CS300E User Manual MDI32BIS Digital Input Module 32 Channel - Isolated Document No: 008-5101-01 ‘This manual covers the following items: Conformal Coating Model Ref Fer: Part No. Basie 35°C Basic 35°C MDI32BIS 001-1104 = 001-1132 ela August SystemsAugust Systems Area Offices Europe & CIS: August Systems Limited ‘Telephone: +44 1293 442135 Manor Royal Fax: +44 1293 442149 Crawley E-Mail: 100256.3205 @compuserve.com West Sussex RHIO2PY UK USA, Canada & August Systems Inc ‘Telephone: +1 713 9397172 Latin America: 8901 Jameel Fax: +1 713 9397175 Suite 180 E-Mail: 74514.2404@compuserve.com Houston ‘Texas 77040 - 5057 USA Pacific Rim: August Systems Pte Lid ‘Telephone: +65 323 7433 10 Ang Mo Kio Street 65 #05-13 Fax: +65 323 7422 TechPoint |: 75452.2403@ compuserve.com ‘Singapore 569059 Republic of Singapore Middle Fast: ‘August Systems Saudi Arabia Lid Telephone: +966 3 859 2890 PO Box 3788 Fax: +966 3 859 2890 ‘AL-Khobar 31952 Kingdom of Saudi Arabia Disclaimer ‘Whilst August Systems endeavours to ensure that tbe information contained in this document is accurate atthe time of publication, it accepts no ability for errors or omissions therein. August ‘Systems reserves the right to intreduce changes to the equipment, design and specification without prior notice. ‘Some information contained in this document may be of @ general nature due to the variety Cf systems in which the equipment can be used. August Systems disclaims any implied warranty of fitness for a particular application. It is up to the user to ascertain that the equipment is fit for a particular application, and that any procedure adopted is not prejudicial tothe safety of personnel and equipment. August Systems accepts no liability for damages resulting from the use of this equipment. If in doubt, contact August Systems for adviee. Copyright © 1997 August Systems “This document is the property of August Systems and is issued on the express condition that it is not disclosed, reproduced in whole or in pat, or used for manufacture by anyone other than August Systems without writen consent; and that no right is granted to disclose or use any information contained in this document. These restrictions do not limit the right to use {information obtained ftom another source. Page 2 of 16 008-5101-01 (06/97)CS300E - Ecotutéon User Manual Digital Input Module MDI32BIS BS cE CSA DAC dc Degradation EPROM ESD F&G Failsafe Fallback FET FM HIFT vO IEC IEEE 802.3 Iso LAN LED MPP PCB PCS PLC PsD RAM RS232 RTTS SIFT TCP/IP TR TOV UL Glossary of Terms Positive Negative One out of two voting ‘Two out of two voting ‘Two out of three voting ‘Three system processor elements working: reverting to two system processor elements ‘working in the presence of a single fault, reverting to one system processor element ‘working in the presence of two faults. Three system processor elements working: reverting to two system processor elements ‘working in the presence of a single fault, reverting to no system processor elements ‘working in the presence of two faults. Alternating Current Analogue to Digital Converter British Standards Indicates compliance with applicable European Community directives Canadian Standards Authority Digital to Analogue Converter Direct Current ‘The processes described under 3-2-1 and 3-2-0 Erasable Programmable Read Only Memory Emergency Shutdown Fire and Gas Fails toa safe state Forces output to a known state during system failure Field Effect Transistor Factory Mutual Hardware Implemented Fault Tolerance InpuvOurput International Electrotechnical Commission Institute of Electrical and Electronic Engineer's communications standard International Standards Organisation Local Arca Network Light Emitting Diode Main Processor Printed Circuit Board Process Control System Programmable Logic Controller Process Shutdown Random Access Memory Serial binary data exchange standard Real Time Task Supervisor Software Implemented Fault Tolerance Transmission Control Protocol/Internet Protocol Triple Modular Redundancy Technischer Uberwachungs Verein, translates to Technical Supervisory Association, of Germany Underwriters Laboratories 008-5101-01 (06/97) Page 3 of 16Digital Input Module MDI32BIS CS300E - Evatatiow User Manual Warnings, Cautions and Notes These indicate the following:~ WARNING: A WARNING INDICATES THAT THERE IS A DANGER OF INJURY OR DEATH TO PERSONNEL. CAUTION: A CAUTION INDICATES THAT THERE IS A POSSIBILITY OF DAMAGE. TO EQUIPMENT. NOTE: A Note is used to convey additional information, e.g. to indicate actions likely to cause abnormal or unexpected operating conditions. Acknowledgements All trade references are duly acknowledged. Page 4 of 16 008-5101-01 (06/97)CS300E - Eeotatiow User Manual Digital Input Module MDI32BIS Contents 1, INTRODUCTION & TECHNICAL DATA 1.1 PURPOSE... 