Rockwell automation Trusted tmr expander interface User manual

PD-T8311 Trusted

Rockwell Automation Publication PD-T8311 Issue 15

Trusted TMR Expander Interface

Product Overview

The Trusted® TMR Expander Interface Module resides in the Trusted 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

Unshielded Twisted Pair (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.

•TϋV Certified IEC 61508 SIL 3.

Trusted PD-T8311

Rockwell Automation Publication PD-T8311 Issue 15

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Trusted TMR Expander Interface PREFACE

Rockwell Automation Publication PD-T8311 Issue 15 i

PREFACE

In no event will Rockwell Automation be responsible or liable for indirect or consequential damages

resulting from the use or application of this equipment. The examples given in this manual are

included solely for illustrative purposes. Because of the many variables and requirements related to

any particular installation, Rockwell Automation does not assume responsibility or reliability for

actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation, with respect to use of information, circuits,

equipment, or software described in this manual.

All trademarks are acknowledged.

DISCLAIMER

It is not intended that the information in this publication covers every possible detail about the

construction, operation, or maintenance of a control system installation. You should also refer to

your own local (or supplied) system safety manual, installation and operator/maintenance manuals.

REVISION AND UPDATING POLICY

This document is based on information available at the time of its publication. The document

contents are subject to change from time to time. The latest versions of the manuals are available at

the Rockwell Automation Literature Library under "Product Information" information "Critical

Process Control & Safety Systems".

TRUSTED RELEASE

This technical manual applies to Trusted Release: 3.6.1.

LATEST PRODUCT INFORMATION

For the latest information about this product review the Product Notifications and Technical Notes

issued by technical support. Product Notifications and product support are available at the Rockwell

Automation Support Centre at

http://rockwellautomation.custhelp.com

At the Search Knowledgebase tab select the option "By Product" then scroll down and select the

Trusted product.

Some of the Answer ID’s in the Knowledge Base require a TechConnect Support Contract. For more

information about TechConnect Support Contract Access Level and Features please click on the

following link:

https://rockwellautomation.custhelp.com/app/answers/detail/a_id/50871

This will get you to the login page where you must enter your login details.

PREFACE Trusted TMR Expander Interface

ii Issue 15 Rockwell Automation Publication PD-T8311

IMPORTANT A login is required to access the link. If you do not have an account then you can create one

using the "Sign Up" link at the top right of the web page.

DOCUMENTATION FEEDBACK

Your comments help us to write better user documentation. If you discover an error, or have a

suggestion on how to make this publication better, send your comment to our technical support

group at http://rockwellautomation.custhelp.com

Trusted TMR Expander Interface PREFACE

Rockwell Automation Publication PD-T8311 Issue 15 iii

SCOPE

This manual specifies the maintenance requirements and describes the procedures to assist

troubleshooting and maintenance of a Trusted system.

WHO SHOULD USE THIS MANUAL

This manual is for plant maintenance personnel who are experienced in the operation and

maintenance of electronic equipment and are trained to work with safety systems.

SYMBOLS

In this manual we will use these notices to tell you about safety considerations.

SHOCK HAZARD: Identifies an electrical shock hazard. If a warning label is fitted, it

can be on or inside the equipment.

WARNING: Identifies information about practices or circumstances that can cause

an explosion in a hazardous environment, which can cause injury or death,

property damage or economic loss.

ATTENTION: Identifies information about practices or circumstances that can cause

injury or death.

CAUTION: Identifies information about practices or circumstances that can cause

property damage or economic loss.

BURN HAZARD: Identifies where a surface can reach dangerous temperatures. If a

warning label is fitted, it can be on or inside the equipment.

This symbol identifies items which must be thought about and put in place when

designing and assembling a Trusted controller for use in a Safety Instrumented

Function (SIF). It appears extensively in the Trusted Safety Manual.

IMPORTANT Identifies information that is critical for successful application and understanding of

the product.

NOTE Provides key information about the product or service.

TIP Tips give helpful information about using or setting up the equipment.

PREFACE Trusted TMR Expander Interface

iv Issue 15 Rockwell Automation Publication PD-T8311

WARNINGS AND CAUTIONS

WARNING: EXPLOSION RISK

Do not connect or disconnect equipment while the circuit is live or unless the area is

known to be free of ignitable concentrations or equivalent

AVERTISSEMENT - RISQUE D’EXPLOSION

Ne pas connecter ou déconnecter l’équipement alors qu’il est sous tension, sauf si

l’environnement est exempt de concentrations inflammables ou équivalente

MAINTENANCE

Maintenance must be carried out only by qualified personnel. Failure to follow these

instructions may result in personal injury.

CAUTION: RADIO FREQUENCY INTERFERENCE

Most electronic equipment is influenced by Radio Frequency Interference. 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.

CAUTION:

The module PCBs contains static sensitive components. Static handling precautions

must be observed. DO NOT touch exposed connector pins or attempt to dismantle a

module.

