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Rockwell Automation Publication ICSTT-RM451D-EN-P - March 2021 

35 

 

Chapter 6 

Fault Finding and Maintenance 

Output Module faults are reported to the user through visual indicators on 
the Front Panel of the Module and through status variables, which may be 

automatically monitored in the application programs and external system 
communications interfaces. There are generally two types of faults that must 
be remedied by the user: external wiring and Module faults. External wiring 
faults require corrective action in the field to repair the fault condition. 
Module faults require replacement of the Output Module. 

By measuring the output channel voltage and current, the Module 
automatically detects field-wiring and load faults. When a field signal fails 

open circuit, short circuit or there is no field supply voltage connected, the 
output status indicator displays the configured LED mode, the corresponding 
output state is reported and the line fault status for that channel is set to ‘1’. All 
other output channels are unaffected, except in the case of common cause 
wiring and supply voltage faults in the field. 

The field output voltage and current variables can be monitored to determine 
the actual operating conditions of each output channel. This additional 
information assists the user in determining the specific type of wiring fault. 

Once the specific field-wiring fault has been identified and corrected, the 
output status variables and output status indicator display the normal on/off 
status of the field device. 

Extensive diagnostics provide the automatic detection of Module faults. The 
TMR architecture of the Output Module and the diagnostics performed verify 

the validity of all critical circuits. Using the TMR architecture provides a Fault 
Tolerant method to withstand the first fault occurrence on the Module and 
continue normal output controls without interruption in the system or 
process. Faults are reported to the user through the Healthy status indicators 
on the Front Panel of the Module and through the INFO and HKEEPING 
variables. Under normal operations, all three Healthy Indicators are green. 
When a fault occurs, one of the Healthy Indicators is flashing red. It is 
recommended that this condition is investigated and if the fault is within the 
Module, it should be replaced. 

Module replacement activities depend on the type of spare Module 
configuration that is chosen when the system was configured and installed. 
The Module may be configured with a Dedicated Standby Slot or with a 
SmartSlot for a spare replacement Module. 

Fault Reporting 

Field Wiring Faults 

Module Faults 

Содержание Trusted TMR 24V DC

Страница 1: ...omation Publication ICSTT RM451D EN P March 2021 Supersedes Publication ICSTT RM451C EN P January 2019 Product Description Original Instructions Trusted TMR 24V DC 48V DC Output Module 40 Channel PD T8461 Issue 16 ...

Страница 2: ...ll 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 t...

Страница 3: ...ch Structure 14 Switch Diagnostics 16 Short Circuit Protection 16 Group Fail Safe Switches 16 Chapter 3 Module Insertion and Removal 19 Cable Selection 19 Termination 20 Module Pin out Connections 20 Trusted Module Polarisation Keying 21 Chapter 4 Module Configuration 23 T8461 Complex Equipment Definition 23 Rack 3 AI 25 Rack 4 CI 25 Rack 5 LINE_FLT 26 Rack 6 DISCREP 26 Rack 7 HKEEPING 26 Rack 8 I...

Страница 4: ...1D EN P March 2021 Chapter 6 Fault Reporting 35 Field Wiring Faults 35 Module Faults 35 Companion Slot 36 SmartSlot 36 Cold Start 36 Transfer between Active and Standby Modules 37 Chapter 7 Appendix A Fault Finding and Maintenance Specifications History of Changes ...

Страница 5: ...t troubleshooting and maintenance of a Trusted system 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 installati...

Страница 6: ... For the latest information about this product review the Product Notifications and Technical Notes available at rok auto knowledgebase Some of the Articles in the Knowledgebase require a TechConnect Support Contract For more information go to Knowledgebase Document ID IP622 TechConnect Support Contract Access Level Features Tip Sign in to your Rockwell Automation account to view Knowledgebase art...

Страница 7: ...determined by voltage and current measurements onboard the Module This Module is not approved for direct connection to hazardous areas and should be used in conjunction with Intrinsic Safety Barrier devices Features 40 TMR output channels per Module Comprehensive automatic diagnostics and self test Automatic line monitoring per channel to detect open circuit and short circuit field wiring and load...

Страница 8: ......

Страница 9: ...t 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 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 ...

Страница 10: ... Publication ICSTT RM451D EN P March 2021 Figure 1 Module Architecture All High Integrity I O Modules are made up of four sections Host Interface Unit HIU the Field Interface Unit FIU the Field Termination Unit FTU and the Front Panel Unit or FPU ...

Страница 11: ...s The SmartSlot link is passed from the HIU to the field connections via the FTU These signals go directly to the field connector 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 cir...

Страница 12: ...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 incoming IMB data and distribute outgoing I O Module data to IMB Galvanically isolated serial data interface to the...

Страница 13: ...ule and the diagnostics performed verify the validity of all critical circuits Using the TMR architecture provides a Fault Tolerant method to withstand the first fault occurrence on the Module and continue normal output controls without interruption in the system or process Faults are reported to the user through the Healthy status indicators on the Front Panel of the Module and through the inform...

