Rockwell Automation T8311 User Manual

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PD-T8311

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TMR Expander Interface

Introduction

The TrustedTM TMR Expander Interface module resides in the TrustedTM Controller Chassis and provides the ‘master’ interface between the Inter-Module Bus (IMB) in the Controller Chassis and the Expander Bus. The Expander Bus allows multiple chassis systems to be implemented using UTP cable connections whilst maintaining the fault tolerant, high bandwidth IMB capabilities.

The module provides fault containment for the Expander Bus, the module itself and the IMB in the Controller Chassis, ensuring that the effects of these potential faults are localised and system availability maximised. The module is fault tolerant with HIFT TMR architecture. Comprehensive diagnostics, monitoring and testing provide rapid fault identification. Hot standby and module spare slot configurations are supported, allowing automatic and manual repair strategies.

Features

• Triple Modular Redundant (TMR), fault tolerant (3-2-0) operation

• Hardware Implemented Fault Tolerant (HIFT) architecture

• Dedicated hardware and software test regimes which provide very

fast fault recognition and response times

• Automatic fault handling without nuisance alarming

• Hot replacement

• Front panel indicators that show module health and status.

2V Certified IEC 61508 SIL 3

• T

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Issue Record

Issue

Number Date Revised by Technical CheckAuthorised by Modification

9 Oct 05 J W Clark Format

10 Nov 06 N Owens I Vince P Stock Specification

11 Dec 06 N Owens I Vince P Stock Cable distance

12 Mar 07 N Owens I Vince P Stock System INI

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Table of Contents

1. Description......................................................................................................................................8

1.1. Overview......................................................................................................................................9

1.2. Power Distribution........................................................................................................................9

2. Installation ....................................................................................................................................10

2.1. Module Installation .....................................................................................................................10

2.2. Module Insertion and Removal ..................................................................................................10

2.2.1. Module Replacement ...................................................................................................................11

2.3. Expander Bus Connection .........................................................................................................12

2.3.1. Cable Assembly Replacement .....................................................................................................12

2.4. TrustedTM Module Polarisation/Keying.......................................................................................13

3. Application ....................................................................................................................................14

3.1. Message Forwarding .................................................................................................................14

3.2. Control Signal Forwarding .........................................................................................................14

3.3. I/O Complex Equipment Definition T8311 .................................................................................15

3.3.1. Voltage Level Format ...................................................................................................................16

3.4. Module Information ....................................................................................................................17

3.5. System Initialisation File ............................................................................................................17

3.6. Expander Chassis IMB Connector (SK1) ..................................................................................18

3.7. Expander chassis Bus Connector (PL4)....................................................................................19

4. Operation......................................................................................................................................20

4.1. Operating Modes .......................................................................................................................20

4.1.1. Standby ........................................................................................................................................20

4.1.2. Active ............................................................................................................................................20

4.1.3. Expander Interface Module Active/standby Control .....................................................................20

4.2. Communication Busses .............................................................................................................21

4.2.1. Expander bus ...............................................................................................................................21

4.2.2. Inter-Module Bus ..........................................................................................................................21

4.3. Front Panel ................................................................................................................................22

4.3.1. Healthy Indicator` .........................................................................................................................23

4.3.2. Active Indicator.............................................................................................................................23

4.3.3. Standby Indicator..........................................................................................................................23

5. Fault Finding and Maintenance ....................................................................................................24

5.1. PCBS and Connectors...............................................................................................................24

5.2. Troubleshooting .........................................................................................................................24

6. Specifications ...............................................................................................................................26

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Figures

Figure 1 Functional Block Diagram ..........................................................................................................8

Figure 2 Module Polarisation ..................................................................................................................13

Figure 3 Module Front Panel ..................................................................................................................22

Tables

Table 1 Chassis Connector (SK1) Pinout ...............................................................................................18

Table 2 Chassis Bus Connector (PL4) ...................................................................................................19

Table 3 Troubleshooting Guide ..............................................................................................................25

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Notice

The content of this document is confidential to ICS Triplex Technology Ltd. companies and their partners. It may not be given away, lent, resold, hired out or made available to a third party for any purpose without the written consent of ICS Triplex Technology Ltd.

his document contains proprietary information that is protected by copyright. All rights are reserved.

Microsoft, Windows, Windows 95, Windows NT, Windows 2000, and Windows XP are registered trademarks of Microsoft Corporation.

