Rockwell Automation Trusted TMR 24 User manual

Rockwell Automation Publication ICSTT-RM273Q-EN-P - August 2021
Supersedes PD-T8431 Issue 18 June 2018
Product Description
Original Instructions
Trusted TMR 24 Vdc Analog
Input Module 40 Channel
PD-T8431 Issue 19

Trusted TMR 24 Vdc Analog Input Module 40 Channel
2 Rockwell Automation Publication ICSTT-RM273Q-EN-P - August 2021
Important User Information
Read this document and the documents listed in the additional resources section about installation, configuration, and
operation of this equipment before you install, configure, operate, or maintain this product. Users are required to familiarize
themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws, and standards.
Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required to
be carried out by suitably trained personnel in accordance with applicable code of practice.
If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be
impaired.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use
or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for
actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software
described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is
prohibited.
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
WARNING:
Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to
personal injury or death, property damage, or economic loss.
ATTENTION:
Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss.
Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.
IMPORTANT
Identifies information that is critical for successful application and understanding of the product.
Labels may also be on or inside the equipment to provide specific precautions.
SHOCK HAZARD:
Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be present.
BURN HAZARD:
Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach dangerous
temperatures.
ARC FLASH HAZARD:
Labels may be on or inside the equipment, for example, a motor control center, to alert people to potential Arc Flash. Arc Flash will
cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL Regulatory requirements for safe work practices and for
Personal Protective Equipment (PPE).

Rockwell Automation Publication ICSTT-RM273Q-EN-P - August 2021 3
Summary of changes
This manual includes new and updated information. Use these reference
tables to locate changed information.
Grammatical and editorial style changes are not included in this summary.
Global changes
This table identifies changes that apply to all information about a subject in
the manual and the reason for the change. For example, the addition of new
supported hardware, a software design change, or additional reference
material would result in changes to all of the topics that deal with that subject.
Change
Topic
Updated branding.
Throughout
New or enhanced features
This table contains a list of topics changed in this version, the reason for the
change, and a link to the topic that contains the changed information.
Topic Name
Reason
About this publication Updated link for TechConnectSM Support Contract Access Level
and Features.
Removed instruction for using By Product when searching
Knowledgebase.

Rockwell Automation Publication ICSTT-RM273Q-EN-P - August 2021 5
Table of Contents
About this publication ................................................................................ 7
Download firmware, AOP, EDS, and other files....................................... 7
Additional resources................................................................................... 7
Chapter 1
Chapter 2
Field Termination Unit (FTU)................................................................... 13
Field Interface Unit (FIU).......................................................................... 13
Host Interface Unit (HIU) .........................................................................14
Front Panel Unit (FPU) ..............................................................................14
Line Monitoring Thresholds......................................................................15
Housekeeping.............................................................................................16
Fault detection and testing........................................................................16
Sequence of Events characteristics...........................................................16
Chapter 3
Module insertion and removal..................................................................17
Field cable selection...................................................................................17
Module pin-out connections .....................................................................18
Trusted module polarization and keying .................................................18
Chapter 4
Module configuration................................................................................21
T8431 Complex Equipment Definition.....................................................21
Rack 1: THRSHIN ................................................................................ 22
Rack 2: STATE...................................................................................... 22
Rack 3: AI...............................................................................................23
Rack 4: THRSHOUT ............................................................................ 24
Rack 5: LINE_FLT ................................................................................ 25
Rack 6: DISCREP................................................................................. 25
Rack 7: HKEEPING ............................................................................. 25
Rack 8: Information ............................................................................ 26
Sequence of Events configuration ........................................................... 28
System.INI file configuration .................................................................. 28
Chapter 5
Front panel ................................................................................................ 29
Module status LEDs.................................................................................. 30
I/O status LEDs........................................................................................... 31
Summary of changes
Preface
Product overview
Description
Installation
Application
Operation

Table of Contents
6 Rockwell Automation Publication ICSTT-RM273Q-EN-P - August 2021
Chapter 6
Fault reporting ...........................................................................................33
Field wiring faults......................................................................................33
Module faults ..............................................................................................33
Companion slot ..........................................................................................34
SmartSlot ....................................................................................................34
Cold Start ....................................................................................................34
Input Channel Calibration Check.............................................................35
Transfer between Active and Standby Modules.......................................35
Chapter 7
Appendix A
Fault finding and maintenance
Specifications
History of changes

Rockwell Automation Publication ICSTT-RM273Q-EN-P - August 2021 7
Preface
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.
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: rok.auto/literature.
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 Center: rok.auto/knowledgebase.
Some of the Answer IDs in the Knowledgebase require a TechConnectSM
Support Contract. For more information about TechConnect Support
Contract Access Level and Features, see Knowledgebase Document ID: IP622 -
TechConnect Support Contract - Access Level & Features.
Tip: Sign in to your Rockwell Automation account to view Knowledgebase articles.
Download firmware, associated files (such as AOP, EDS, and DTM), and
access product release notes from the Product Compatibility and Download
Center at rok.auto/pcdc.
These documents contain additional information concerning related
Rockwell Automation products.
About this publication
Download firmware, AOP,
EDS, and other files
Additional resources