3 : 1.2 ASSOCIATED DOCUMENTATION, 1.3 SPECIFICATION, 1.4 TRANSPORT AND HANDLING. 2. TECHNICAL DESCRIPTION 2.1 PHYSICAL 2.1.1 Slot Coder Blocks.. 2.1.2 External Connections... 2.1.2.1 Field Circuits. 2.1.2.2 Module Connectors 2.2, THEORY OF OPERATION. 2.2.1 Digital Input Module. 2.2.2 Common Interface.. 3. SERVICING 3.1 EQUIPMENT REQUIRED... 3.2 DIAGNOSIS... 3.3 REPAIR 3.3.1 Preparation. 3.3.2 Configuration 3.3.3 Removal and Replacement 3.3.31 Single Slot Hot Repair. 3.3.3.2 Dual Sot Hot Repalr 3.4 PREVENTIVE MAINTENANCE. 4, SERVICE SUPPORT. Illustrations Figure 1: GENERAL VIEW. i Ficus 2: Cuassis Copinc For 32 CHANNEL DicrTAL INPUT MODULE, FlourE 3: BASICFIELDINPUT CIRCUIT... 2 Figure 4: Fie INPUT CONNECTORS J2 AND J3 PINOUTS..... Fioure 5: Diorra. INput MODULE - BLOCK DIAGRAM. FIGURE 6: COMMON INTERFACE - BLOCK DIAGRAM. 008-5101-01 (06/97) Page 5 of 16Digital Input Module MDI32BIS Page 6 of 16 CS300E ~- Evotucéon User Manual Intentionally blank 008-5101-01 (06/97)CS300E - Ecotation User Manual Digital Input Module MDI32BIS ay CCoMMON INTEREACE 2120 Link (ON DAUGHTER BOARD) 32189) #320 EJECTOR oe) tEvER | H a ‘| H conwecror E ar i! CHANNEL fs r LEDs z 3 2 CONNECTOR un ne Meaunie : ONOFF LINE es E connector tbe € Bi onorr LINE 8 Request a Swirat | euEcTor —— LEVER ve Figure 1: General View 1. INTRODUCTION & TECHNICAL DATA 1.1 PURPOSE The Digital Input Module provides an interface between the user field environment and the CS300E processing environment for up to 32, low voltage, de channel inputs. All channel inputs into the module are Galvanically isolated from each other and from the system environment, 008-5101-01 (06/97) Page 7 of 16Digital Input Module MDI32BIS CS300E - Evolution User Manual Circuit triplication and voting procedures make the module single-fault tolerant and latent testing ensures that the failure of a normally ON (energised) channel will be recognised and reported to the Main Processors (MPPs). Front panel indicators show the state of all channels, the circuit on-line status and the health of the module. ‘The module, which is compatible with ‘dual slot hot repair’, can be fitted in any of the ten 1/0 slots in the CS300E Chassis, ‘wrong slotting’ is prevented by physical coding. The CS300E MPP software identifies the module via a built-in hardware identifier. Channel inputs are wired to the module via the DIN 41612 ‘rear plug-up’ system on the Chassis backplane. This document is intended to provide a general understanding of the function of the Digital Input Module, sufficient to enable basic maintenance operations to be effected in the field. 1.2 ASSOCIATED DOCUMENTATION Ref Title 008-5112 CS300E Product and Applications Guide 008-5113 CS300E Ancillary Components 008-5097 Chassis 008-5121 TDII6AIA Digital Input Termination Card, DIN to screw terminal 008-5122 TDIIGBIA Digital Input Termination Card, DIN to DIN 008-5130 TDII6EIA Digital Input Termination Card, DIN to Eleo 008-5104 User Manual for Power Distribution Panel (PDD24) 1.3 SPECIFICATION Input Parameters Inputs: 32 Channels at 24Vde nominal Input Current: SmA at 24V per Channel ‘Channel/Channel Isolation: 300Vde ‘Channel/System Isolatior 1000Vde Dimensions and Weights Size: 365.8mm high x 394.3mm deep x 27.7mm wide Weight: 1.6kg Power Supply Requirements Voltage: 5.5Vde Current: 0.6A Page 8 of 16 008-5101-01 (06/97)CS300E - Evolution User Manual Digital Input Module MDI32BIS Environmental Data ‘Temperature: Oto 60°C Humidity: 5 to 95% non-condensing at ambient <40°C Vibration: 1g at 5 to SOOHz sinusoidal Certification General Certification Ref. CS300E Product and Applications Guide 1.4 TRANSPORT AND HANDLING The Module must be transported and stored in its original packing material which should be retained for this purpose. 