The information contained in this document is subject to change without notice. The reader should, in all cases, consult ICS Triplex Technology Ltd. to determine whether any such changes have been made. From time to time, amendments to this document will be made as necessary and will be distributed by ICS Triplex Technology Ltd.

Information in this documentation set may be subject to change without notice and does not represent a commitment on the part of ICS Triplex Technology Ltd.

The contents of this document, which may also include the loan of software tools, are subject to the confidentiality and other clause(s) within the Integrator Agreement and Software License Agreement.

No part of this documentation may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying and recording, for any purpose, without the express written permission of ICS Triplex Technology Ltd.

Disclaimer

The illustrations, figures, charts, and layout examples in this manual are intended solely to illustrate the text of this manual.

The user of, and those responsible for applying this equipment, must satisfy themselves as to the acceptability of each application and use of this equipment.

This document is based on information available at the time of its publication. While efforts have been made to be accurate, the information contained herein does not purport to cover all details or variations in hardware or software, nor to provide for every possible contingency in connection with installation, operation, or maintenance. Features may be described herein which are present in all hardware or software systems. ICS Triplex Technology Ltd. assumes no obligation of notice to holders of this document with respect to changes subsequently made.

ICS Triplex Technology Ltd. makes no representation or warranty, expressed, implied, or statutory with respect to, and assumes no responsibility for the accuracy, completeness, sufficiency, or usefulness of the information contained herein. No warranties of merchantability or fitness for purpose shall apply.

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Revision and Updating Policy

All new and revised information pertinent to this document shall be issued by ICS Triplex Technology Ltd. and shall be incorporated into this document in accordance with the enclosed instructions. The change is to be recorded on the Amendment Record of this document.

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

Most electronic equipment is influenced by Radio Frequency Interference (RFI). Caution should be exercised with regard to the use of portable communications equipment around such equipment. Signs should be posted in the vicinity of the equipment cautioning against the use of portable communications equipment.

MAINTENANCE

Maintenance must be performed only by qualified personnel, otherwise personal injury or 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 PD8082B – 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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1. Description

Figure 1 Functional Block Diagram

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1.1. Overview

The TMR Expander Interface is a fault tolerant design based on TMR architecture arranged in a lockstep configuration. Figure 1 shows, in simplified terms, the basic structure of the TMR Expander Interface.

he module has three main fault containment regions (FCR A, B and C). Each of the main FCRs

T contains interfaces to the Expander Bus and Inter-Module Bus (IMB), an active/standby interface to the other TMR Expander Interface in the chassis, control logic, communications transceivers and power supplies.

Communication between the module and the TMR Processor is via the IMB on the backplane of the Controller Chassis. The IMB provides fault tolerance and high bandwidth communications between the Interface Modules and the TMR Processor. All transactions are voted, localising faults to the IMB should they occur.

Communication between the Interface Module and the TMR Expander Processor in the Expander Chassis is via the Expander Bus. The Expander Bus is triplicated, point-to-point architecture. Each channel of the Expander Bus comprises separate command and response media. Voting is provided at the Expander Bus Interface to ensure that cable faults are tolerated, and the remainder of the Expander Processor operates in a fully triplicated mode, even in case of cable faults occurring.

A fourth FCR (FCR D) provides the non-critical monitoring and display functions and is also part of the inter-FCR Byzantine voting structure.

Isolation is provided between FCRs wherever interfaces are required, to ensure that faults can not propagate between them.

1.2. Power Distribution

The TMR Expander Interface Module derives its internal voltages from dual redundant +24V dc power supplied via the module connector from the Trusted derives the required supplies independently.

Controller Chassis backplane. Each FCR

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2. Installation

2.1. Module Installation

The Expander Interface Modules may reside in any of the I/O slots within the Controller Chassis. The modules are installed in pairs with the left-hand module occupying an odd numbered slot. The Expander Interface must NOT be installed in these other module locations, as this may cause damage to the module.

The two Interface slots must be interconnected using the Expander Interface Adaptor Unit T8312.

The Expander Interface Modules are connected to the Expander Processor Modules by the Expander Interface Hot Link Cable TC-301 via the Trusted

The connection to remote Expander Chassis is via the Trusted Expander Interface Adaptor to Fibre Tx/Rx Unit (Remote Expanders) Cable TC-302.

Expander Interface Adaptor Unit T8312.