Страница 14: ...ld voltage and current to determine the state of each output channel An event occurs when the output transitions from one state to another When a channel changes state the onboard timer value is recorded When the TMR Processor next reads data from the Output Module the channel state and real time clock value are retrieved The TMR Processor uses this data to log the state change into the system Seq...

Страница 15: ... are specified to be on in the absence of control signal power is to allow two channels to power the load should an entire slice fail Even if an entire slice fails the surviving output circuits carries the necessary control The structure of each FIU output is shown in this diagram Figure 4 Simplified Switch Circuit Diagram A resistor provides a means of continuously monitoring the switch current A...

Страница 16: ... load current Short Circuit Protection Output channels are classified as protected under IEC 61131 2 specifically Protected Outputs Requirements While energizes the channel output current is monitored to protect the channel switches from damage by a sustained overcurrent condition Having detected a sustained overcurrent condition a short circuit fault state is latched and the output is de energize...

Страница 17: ...d be then it can command its own GFSS and those of the other slices GFSS to de energize This results in two of the three elements of the GFSS structure to de energize leaving only one GFSS element energized If two slices do the same thing then the last GFSS output de energizes For example this would occur if two or more output switch elements fail in a stuck on state such that the output cannot de...

Страница 18: ......

Страница 19: ...d 2 If I O Module keys are used verify that all keys are installed in the correct positions and properly seated in their slots 3 Release the ejector tabs on the Module using the release key Ensure that the ejector tabs are fully open 4 Holding the ejectors carefully insert the Module into the intended slot 5 Push the Module fully home by pressing on the top and bottom of the Module fascia 6 Close ...

Страница 20: ...nk A 2 3 Chan 5 Pwr Group 1 Chan 1 4 Chan 6 Pwr Group 1 Chan 2 5 Pwr Group 1 Rtn Pwr Group 1 Pwr Group 1 Rtn 6 Chan 7 Pwr Group 1 Chan 3 7 Chan 8 Pwr Group 1 Chan 4 8 9 Chan 13 Pwr Group 2 Chan 9 10 Chan 14 Pwr Group 2 Chan 10 11 Pwr Group 2 Rtn Pwr Group 2 Pwr Group 2 Rtn 12 Chan 15 Pwr Group 2 Chan 11 13 Chan 16 Pwr Group 2 Chan 12 14 15 Chan 21 Pwr Group 3 Chan 17 16 Chan 22 Pwr Group 3 Chan 18...

Страница 21: ...h Module type has been keyed during manufacture The organization 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 that are fitted to the associated Module before fitting Figure 5 Module Polarization For Cables with Companion slot installations both keying strips must be polarized For this Mo...

Страница 22: ......

Страница 23: ...n I O Module definition in the I O Connection Editor for each I O Module The I O Module definition defines physical information for example Chassis and Slot location and allows variables to be connected to the I O channels of the Module 3 Using the Trusted System Configuration Manager define custom LED indicator modes per channel default or fail safe states and other Module settings The T8461 I O ...

Страница 24: ... installed The I O Module slots in the Trusted Controller Chassis are numbered from 1 to 8 The I O Module slots in the Trusted Expander Chassis are numbered from 1 to 12 This board provides the connection to the logical output control signal for each of the field outputs Table 5 Rack 1 DO descriptions Channel Description 1 Field output channel 1 logical state 2 Field output channel 2 logical state...

Страница 25: ...ian value that is taken from the triplicated Module The voltage level is reported as an integer with the units being 1 500V This may be used directly scaled arithmetically or scaled using the IEC 61131 TOOLSET conversion tables To scale the value arithmetically simply divide the returned integer by 500 to return the voltage as either a REAL or INTEGER as required The IEC 61131 TOOLSET conversion t...

Страница 26: ...5 LINE_FLT Table 10 Rack 5 LINE_FLT Descriptions Channel Description 1 Field output channel 1 line fault 2 Field output channel 2 line fault 40 Field output channel 40 line fault The line fault input state is reported as true logic 1 for a line fault condition open circuit short circuit and no field supply voltage The logic state is the majority voted value Rack 6 DISCREP This table describes Rack...

Страница 27: ...tage 32768 32767 mV 23 B 24 C 25 A FIU Output Group 1 Field Supply Voltage 32768 32767 1 500V 26 B 27 C 28 A FIU Board Temperature Output Group 1 Note Temperature C input value 256 32768 32767 29 B 30 C 31 A FIU Output Group 2 Field Supply Voltage 32768 32767 1 500V 32 B 33 C 34 A FIU Board Temperature Output Group 2 Note Temperature C input value 256 32768 32767 35 B 36 C 37 A FIU Output Group 3 ...

Страница 28: ...le chassis number 6 Standby Module slot number 7 Standby Module healthy 8 Standby Module mode 9 FCR status 10 Primary Module is active 11 Active Module is simulated The Active Module chassis and slot numbers indicate the position of the currently Active Module These values change to match the primary or secondary Module position depending on their Active status that is Active Standby changeover sw...