2. TECHNICAL DESCRIPTION 2.1 PHYSICAL The Digital Input Module is a 9U high PCB with integral front panel and rear connectors; a plug-in daughter board carries the Common Interface circuits. Figure 1 shows the general layout, location of the connectors, front panel components and the 321/320 configuration link. 2.1.1 Slot Coder Blocks All Input/Output modules carry two coder blocks equipped with pins which mate with holes in corresponding blocks in the chassis and prevent the module being inserted into the wrong slot. ‘The pins in the module blocks are fixed and the chassis blocks are arranged to accept them; unused holes are plugged with grub screws. Figure 2 shows the slot coding for this module. ror Bottom O: a oO Figure 2: Chassis Coding for 32 Channel Digital Input Module 2.1.2 External Connections 2.1.2.1 Field Circuits ‘The field input circuit shown in Figure 3 is the absolute minimum required for the safe connection of digital inputs to the module. August Systems however, recommend the use of their 16 Channel Digital Input Termination cards TDI16*** which offer full connection facilities with indicating fuses and alarm outputs (Ref. ASSOCIATED DOCUMENTATION). 008-5101-01 (06/97) Page 9 of 16Digital Input Module MDI32BIS CS300E - Evolution User Manual FIELD 1 sve POWER -ve I prorrat suPPLy INPUT INPUT ! MODULE DIGITAL, INPUT, 1 SUPPRESSOR SOURCE TO ! OTHER 1 CHANNELS 1 noose Figure 3: Basic Field Input Circuit 2.1.2.2 Module Connectors ‘The System bus connector is J1 and the Common Interface is connected via J4 and J5 (not shown). In the external connection diagram Figure 4, ® denotes First mate (long pin), x denotes a normal connector pin and NC denotes no connection. Tor To Toa) ms > solemn =] me + alton, o6| ode! 2a | a tam oe ti aoe esos os nen eel as os ce [aw fae alee aeeice as cole og eer ae ae a cee C5 sate a eel oe elas a elas oe = 7 cme Figure 4: Field Input Connectors J2 and J3 Pinouts Page 10 of 16 008-5101-01 (06/97)CS300E - Euotation User Manual Digital Input Module MDI32BIS i ‘rest 1 4 L To] an | TE) ovate pe L i i pati a t pus. aus conrRoL ‘eter vase . 108 4 a IsoLaToR t : avert aus coxrzot | counox i i ‘cars | aunts i viet! Z| ines T art 8ST tgoraton [1 PE | Hl 1 \ iter be y rscissv—| svi ssv— mame |_| ns |—vees LINK xs nore Line |__} wo a— Request aoc | cuanwer vpeaTORS ret a swpieatoRs Figure 5: Digital Input Module - Block Diagram 2.2 THEORY OF OPERATION ‘The Digital Input Module assembly comprises the module board, which slides directly into the 008-5101-01 (06/97) Page 11 of 16Digital Input Module MDI32BIS CS300E - Euotatiow User Manual chassis and accepts the client input channels, and a Common Interface circuit mounted as a daughter board on the module. 2.2.1 Digital Input Module Up to 32 field channels are connected to the Digital Input Module via the ‘plug-up’ connections on the rear of the Chassis, from where they are fed to the field input connectors J2 and J3 which connect them to the isolation circuits in the module. There are 32 isolation circuits, one for each channel, and each comprises three paths. The block diagram (Figure 5) shows the arrangement for receiving one channel, the signal being divided to feed the three paths A, B and C. At the path input the 24Vde signal is passed through a high frequency filter with an effective 204B attenuation range of 6 to 1000 MHz. The signal is then applied to an Opto-isolator circuit which provides channeV/channel isolation of 300Vde and channel/system isolation of 1000Vdc. Typically the current drawn from an energised 24V channel input will be approximately SmA. ‘The data output (D) of each isolator (A, B or C) forms one of 32 inputs to inverting transparent latches which load it, on command, to an 8-bit bus for sending to the Common Interface Module. The data is continuously monitored by the MPPs and, if unsatisfactory, a monitor fault is logged. A signal is also sent back to the module to extinguish the ‘HEALTHY’ LED on the front