Preface
8 Rockwell Automation Publication ICSTT-RM273Q-EN-P - August 2021
Resource
Description
Trusted TMR Safety Manual T8094, publication ICSTT-
RM459
Provides the requirements that must be met at
different stages of a safety-related system to verify
that the safety-related objectives of a Trusted® TMR
System are achieved.
Industrial Automation Wiring and Grounding
Guidelines, publication 1770-4.1
Provides general guidelines for installing a Rockwell
Automation industrial system.
Product Certifications website,
rok.auto/certifications
Provides declarations of conformity, certificates, and
other certification details.
You can view or download publications at http://rok.auto/literature.

Rockwell Automation Publication ICSTT-RM273Q-EN-P - August 2021 9
Chapter 1
Product overview
The Trusted® TMR 24 Vdc Analog Input module interfaces to 40 sourcing field
input devices, acting as a current sink for all these devices. Comprehensive
diagnostic tests are performed on each input channel. Fault tolerance is
achieved through a Triple Modular Redundant (TMR) architecture within the
Module for each of the 40 input channels.
Using the built-in line-monitoring feature, the Module can detect open and
shorted field cables. Line monitoring functions are independently configured
for each input channel.
The Module provides onboard Sequence of Events (SOE) reporting with a
resolution of 1 ms. A change of state triggers an SOE entry. States are
determined by voltage thresholds that can be configured on a per channel
basis. When the field voltage and field return are connected to the auxiliary
input channels of the Module, thresholds can be specified as a ratio of the field
supply voltage.
Features
•40 Triple Modular Redundant (TMR) input channels per Module.
•Comprehensive, automatic diagnostics and self-test.
•Selectable line monitoring per channel to detect open circuit and short
circuit field wiring faults.
•2500V impulse withstand opto/galvanic isolation barrier.
•Onboard Sequence of Events (SOE) reporting with 1 ms resolution.
•Module can be hot-replaced online using dedicated Companion
(adjacent) Slot or SmartSlot (one spare slot for many modules)
configurations.
•Front panel input status Light Emitting Diodes (LEDs) for each
channel indicate input status and field wiring faults.
•Front panel module status LEDs indicate module health and
operational mode (Active, Standby, Educated).
•TϋV Certified IEC 61508 SIL 3.

Rockwell Automation Publication ICSTT-RM273Q-EN-P - August 2021 11
Chapter 2
Description
The Trusted® TMR 24 Vdc Analog Input Module is a member of the Trusted
range of Input/Output (I/O) modules. All Trusted I/O Modules share common
functionality and form. At the most general level, all I/O Modules interface to
the Inter-Module Bus (IMB) which provides power and allows communication
with the Trusted TMR Processor. In addition, all Modules have a field
interface that is used to connect to module-specific signals in the field. All
Modules are Triple Modular Redundant (TMR).

Chapter 2 Description
12 Rockwell Automation Publication ICSTT-RM273Q-EN-P - August 2021
Figure 1: Module Architecture

Chapter 2 Description
Rockwell Automation Publication ICSTT-RM273Q-EN-P - August 2021 13
All High Integrity I/O Modules comprise four sections: Host Interface Unit
(HIU), the Field Interface Unit (FIU), the Field Termination Unit (FTU) and
the Front Panel Unit (or FPU).
Figure 2 shows a simplified functional block diagram of the Trusted 24 Vdc
Analog Input Module.
Figure 2: Functional Block Diagram
The Field Termination Unit (FTU) is the I/O Module assembly that connects
all three FIUs to a field connector. The FTU primarily contains passive
components necessary for front-end signal conditioning. When installed in a
Trusted Controller or Expander Chassis, the FTU field connector mates to the
Field I/O Cable Assembly attached at the rear of the Chassis.
The SmartSlot link is passed from the HIU to the field connections via the
FTU. These signals go directly to the I/O cable assembly and maintain
isolation from the I/O signals on the FTU. The SmartSlot link is the intelligent
connection between Active and Standby Modules for coordination during
Module replacement.
The Field Interface Unit (FIU) is the section of the Module that contains the
specific circuits necessary to interface to the particular types of field I/O
signals. Each Module has three FIUs, one per slice. For the TMR 24 Vdc Analog
Input Module, the FIU contains an analog to digital converter (ADC) for each
of the 40 field inputs.
The FIU receives isolated power from the HIU for logic. The FIU provides
additional power conditioning for the operational voltages required by the
Field Termination Unit (FTU)
Field Interface Unit (FIU)