Trusted TMR Expander Interface PREFACE

Rockwell Automation Publication PD-T8311 Issue 15 v

ISSUE RECORD

Issue Date Comments

9 Oct 05 Format

10 Nov 06 Specification

11 Dec 06 Cable distance

12 May 07 System INI

13 Oct 15 Rebranded and reformatted

14 Apr 16 Standardisation of Relative Humidity Range and Operating Temperature

Statements in the Specification Section

15 Apr 18 New look front panel. Reformatted and updated Specifications table.

PREFACE Trusted TMR Expander Interface

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Trusted TMR Expander Interface Table of Contents

Rockwell Automation Publication PD-T8311 Issue 15 1

Table of Contents

1. Description .............................................................................................................3

1.1. Overview .....................................................................................................................................4

1.2. Power Distribution ...................................................................................................................... 4

2. Application .............................................................................................................5

2.1. Module Installation ..................................................................................................................... 5

2.2. Module Insertion and Removal................................................................................................... 5

2.2.1. Module Replacement .......................................................................................................... 6

2.3. Expander Bus Connection ........................................................................................................... 7

2.3.1. Cable Assembly Replacement .............................................................................................7

2.4. Trusted Module Polarisation/Keying ..........................................................................................8

3. Operation ...............................................................................................................9

3.1. Message Forwarding...................................................................................................................9

3.2. Control Signal Forwarding........................................................................................................... 9

3.3. I/O Complex Equipment Definition T8311................................................................................10

3.3.1. Voltage Level Format.........................................................................................................11

3.4. Module Information..................................................................................................................12

3.5. System Initialisation File............................................................................................................12

3.6. Expander Chassis IMB Connector (SK1) ....................................................................................13

3.7. Expander Chassis Bus Connector (PL4) .....................................................................................14

4. Operation .............................................................................................................16

4.1. Operating Modes ...................................................................................................................... 16

4.1.1. Standby..............................................................................................................................16

4.1.2. Active................................................................................................................................. 16

4.1.3. Expander Interface Module Active/Standby Control ........................................................ 16

4.2. Communication Busses .............................................................................................................17

4.2.1. Expander Bus .....................................................................................................................17

4.2.2. Inter-Module Bus...............................................................................................................17

4.3. Front Panel ................................................................................................................................ 18

4.3.1. Healthy Indicator............................................................................................................... 19

4.3.2. Active Indicator .................................................................................................................19

4.3.3. Standby Indicator ..............................................................................................................19

5. Fault Finding and Maintenance..............................................................................20

5.1. PCBs and Connectors ................................................................................................................20

5.2. Troubleshooting ........................................................................................................................20

Table of Contents Trusted TMR Expander Interface

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6. Specifications........................................................................................................22

Trusted TMR Expander Interface 1. Description

Rockwell Automation Publication PD-T8311 Issue 15 3

1. Description

Figure 1 Functional Block Diagram

1. Description Trusted TMR Expander Interface

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1.1. Overview

The TMR Expander Interface is a fault tolerant design based on TMR architecture arranged

in a lock-step configuration. Figure 1shows, in simplified terms, the basic structure of the

TMR Expander Interface.

The Module has three main fault containment regions (FCR A, B and C). Each of the main

FCRs 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

cannot propagate between them.

1.2. Power Distribution

The TMR Expander Interface Module derives its internal voltages from dual redundant

+24 Vdc power supplied via the module connector from the Trusted Controller Chassis

Backplane. Each FCR derives the required supplies independently.

Trusted TMR Expander Interface 2. Application

Rockwell Automation Publication PD-T8311 Issue 15 5

2. Application

2.1. Module Installation

CAUTION:

The Expander Interface Module must reside in one of the I/O slots within the

Controller Chassis. Modules must be configured as a pair in the System Configuration

Tool, in adjacent slots, and with the left hand slot an odd numbered slot. An even

numbered slot can only be configured as an Expander Interface Module if the

preceding odd numbered slot is already configured as an Expander Interface Module.

To provide redundancy the Modules can be installed in pairs, but can also be installed

singly, in either configured slot. If a single Module is installed the adjacent slot in the

configured pair must be empty. Expander Interface Modules must not be fitted in the

triple-width Main Chassis Processor slots as this may cause damage to the Modules.

The two Interface slots must be interconnected using the Expander Interface Adapter 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 Expander Interface Adapter Unit

T8312.

The connection to remote Expander Chassis is via the Trusted Fibre Optic Tx/Rx Unit using

the Expander Interface Adapter to Fibre Tx/Rx Unit (Remote Expanders) Cable TC-302.

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.

2. Application Trusted TMR Expander Interface

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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-T8100) 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 by pressing on the top and bottom of the module fascia.

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

2.2.1. Module Replacement

The replacement module must be inserted in 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 Light Emitting Diode (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.

Trusted TMR Expander Interface 2. Application

Rockwell Automation Publication PD-T8311 Issue 15 7

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.

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 and 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.

2. Application Trusted TMR Expander Interface

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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 Smart Slot capability.

2.4. Trusted Module Polarisation/Keying

All Trusted 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.

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.

Cable Exit

Release button

Polarising/Keying

Pins.

(Remove using

side cutters where

identified below)

Trusted

Cable hood

Smart Swap

Connector

if Fitted

Trusted TMR Expander Interface 3. Operation

Rockwell Automation Publication PD-T8311 Issue 15 9

3. Operation

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.

3. Operation Trusted TMR Expander Interface

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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.

3.3. I/O Complex Equipment Definition T8311

The Expander Interface requires no configuration to the Module itself.

Each Module fitted in a Trusted System requires an entry in the I/O Connection table,

specifying its chassis and slot number. The I/O Complex Equipment Definition allows control

of the Module’s functions, and provides information on its status. For information on editing

the I/O Connection table, refer to PD-T8082. The definition for this Module is described

below.

OEM PARAMETERS

OEM parameter Valid numbers Description

TICS_CHASSIS

TICS_SLOT

1 - 8 (Chassis 1)

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 Trusted range.

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.

CONFIGURATION

Physical Module:

RACK 1: [XIM_0] 16 ANALOGUE

inputs Channel 1: Not used

Channel 2: 24 Vdc Feed 1 (always 0)

Channel 3: 24 Vdc 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

Trusted TMR Expander Interface 3. Operation

Rockwell Automation Publication PD-T8311 Issue 15 11

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

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

APPENDIX:

Note: Bit 0 AM slice A: