8160 connects to the nearest Regent chassis using a TC-320-01 cable as shown in Figure 1. It
can also be connected to the end of the original Safetybus cables to the processor chassis using a TC321-01 cable. This has connectors to match the existing cables. The existing chain of safetybus cables
is used to communicate with the remaining chassis.
Figure 1 Safetybus Wiring Example
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Figure 2 Example Power Supply Overview
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3. Installation
Both the Regent and Trusted are 3-2-0 degradation systems. When fully healthy, all three slices are
working (3). On one fault, the remaining two slices can continue operating as long as they agree (2).
On a fault in one of the two remaining slices, the system shuts down (0).
This provides higher integrity than 3-2-1-0 since at least two system slices must be operational for the
system to be operational, allowing instant and robust diagnostics through voted comparison. However,
since each system requires two of the three slices to operate, an online changeover is not possible and
the changeover must be made with the system in shutdown.
The new Trusted chassis may be fitted in place of an existing rack-mounted Regent+Plus processor
chassis if time is available for physical installation, or it may be fitted in spare space nearby whilst the
existing system is operating. The standard TC-321-01 cable is 4 metres long, but the existing Regent
Safetybus cables to the Regent processor chassis may also have slack inside trunking, or it may be
possible to route them differently to gain length.
Power the Regent I/O chassis first and allow them to start. Then power the Trusted processor chassis
with the Safetybus connected. If the Trusted application and system.INI are correct, the application will
start and the application can be commissioned.
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4. Application
There is no automated tool for application conversion from Regent to Trusted, and the applications are
very different. However, it is possible to copy the functionality with the resulting programs looking
similar to the original programs. Use the following steps to ease the process.
In this section, ‘Winterpret’ is used as the name of the Regent application tool. Its predecessor was
PDS, which is still in use on the older Regent systems. The presentation is different but the core
functionality is similar.
A copy of Winterpret (or PDS) will be necessary to read the Regent configuration. This does not need
to be the same issue as used before, but must be loaded with the same extra packages.
4.1. System Configuration
The System.INI file for a Trusted-Regent hybrid is very simple. Insert a T8160 TMR Interface into the
chassis, and insert another T8160 in its companion slot to the right. This allows the system to blackstart with the T8160 in either slot. By convention, slots 1 and 2 are used.
Insert T8151 communications interfaces into the chassis. By convention, slots 7 and 8 are used.
This leaves four slots spare for Trusted I/O modules and interfaces to future Trusted expansion I/O
chassis, which will have a much smaller panel space than the corresponding Regent I/O equivalent.
Configure the communications interface parameters. Replicate the serial port settings from Regent
(baud rate, bits and parity). For Modbus slaves, enable slaves on the ports as appropriate. For Modbus
Master, create a Modbus Master and define its slaves and messages as in the Regent application. For
further information, refer to product description PD-T8151B.
4.2. Toolset I/O Connection Table
The first step is to build the I/O connection table. Add definitions for modules in the Trusted chassis
first.
ttmrp Trusted processor Only one definition required
ttmri_ii TMR Interface One ttmri_ii definition covers both module positions
There is no need to add definitions for the communications interfaces. If the TMR Interface was not
placed in the left-hand slot of the eight narrow slots in the Trusted processor chassis, correct the Slot
number on each of the two boards of the ttmri_ii definition.
Now add the definitions for each Regent I/O module. It is recommended to place these definitions in
the order that they appear in the chassis and slots, but the only real constraint is that 7491 multiplexer
modules must be defined before their multiplexer I/O. Product description PD-T8160 describes each
definition. These definitions each provide connection boards for variables used in the application.
Each definition for a Regent module must be set up with the following parameters:
TICS_CHASSIS and _SLOT The chassis number (1) and the slot number (usually 1) of the
T8160 TMR Interface. (It helps here if the T8160 is in the default position, chassis 1 slot 1).
REGENT_CHASSIS and _SLOT The position of the Regent module; the first I/O chassis is
chassis 1.
There will be further parameters for the second and third module position in definitions applying to
multiple module sets.
Copy these parameters to the entry points on each board.
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