Страница 29: ...this is only set if the Module is not present or the simulation enable has been set within the Module s configuration in the System INI file Each Boolean Output Variable can be configured for automatic Sequence of Events SOE logging This applies to the Output Status and Line Fault Status variables A Boolean variable is configured for SOE during the variable definition in the Data Dictionary Editor...

Страница 30: ......

Страница 31: ...erational status and field output status Each indicator is a bicolor LED At the top and bottom of each Module is an ejector lever that is used to remove the Module from the Chassis Limit switches detect the open closed position of the ejector levers The ejector levers are normally latched closed when the Module is firmly seated into the Controller or Expander Chassis Front Panel ...

Страница 32: ...one Educated The Healthy indicators are controlled directly by each Module slice The Active Standby and Educated indicators are controlled by the FPU The FPU receives data from each of the Module slices It performs a 2oo3 vote on each data bit from the slices and sets the indicators accordingly The Module status indicator modes and their meanings are described as follows Table 16 Module Status LED...

Страница 33: ...ucated Module is educated Module is recognized by the Processor but education is not complete Active Standby changeover in progress There are 40 output channel status indicators on the Module Front Panel one for each field output These indicators are controlled by the FPU The FPU receives data from each of the Module slices The FPU performs a 2oo3 vote on each data bit from the slices and sets the...

Страница 34: ...T RM451D EN P March 2021 Tip The LEDs indicating channel status may be configured to suit user requirements by implementing the procedure for configuring the System INI file detailed in Trusted Toolset Suite Product Description publication ICSTT RM249 PD T8082 ...

Страница 35: ...perating conditions of each output channel This additional information assists the user in determining the specific type of wiring fault Once the specific field wiring fault has been identified and corrected the output status variables and output status indicator display the normal on off status of the field device Extensive diagnostics provide the automatic detection of Module faults The TMR arch...

Страница 36: ... the highest density of Modules to be fitted in a given physical space At the rear of the Trusted Chassis a single wide I O Cable connects the secondary slot directly to the I O Cable connected to the failed primary Module With a spare Module installed in the SmartSlot and the SmartSlot I O Cable connected to the failed primary Module the SmartSlot can be used to replace the failed primary Module ...

Страница 37: ...he secondary Module location is not unique as in a SmartSlot configuration then NO Module for that Module pair becomes Active In order for a Module to become the Active Module the TMR Processor verifies that the Module is the correct I O Module type and that both Module Removal switches are closed At this point the I O Module is configured and eventually placed in the Active state A Module in the ...

Страница 38: ...ate reverts to the Active state When both Module Removal switches are opened on an Active Module regardless of the Module fault status the TMR Processor treats it as a request to perform an Active Standby changeover Under normal conditions an Active Standby changeover only occurs if the new Active Module is fault free Under some circumstances it is desirable to be able to force a changeover to a k...

Страница 39: ...of Outputs 40 Number of Power Groups 5 Each Power Group comprises 8 channels Output Output On State resistance 1 6 Ω Maximum Current Rating Continuous 0 75 A per channel Minimum On State Load Current 25 mA Current Measurement Range 0 A to 1 35 A 5 5 mA7 Voltage Measurement Range 0V DC to 58V DC 2V DC Maximum Withstanding 1V DC to 60V DC Channel to Channel Crosstalk 1 Maximum Load Capacitance 500 μ...

Страница 40: ... 32 F to 140 F Storage Temperature 25 C to 70 C 13 F to 158 F Relative Humidity Operating and Storage 10 95 noncondensing Environmental Specifications See Trusted 8000 Series International Safety and Environmental Approvals publication ICSTT TD003 Dimensions Height 266 mm 10 5 in Width 31 mm 1 2 in Depth 303 mm 12 0 in Weight 1 3 kg 2 7 lb ...

Страница 41: ...ing PD T8461 Issue 15 January 2019 Change Updated Specifications section and main text to a more consistent format Updated Front Panel section to updated product design Updated to display Rockwell Automation publication numbers Added trademarks statement PD T8461 Issue 14 June 2016 Change Rebranded and reformatted with correction to Relative Humidity Range and Operating Temperature statements in t...

Страница 42: ...ges 42 Rockwell Automation Publication ICSTT RM451D EN P March 2021 PD T8461 Issue 11 December 2006 Change Weights Dims PD T8461 Issue 10 August 2006 Change Channel States PD T8461 Issue 9 August 2005 Change Format Text editing ...

Страница 43: ...nd product notification updates rok auto support Knowledgebase Access Knowledgebase articles rok auto knowledgebase Local Technical Support Phone Numbers Locate the telephone number for your country rok auto phonesupport Literature Library Find installation instructions manuals brochures and technical data publications rok auto literature Product Compatibility and Download Center PCDC Get help det...

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