panel. A failed channel is detectable as a consecutive discrepancy on the data bus. A latent test facility is built into each isolator and, on command, will override ON channel inputs and reduce them below the input threshold to simulate OFF channels. If a channel remains ON during the test a signal is sent to the module to extinguish the HEALTHY LED. The triplicated isolator outputs (L) for each path are also ORed to operate a front panel LED which, when lit, indicates that the particular channel is energised. Power to the module is 5.5Vdc supplied by each of the dual redundant CS300E power supply units and enters the module via the module bus connector J1. Each line is fused at 2A before being divided into four branches to provide a simplex supply and the three path supplies (A, B and C). The pair of lines in each branch are ORed via diodes to provide the dual redundancy and the output lines are fused (0.5A in the simplex line and 1A each in the other three). After filtering and surge limitation the simplex line VCCS supplies the front panel Channel and Health LEDs while the other three VCCA, VCCB and VCCC supply power to the A, B and C path circuits respectively, and to the corresponding control circuits in the Common Interface. Each of the path supplies is also continuously monitored by a circuit with a built in time delay to avoid nuisance alarms. The monitor outputs A/PSUOK, B/PSUOK and C/PSUOK are sent via the Common Interface to the MPPs for diagnostic purposes. An ON/OFF LINE REQUEST switch on the front panel enables a request to be sent to the ‘MPPs that the module be taken off-line for maintenance purposes. Page 12 of 16 008-5101-01 (06/97)(CS300E - Ecotatiow User Manual Digital Input Module MDI32BIS ‘The module contains a hardware identity circuit that enables system identification of the module and a manual link that allows the module to be set up for 321 or 320 mode operation. ‘The 321 or 320 mode sets the threshold that determines how much of the circuit can be degraded while still preserving overall operation. 320 mode means that the system will continue to function with two out of three serviceable circuits; if the number falls to one out of three the last read data is frozen. In 321 mode the system will continue to function with one out of three serviceable circuits; if that fails the last read data is frozen and the module is taken off line. CONTROL wean s wooLe ‘coKNECTORS yo aus 8 yo aus ‘CONTROL BEE crsvor MOF LINE REQUEST fc Figure 6: Common Interface - Block Diagram 2.2.2 Common Interface ‘coxnécToRs The three discrete control circuits in the Common Interface (A, B, and C) are each responsible for the control of the corresponding one third of the /O module circuits. Each control circuit 008-5101-01 (06/97) Page 13 of 16Digital Input Module MDI32BIS CS300B - Evolution User Manual comprises a microcontroller with a dedicated watchdog, data buffers and shared RAM. The circuit is powered via the module and permits live insertion of replacement modules. The microcontroller co-ordinates I/O signal processing, signal path diagnostics, on-line/off-line status and signal status read/write cycles to and from the MPPs via an I/O communications bus. All I/O modules have an identification code which is read by the Common Interface and passed to the MPPs for verification. The on-line/off-line status is determined by the MPPs. If, for maintenance purposes, the ON/OFF LINE REQUEST switch on the front of the module is operated, the action is read by all three microcontrollers and the request passed to the MPPs which may then grant the request. The watchdog extinguishes the HEALTH LED on the /O module front panel! in the event of a microcontroller failure, LFD action or a voting discrepancy. 3. SERVICING CAUTION: THE MODULE CONTAINS COMPONENTS THAT MAY BE ELECTROSTATICALLY SENSITIVE, IT SHOULD BE TRANSPORTED AND STORED IN ITS ORIGINAL PACKAGING MATERIAL. 3.1 EQUIPMENT REQUIRED No special tools or equipment are required to service the module. 3.2 DIAGNOSIS ‘The TRIGARD Workstation is used for fault diagnosis. In the case of an Input/Output fault the HEALTH LED on the faulty module will be extinguished. 3.3 REPAIR System repair is by module replacement. Faulty modules are not repairable in the field, they should be replaced by new modules and returned to August Systems for repair. CAUTION: BEFORE FITTING A NEW MODULE ENSURE THAT THE 321/320 LINK. SETTING IS THE SAME AS THAT ON THE OLD MODULE. 3.3.1. Preparation To ascertain whether the Chassis /O slot containing the faulty module has been allocated a hot repair partner use one of the following methods: * Check the system drawings © Check the Chassis wiring configuration * Use the I/O Chassis Configuration Report on the TRIGARD Workstation. Where there is a hot repair partner allocation, use the “Dual-Slot Hot Repair” procedure, otherwise use the “Single-Slot Hot Repair” procedure. Page 14 of 16 008-5101-01 (06/97)(CS300E - Evotation User Manual Digital Input Module MDI32BIS 3.3.2 Configuration The only configuration necessary is the correct location of the 321/320 Link as shown in Figure 1. Ensure that the link configuration on the new module is identical to that on the old module. 3.3.3 Removal and Replacement CAUTION 1: FAILURE TO TAKE THE FAULTY MODULE OFF-LINE BEFORE REMOVING IT FROM THE CHASSIS COULD TRIGGER A FAULT ALARM OR CAUSE PLANT SHUTDOWN. CAUTION 2 WHEN INSERTING A MODULE ENSURE THAT IT IS ALIGNED WITH THE MARKINGS ON THE CHASSIS RAILS AND THAT IT ENGAGES WITH THE TOP AND BOTTOM GUIDES. IMPROPER INSERTION MAY CAUSE DAMAGE TO THE MODULE AND/OR CHASSIS CONNECTORS 3.3.3.1 Single -Slot Hot Repair Operate the ON/OFF LINE REQUEST switch on the faulty module, the three ON LINE LEDs should all go out to indicate that the MPPs have recognised the request and taken the module off-line. The last read data input from the module will be frozen until the new module is on-line. Slacken the two module securing screws and use the black ejection levers (top and bottom) to draw the module from its slot. Insert the new module ensuring that it engages properly in the top and bottom guides in the Chassis, the top and bottom chassis rails carry alignment marks to assist. Pull out the black top and bottom levers and as the module is pushed back engage the levers on the chassis rails. The levers should then be used to draw the module into position, some resistance will be felt as the rear connector pins engage. The module should be fixed in position with the securing screws. Operate the ON/OFF LINE REQUEST switch and check that the three ON LINE LEDs light for one second, go off for one second and then light permanently to indicate that the module has been put on-line. If the LEDs do not light either the first or second time or fail to stay on, then the module must be considered faulty 3.3.3.2 Dual-Slot Hot Repair Insert the new module into the vacant hot repair slot ensuring that it engages properly in the top and bottom guides in the Chassis, the top and bottom chassis rails carry alignment marks to assist. Pull out the black top and bottom levers and as the module is pushed back engage the levers on the chassis rails. The levers should then be used to draw the module into position, some resistance will be felt as the rear connector pins engage. ‘The module should be fixed in position with the securing screws. 008-5101-01 (06/97) Page 15 of 16Digital Input Module MDI32BIS CS300E - Evotutéon User Manual Operate the ON/OFF LINE REQUEST switch on the new module. Ascertain that the three ON LINE LEDs on the new module light for one second, go off for one second and then light permanently as the LEDs on the old module go off. This sequence indicates that the new module has been put on line and the old module taken off line. If the LEDs on the new module do not light either the first or second time or fail to stay on, the new module must be regarded as faulty. The old module LEDs should stay on indicating that itis still online, If the new module is serviceable slacken the screws on the old module and use its ejection levers to remove it from the Chassis. 3.4 PREVENTIVE MAINTENANCE No preventive maintenance is necessary. 4, SERVICE SUPPORT Spare parts and technical advice can be obtained from the your local area August Systems office (see inside front cover). Page 16 of 16 008-5101-01 (06/97)