Chapter 2 Description
14 Rockwell Automation Publication ICSTT-RM273Q-EN-P - August 2021
FIU circuitry. An isolated 6.25 Mbit/sec serial link connects each FIU to one of
the HIU slices.
The FIU also measures a range of onboard “housekeeping” signals that assist
in monitoring the performance and operating conditions of the Module.
These signals include power supply voltages, current consumption, onboard
reference voltages and board temperature.
The HIU is the point of access to the Inter Module Bus (IMB) for the Module.
It also provides power distribution and local programmable processing
power. The HIU is the only section of the I/O Module to directly connect to the
IMB Backplane. The HIU is common to most Trusted I/O Module types and
has type dependent and product range common functions. Each HIU contains
three independent slices, commonly referred to as A, B, and C.
All interconnections between the three slices incorporate isolation to prevent
any fault interaction between the slices. Each slice is considered a Fault
Containment Region (FCR), as a fault on one slice has no effect on the
operation of the other slices.
The HIU provides the following services common to the Modules in the
family:
•High Speed Fault Tolerant Communications with the TMR Processor
via the IMB interface.
•FCR Interconnect Bus between slices to vote coming IMB data and
distribute outgoing I/O Module data to the IMB.
•Optically isolated serial data interface to the FIU slices.
•Redundant power sharing of dual 24 Vdc chassis supply voltage and
power regulation for logic power to HIU circuitry.
•Magnetically isolated power to the FIU slices.
•Serial data interface to the FPU for Module status LEDs.
•SmartSlot link between Active and Standby modules for coordination
during Module replacement.
•Digital Signal Processing to perform local data reduction and self-
diagnostics.
•Local memory resources for storing Module operation, configuration,
and field I/O data.
•Onboard housekeeping, which monitors reference voltages, current
consumption and board temperature.
The Front Panel Unit (FPU) comprises a Front Panel Termination Unit (FPTU)
and a Front Panel Display Unit (FPDU). The overall FPU contains the
necessary connectors, switches, logic, and LED indicators for the Front Panel.
For every type of Trusted I/O Module, the FPU contains the Slice Healthy,
Active/Standby and Educated indicators (LEDs), and the module removal
switches. Additional bicolor LEDs provide status indication for the individual
Host Interface Unit (HIU)
Front Panel Unit (FPU)

Chapter 2 Description
Rockwell Automation Publication ICSTT-RM273Q-EN-P - August 2021 15
I/O signals. Serial data interfaces connect the FPU to each of the HIU slices to
control the LED status indicators and monitor the module removal switches.
The Module determines the contact state and line fault status by comparing
the input voltage level to four user programmed thresholds and two fixed
(minimum and maximum) thresholds. Hysteresis is provided on the
thresholds by upscale and downscale values, corresponding to the thresholds
for increasing and decreasing values respectively.
Table 1 Example Threshold Data (24 Vdc)
Note: The channel state value returned is dependent on the previous state value. If the input level is
increasing, then the lower state value will be returned. If the input level is decreasing, the higher
state value will be returned.
Default threshold values used for non-line monitored inputs are as follows (in
raw units):
Default = 448, 576, 1344, 1472, 2240, 2368, 3520, 3648, 5120
Line Monitoring Thresholds

Chapter 2 Description
16 Rockwell Automation Publication ICSTT-RM273Q-EN-P - August 2021
The Input Module automatically performs local measurements of several
onboard signals that can be used for detailed troubleshooting and verification
of Module operating characteristics. Measurements are made within each
slice’s HIU and FIU.
From the IMB to the field connector, the Input Module contains extensive
fault detection and integrity testing. As an input device, all testing is
performed in a non-interfering mode. Data input from the IMB is stored in
redundant error-correcting RAM on each slice portion of the HIU. Received
data is voted on by each slice. All data transmissions include a confirmation
response from the receiver.
Between the HIU and FIU, there are a series of optically isolated links for data
and power. The data link is synchronized and monitored for variance. Both
the FIU and HIU have onboard temperature sensors to characterize
temperature-related problems.
The power supplies for both the HIU and FIU boards are redundant, fully
instrumented and testable. Together, these assemblies form a Power Integrity
Subsystem.
The module field input is connected to a single bit ADC known as the ΣΔ input
circuit. These circuits, one per channel on each slice, produce a digital output
that naturally transitions between on and off. Any failure in the circuit causes
the output to saturate to stuck-on or stuck-off, which is automatically
detected. As the conversion process is dynamic and not gated like traditional
ADCs, failures are rapidly diagnosed and located.
By using the ΣΔ circuit, the analog path in the Module is short and does not
involve many components. This results in analog failures being contained to a
single channel on a single slice instead of causing a group of eight or more
inputs to fail.
The Input Module automatically measures the field input voltage, compares
the value to the configurable thresholds, and determines the state of the field
input. An event occurs when the input transitions from one state to another.
When an input changes state, the onboard real-time clock value is recorded.
When the TMR Processor next reads data from the Input Module, the input
state and real-time clock values are retrieved. The TMR Processor uses this
data to log the input state change into the system Sequence of Events (SOE)
log. The user may configure each input to be included in the system SOE log.
Full details of SOE are contained in Trusted Sequence of Events and Process
Historian Package Product Description, publication ICSTT-RM243 (PD-
T8013).
Housekeeping
Fault detection and testing
Sequence of Events
characteristics