Fibre Optic Tx/Rx Unit using the

2.2. Module Insertion and Removal

CAUTION:

THE MODULE CONTAINS STATIC SENSITIVE PARTS. STATIC HANDLING PRECAUTIONS MUST BE OBSERVED. SPECIFICALLY ENSURE THAT EXPOSED CONNECTOR PINS ARE NOT TOUCHED. UNDER NO CIRCUMSTANCES SHOULD THE MODULE HOUSING BE REMOVED.

Before installation, visually inspect the module for damage. Ensure that the module housing appears undamaged and inspect the I/O connector at the back of the module for bent pins. If the module appears damaged or any pins are bent, do not install the module. Do not try to straighten bent pins. Return the module for replacement.

Ensure that the module is of the correct type.

Record the module type, revision and serial number of the module before installation.

If the module is to reside in a new chassis, or the system is being configured for the first time, ensure that the chassis address has been set correctly before installing the modules. See Controller Chassis Product Description (PD-8100) for further details.

To install the module:

1. Ensure that the cable assembly is correctly located.

2. Release the ejector tabs on the module using the release key. Ensure that the ejector tabs are fully open.

3. Holding the ejectors, carefully insert the module into the intended slot.

4. Push the module fully home but pressing on the top and bottom of the module fascia.

5. Close the module ejectors, ensuring that they click into their locked position.

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2.2.1. Module Replacement

The replacement module must be inserted in to the vacant processor slot, ensuring that the module is correctly located and the ejector tabs are closed (see 2.2). The newly installed module will perform its power-up sequence.

Ensure that the LED indicators on the newly installed module are as follows:

LED 1 Healthy A Steady Green LED 2 Healthy B Steady Green LED 3 Healthy C Steady Green

If the original module has reported faults, the TMR Processor may automatically initiate the changeover to the newly installed module. Manual changeover may be initiated either using the ejector tabs on the original module or using commands via the diagnostic interface. To initiate the changeover using the ejector tabs use the following sequence:

1. Release both the top and bottom ejector tabs on the original module using the ejector release tool. DO NOT remove the module.

2. Wait until the original module indicates that it is in the standby mode of operation and the newly installed module is in the active mode.

3. Remove the original module.

Note: Under no circumstances remove a module that is indicating ACTIVE mode. Removal of an

active module may result in modules within the chassis adopting their default (shutdown) state, and initiate shutdown states via the application program.

In Hot-standby configurations, with both Expander Interface Modules installed, the faulted module may be either the active or the standby module. In most cases the system will automatically switch to the healthiest module, therefore only the standby module will require replacement. To replace the active module follow the steps described above. To replace the standby module:

1. Release both the top and bottom ejectors tabs on the standby module using the ejector release tool.

2. Ensure that the other module is indicating the active mode of operation.

3. Remove the standby module.

In Hot-standby configurations, the replacement module should then be installed in the position where the previous module was removed. This module will become the standby module.

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2.3. Expander Bus Connection

Further details of the Expander Bus cable assembly are provided in the associated Product Description (PD-TC300).

2.3.1. Cable Assembly Replacement

It is not intended that the cable should need replacement, however this may be achieved by replacement of the complete cable assembly that requires that the system be shutdown. To remove a cable:

1. Ensure that the correct chassis and slot positions are selected.

2. Ensure the associated chassis slots are not occupied by modules.

3. Press in the hood release button and slide the hood downwards.

4. Remove the hood from the chassis slot by sliding down and rearward.

To insert a new or replacement cable:

1. Ensure that the correct chassis and slot positions are selected.

2. Ensure that the associated chassis slots are not occupied by modules.

3. Present the connector to the chassis backplate slot, taking care to align the lugs of the connector with the cut-outs of the slot.

4. Push the connector hood in and upwards into the slot until the latch engages with the backplate lip.

5. Ensure that the connector hood is secure in its position.

Where it is critical to maintain system operation additional chassis may be installed and on-line operation maintained by transferred control to modules within that chassis using the I/O modules SmartSlot capability.

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112Cable Exit

Release button

Module T8311

2.4. TrustedTM Module Polarisation/Keying

All TrustedTM Modules have been Keyed to prevent insertion into the wrong position within a chassis. The polarisation comprises two parts. The module and the associated field cable.

Each module type has been keyed during manufacture. The organisation responsible for the integration of the Trusted

system must key the cable by removing the keying pieces from the cable

so that they correspond with the bungs fitted to the associated module prior to fitting.