Rockwell Automation Publication ICSTT-RM273Q-EN-P - August 2021 17
Chapter 3
Installation
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.
WARNING:
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.
To install the module:
1. Ensure that the field cable assembly is installed and 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.
The module should mount into the chassis with a minimum of resistance. If
the module does not mount easily, do not force it. Remove the module and
check it for bent or damaged pins. If the pins have not been damaged, try
reinstalling the module.
I/O cables suitable for use with the Trusted® TMR 24 Vdc Analog Input
Module are detailed in these publications:
•Trusted I/O Companion Slot Cables Product Description, publication
ICSTT-RM311 (PD-TC200)
•Trusted I/O SmartSlot Cables Product Description, publication ICSTT-
RM313 (PD-TC500)
The publications listed above also detail the types of Field Termination
Assembly (FTA) or Versatile Field Termination Assembly (VFTA) that may be
used with this type of module.
Module insertion and
removal
Field cable selection

Chapter 3 Installation
18 Rockwell Automation Publication ICSTT-RM273Q-EN-P - August 2021
This table describes the module pin-out connections:
Table 2 Field Connector Pin-out
C
B
A
1
SmartSlot Link C
SmartSlot Link B
SmartSlot Link A
2
3 Chan 28 (+) Chan 14 (+) Chan 0 (+)
4 Chan 28 (+) Chan 14 (+) Chan 0 (+)
5
Chan 29 (+)
Chan 15 (+)
Chan 1 (+)
6
Chan 29 (+)
Chan 15 (+)
Chan 1 (+)
7
Chan 30 (+)
Chan 16 (+)
Chan 2 (+)
8
Chan 30 (+)
Chan 16 (+)
Chan 2 (+)
9
Return
Return
Return
10
Chan 31 (+)
Chan 17 (+)
Chan 3 (+)
11
Chan 31 (+)
Chan 17 (+)
Chan 3 (+)
12 Chan 32 (+) Chan 18 (+) Chan 4 (+)
13 Chan 32 (+) Chan 18 (+) Chan 4 (+)
14
Chan 33 (+)
Chan 19 (+)
Chan 5 (+)
15
Chan 33 (+)
Chan 19 (+)
Chan 5 (+)
16
Chan 34 (+)
Chan 20 (+)
Chan 6 (+)
17
Chan 34 (+)
Chan 20 (+)
Chan 6 (+)
18
Chan 35 (+)
Chan 21 (+)
Chan 7 (+)
19
Chan 35 (+)
Chan 21 (+)
Chan 7 (+)
20 Return Return Return
21 Chan 36 (+) Chan 22 (+) Chan 8 (+)
22 Chan 36 (+) Chan 22 (+) Chan 8 (+)
23
Chan 37 (+)
Chan 23 (+)
Chan 9 (+)
24
Chan 37 (+)
Chan 23 (+)
Chan 9 (+)
25
Chan 38 (+)
Chan 24 (+)
Chan 10 (+)
26
Chan 38 (+)
Chan 24 (+)
Chan 10 (+)
27
Chan 39 (+)
Chan 25 (+)
Chan 11 (+)
28
Chan 39 (+)
Chan 25 (+)
Chan 11 (+)
29
Chan 40 (+)
Chan 26 (+)
Chan 12 (+)
30 Chan 40 (+) Chan 26 (+) Chan 12 (+)
32 Chan 41 (+) Chan 27 (+) Chan 13 (+)
32 Chan 41 (+) Chan 27 (+) Chan 13 (+)
All Trusted modules have been Keyed to prevent insertion into the wrong
position within a chassis. The polarization comprises two parts: the module
and the associated field cable.
Each module type has been Keyed during manufacture. The organization
responsible for the integration of the Trusted System must key the cable by
Module pin-out connections
Trusted module polarization
and keying

Chapter 3 Installation
Rockwell Automation Publication ICSTT-RM273Q-EN-P - August 2021 19
removing the keying pieces from the cable so that they correspond with the
bungs fitted to the associated module before fitting.
Figure 3: Module Polarization
For Cables with Companion Slot installations both keying strips must be
polarized.
For this module (T8431) remove keying pins 1, 4, and 5.