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Module Polarisation/Keying.

Polarising/Keying Pins.

(Remove using side cutters where identified

below)

TrustedTM Cable hood

Smart Swap Connector if Fitted

Figure 2 Module Polarisation

For Cables with Companion slot installations both keying strips must be polarised.

For This Module (T8311) remove keying pins 1,2,6.

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3. Application

3.1. Message Forwarding

The primary function of the Expander is to provide a method of extending the IMB beyond a single processor chassis. The active TMR Expander Interface Module receives messages from the processor chassis IMB/backplane and forwards them to the Expander Bus when its slot position is enabled. Similarly, the active TMR Expander Processor Module forwards all messages received from the Expander Bus to the addressed Expander Chassis IMB.

For other command messages the response message received by the active Expander Processor from the addressed module is passed to the Expander Bus and hence to the TMR Expander Interface Module. The active TMR Expander Interface Module then passes the message to the Processor Chassis IMB, subject to the prevailing IMB control signals.

The messages received from the controller chassis IMB at the TMR Expander Interface Module are re-synchronised and majority voted (Byzantine voted) before being passed to the triplicated Expander Bus. Similarly, messages received by the TMR Expander Processor Module from the Expander Chassis IMB are re-synchronised and majority voted before onward transmission.

Messages received from the Expander Bus at both the TMR Expander Interface Module and TMR Expander Processor Module are re-synchronised and majority voted before being passed to the associated IMB.

Errors in messages are corrected, and therefore masked using this method. This, however, makes it important that discrepancies in faults in these signals are detected and the information made available for fault reporting purposes to avoid latent fault issues.

3.2. Control Signal Forwarding

The active TMR Expander Processor Module continually monitors and transmits the state of the following signals:

• Power Failure Warning

• System Watchdog

• Command Response Control

All three signals are fully triplicated. These signals are distributed to all of the attached Expander Busses. The TMR Expander Processor Modules forward the received state of these signals to the Expander Chassis IMB. The direction of these signals is always from TMR Processor to TMR Expander Interface to TMR Expander Processor to interface (I/O) module.

As with the message forwarding, these signals are re-synchronised and majority voted, i.e. Byzantine voted at the TMR Expander Interface and TMR Expander Processor Modules. The signals are synchronous within the Expander Chassis even in the case of a fault within the Processor Chassis.

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3.3. I/O Complex Equipment Definition T8311

The Expander Interface requires no configuration to the module itself.

Each module fitted in a Trusted

hassis and slot number. The I/O Complex Equipment Definition allows control of the module’s

c functions, and provides information on its status. For information on editing the I/O Connection table, refer to PD-8082B. The definition for this module is described below.

OEM PARAMETERS

OEM parameter Valid numbers Description

TICS_CHASSIS

TICS_SLOT

1 - 8 (Chassis 1)

CONFIGURATION

system requires an entry in the I/O Connection table, specifying its

This value is fixed (expander interface modules may only be placed in the processor chassis) and is included for consistency with other modules in the

The processor chassis slot number in which the primary expander interface module is placed. By definition, this must be an odd numbered slot. The secondary module, if configured, resides in an even numbered slot adjacent, and to the right of the primary.

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range.

PHYSICAL MODULE:

RACK 1: [XIM_0] 16 ANALOGUE

RACK 2: (INFO) 11 INTEGER inputs Channel 1:Chassis position of AM

inputs

Channel 1: Not used Channel 2: 24V dc Feed 1 (always 0) Channel 3: 24V dc Feed 2 (always 0) Channel 4: Not used Channel 5: Not used Channel 6: Not used Channel 7: Slice A Rx Error Count Channel 8: Slice B Rx Error Count Channel 9: Slice C Rx Error Count Channels 10 to 16: Not used

Channel 2:Slot position of AM Channel 3:Indication of global health of AM 1 – No slice errors and module is responding 0 – Some error has been found Channel 4:Current state of AM Channel 5:Chassis position of SM 0 – No partner exists Channel 6:Slot position of SM 0 – No partner exists Channel 7:Indication of global health of SM 1 – No slice errors and module is responding 0 – Some error has been found Channel 8:Current state of SM Channel 9:Slice information of modules. See Note Channel 10:Is AM the Primary Module 1 – Yes 0 – Not Channel 11:Not used

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APPENDIX :

Note:

Bit 1 AM slice B:

Bit 0 AM slice A: