CS300E User Manual MDO32BNS Digital Output Module 32 Channel FET Document No: 008-5102-01 ‘This manual covers the following items: Conformal Coating Model Ref Part No. 85°C MDO32BNS | _ 001-1112 = 001-1133 August Systems"am August Systems Area Offices Europe & CIS: August Systems Limited ‘Telephone: +44 1293 442135 Manor Royal Fax: 444 1293 442149 Crawley E-Mail: 100256.3205 @compuserve.com ‘West Sussex RHIO2PY UK USA, Canada & August Systems Inc ‘Telephone: +1 713 939 7172 Latin America: 8901 Jameel Fax: 1713 939 7175 Suite 180 E-Mail: 74514.2404@ compuserve.com Houston ‘Texas 77040 - 5057 USA Pacific Rim: ‘August Systems Pie Lid ‘Telephone: +65 323 7433 10 Ang Mo Kio Street 65 #05-13 ax: 465 323 7422 ‘TechPoint E-Mail: 75452.2403@ compuserve.com ‘Singapore 569059 Republic of Singapore Middle East: ‘August Systems Saudi Arabia Lid Telephone: +966 3 859 2890 PO Box 3788 Fax: 4966 3 859 2890, Al-Khobar 31952 Kingdom of Saudi Arabia Disclaimer ‘Whilst August Systems endeavours to ensure that the information contained in this document is ‘accurate atthe time of publication, it accepts no liability for errors or omissions therein. August Systems reserves the right to introduce changes to the equipment, design and specification without prior notice. ‘Some information contained in this document may be of a general nature due to the variety of 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 thet 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 advice. 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 part, or used for manufacture by anyone other ‘than August Systems without written 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 from another source. Page 2 of 17 008-5102-01 (06/97)CS300E - Evolution User Manual Digital Output Module MDO32BNS ave 1-00-2 2-0-2 2-003 324 3:20 ac ADC BS CE CsA DAC de Degradation EPROM ESD F&G Failsafe Fallback FET FM HIFT vO IEC IEEE 802.3, Iso PsD RAM RS232 RITS SIFT ‘TCP/IP TMR 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 clement working in the presence of two faults. Three system processor elements working: reverting to two systcm 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 Input/Output International Electrotechnical Commission Institute of Electrical and Electronic Engineer's communications standard International Standards Organisation Local Area 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 ProtocoV/Internet Protocol Triple Modular Redundancy Technischer Uberwachungs Verein, translates to Technical Supervisory Association, of Germany Underwriters Laboratories 008-5102-01 (06/97) Page 3 of 17Digital Output Module MDO32BNS CS300E - Eeolaeton 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 Alll trade references are duly acknowledged. Page 4 of 17 008-5102-01 (06/97)CS300E - Evolution User Manual Digital Output Module MDO32BNS Contents 1, INTRODUCTION & TECHNICAL DATA. 1.1 PURPOSE... af 1,2 ASSOCIATED DOCUMENTATION... 1.3 SPECIFICATION. : 1.4 TRANSPORT AND HANDLING. 2. TECHNICAL DESCRIPTION 2.1 PHYSICAL... 2.1.1 Slot Coder 2.1.2 External Connections. 2.1.2.1 Field Circuits 2.1.2.2 Module conneccors 2.2 THEORY OF OPERATION. 2.2.1 Common Interjace.. 3. SERVICING .. 3.1 EQUIPMENT REQUIRED. 3.2 DIAGNOSIS F 3.3 REPAIR.... 3.3.1 Preparation. 3.3.2 Configuration. 5 3.3.3 Removal and Replacement 3.33.1 Single-Slot Hot Repair. 3.3.3.2 Dual-Slot Hot Repair... Fioure 1: Genera View .. ss fies : CHASSIS CODING For DicrraL OUTPUT MODULE. : BASICFIELD LoaD Circurr Piet Ourpur Connectors. 5: DIGITAL OuTPUT MODULE - BLOCK DIAGRAM. 3: COMMON INTERFACE - BLOCK DIAGRAM... 008-5102-01 (06/97) Page 5 of 17Digital Output Module MDO32BNS CS300E - Evolutton User Manual Intentionally blank Page 6 of 17 008-5102-01 (06/97)CS300E - Eeotatiow User Manual Digital Output Module MDO32BNS commonmrerrace 1B a) *HW (ON DAUGHTER BOARD) conricuranion HLV ©3)°GTZ Prinks so520 wsucror Lever §] CONNECTOR " CHANNEL, LEDs an | consecron LEDs ad? ONOFE LINE REQUEST switci, EJECTOR LEVER Figure 1: General View 1. INTRODUCTION & TECHNICAL DATA 1.1. PURPOSE ‘The Digital Output Module provides the output control interface between the CS300E processing environment and up to 32 low voltage field items. All field outputs from the module are Galvanically isolated from the system. 008-5102-01 (06/97) Page 7 of 17Digital Output Module MDO32BNS CS300E - Evotutéon 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) or ‘OFF" channel will be recognised and reported to the system. 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 /O slots in the CS300E Chassis, ‘wrong slotting’ is prevented by physical coding. The CS300E system software identifies the module via a built-in hardware identifier. Channel outputs leave the module via the DIN 41612 ‘rear plug-up’ system on the Chassis backplane. The Digital Output Module has relatively high power dissipation which may place some constraints upon its use (Ref. Appendix 1). ‘This document is intended to provide a general understanding of the function of the Digital Output Module sufficient to enable basic maintenance operations to be effected in the field. 1.2 ASSOCIATED DOCUMENTATION Ref ‘008-5112 | CS300E Product and Applications Guide (008-5113 | CS300E Ancillary Components (008-5097 | Chassis 008-5123 | TDOIGAIA Digital Output Termination Card, DIN to screw terminal, LV 008-5128 | TDOIGAIB Digital Output Termination Card, DIN to screw terminal, HV 008-5125 | TDOIGBIA Digital Output Termination Card, DIN to DIN (008-5131 | TDOIGBIA Digital Output Termination Card, DIN to Elco 008-5104 | Power Distribution Panel (PDD24) 008-5151 | Cabinet Co 1.3 SPECIFICATION Dimensions and Weights: Size: 365.8mm high x 394.3mm deep x 27.7mm wide Weight: L7kg Power Supply Requirements: System Power 5.4Vdc @ 0.5A and 12Vde @ 0.16A Field Power 18 to 30Vde (24V nominal) @ 0.02A (min) to 1A (max) Environmental Data: ‘Temperature: 0 to +60°C Humidity: 5 to 95% RH non-condensing Page 8 of 17 008-5102-01 (06/97)CS300E - Svotuttore User Manual Digital Output Module MDO32BNS Vibration: 1g at 5 to SOOHz sinusoidal Shock: 20g for 12ms Certification: General Certification details 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 Output 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 Jayout, location of the connectors, front panel components and the configuration links. 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; they 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, tor BorToM 10 @ @: O: ane 1) Figure 2: Chassis Coding for Digital Output Module 008-5102-01 (06/97) Page 9 of 17Digital Output Module MDO32BNS (CS300E ~ Evolutioe User Manual 2.1.2 External Connections 2.1.2.1 Field Circuits FIELD DIGITAL 4ve POWER -ve OUTPUT SUPPLY MODULE INPUT : DIGITAL OUTPUT SOURCE SUPPRESSOR TO OTHER CHANNELS DROOSSOa Figure 3: Basic Field Load Circuit The field load circuit shown in Figure 3 is the absolute minimum required for the safe connection of field loads to the Digital Output Module, for any unused channel a dummy field load should be used (value to be advised). August Systems however, recommend the use of their 16 Channel Digital Output Termination cards TDO16*** which offer full connection facilities with indicating fuses, alarm outputs and dummy loads (Ref. ASSOCIATED DOCUMENTATION). 2.1.2.2 Module connectors The System bus connector is J1 and the Common Interface is connected via J4 and JS (not shown). In the external connection diagram (Figure 4) the following symbols are used: © = First mate (long pin) x = Connector pin GND= — Connected to chassis ve = Field supply in -ve = — Field supply return O/P = — Channel output Page 10 of 17 008-5102-01 (06/97)CS300B - Evatetion User Manual ror PIN GND 2 Ge «oF 0% oF oom oP noon “on oP 1s om on non 4 on 2% on om x0 or 2 on 2 Figure 2.2 THEORY OF OPERATION In accordance with TMR practice, channel output command information from the system follows three identical paths through the Digital Output Module (Figure 5) each path at the command of its own microcontroller in the Common Interface. As the switching speed of the module exceeds the system scan rate the channel data can be converted to serial form before entering the module from the Common Interface. In this manner 32 output channels can be served by just three paths instead of 96. The three data streams are each applied to opto-isolators which mark the interface between the system and output sides of the circuit and provide a system to field channel isolation of 1000V minimum. Digital Output Module MDO32BNS PIX eb 2 GxD 02 ‘oP % on % on on oo 2 oP op 6 op so 20 on 2 op 4 on 6 on on 30 oo 2 on 2 : Field Output Connectors J2 and J3 Pinouts cuRtven ” 18 » 2» 2 n 2B 2s 6 n Fa 2 x ” 2 ‘The data streams are then applied to the 32-bit output shift registers. The serial bits are clocked successively into the shift registers until the 32 bit has been received, the registers then latch the data and present it on the 32- output switches. The data is refreshed in this manner at each scan of the system. 008-5102-01 (06/97) it busses (CHANA, CHANB and CHANC) to the Page 11 of 17Digital Output Module MDO32BNS CS300E - Evolution User Manual ‘The output switch for each channel comprises six FETs connected in the series/parallel network shown and providing 2 out of 3 majority voting between the three paths A, B and C. A front panel LED at the switch output is lit when the switch is closed. Voltage and current monitoring circuits are also connected to the switches to provide outputs for the Latent Fault Detection (LFD) system, these are fed back to the microcontrollers via dedicated shift registers and opto-isolators. The feedback information confirms that the output has switched to the commanded state and that the line is not open or short circuit. ‘Testing of the output switches using the LFD circuits is co-ordinated by the microcontrollers. When all outputs are in the healthy condition and the microcontrollers confirm no faults present the main processors will instruct each microcontroller in turn to switeh its output alone to the opposite state and confirm the correct operation of the output switch. ‘The module power requirements are served from two different sources. The power rails and reference levels for the system-side circuits are derived from the 5.4V and 12V supplies from the system chassis. The power rails and reference levels for the output-side circuits are derived from the field supplies and also serve to confirm that the field circuits are in working order ‘An ON/OFF LINE REQUEST switch on the front panel enables a request to be sent to the system that the module be taken off-line for maintenance purposes or returned on-line. ‘The module contains a hardware identity circuit that enables system identification of the module, and three manual links 1, 2 and 3. Link 1 allows the module to be set up for 321 or 320 mode operation which 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. Link 2 (HLV/GTZ) determines whether, in the event of a failure due to 321/320 action, the last read values are held (HLV) or are set to zero (GTZ). Link 2 is only active however, if Link 3 (ICCB/HW) is set to HW, if Link 3 is set to ICCB Link 2 is de-activated. Page 12 of 17 008-5102-01 (06/97)Digital Output Module MDO32BNS CS300E - Svotutéoe User Manual saras noag| eS suas Wanod 3 sare uneino >| oNIouINoN ee oF loxrrosiwonfe— suvi ramos [22 Sars warsis HOLIMS 4SaND34 NIT 440/NO SANIT NOLLVHADIANOD ‘a1 GYD c e Bars Lnaino | 901s wausas 7a nuwan aNi7 440/80 1 L * Wu TOs a ou4o 82 warseay|_,[aoivvos 82 Las ‘uso. wausiom |g __Wouvosi “Lis ouso. : ! Sz sz waisome |_, [Worries a Lanis uso 3 on i z “ANNO waivom |__,[aoiviost * i Lalas aldo i Wisoa WOLvIGs! le le aaa “Linis ouao. wossauzens 7 waisoae|__, iovios “ais ouao T t wisn Woxv0s1 u LAH o1a0. 1 « wusion WOIVIORT vv Sch J 140 woDuLE CONNECTOR Figure 5: Digital Output Module - Block Diagram Page 13 of 17 008-5102-01 (06/97)Digital Output Module MDO32BNS CS300E - Evotatiow User Manual 2.2.1 Common Interface 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 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 microcontrollers co-ordinate /O signal processing, signal path diagnostics, on-line/off-line status and signal status read/write cycles to and from the system processors via an /O communications bus. All /O modules have an identification code which is read by the Common Interface and passed to the MPPs for verification. The on-line/ofi-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 on each microcontroller extinguishes the HEALTH LED on the I/O module front panel in the event of a microcontroller failure, LED failure or a voting discrepancy. CONTROL BUSA A rsvox. ur sus 8 yo sus 8 serrers KY opus ‘coxNecrons wrckocoraotteR opie ‘connectors yo aus CONTROL BUS micnocoxraoLier ON-LINE ¢ crsvor ‘owore Line azQuEst rons Figure 6: Common Interface - Block Diagram Page 14 of 17 008-5102-01 (06/97)CS300E - Evotatéow User Manual Digital Output Module MDO32BNS 3. SERVICING CAUTION: THE MODULE CONTAINS COMPONENTS THAT MAY BE ELECTROSTATICALLY SENSISTIVE, 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 SETTING OF ALL THREE LINKS IS THE SAME AS THAT ON THE OLD MODULE. 3.3.1 Preparation To ascertain whether the Chassis 1/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. 3.3.2 Configuration The only configuration necessary is the correct setting of the three links which are shown in Figure 1. Ensure that the link configuration on the new module is the same as 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. 008-5102-01 (06/97) Page 15 of 17Digital Output Module MDO32BNS CS300E - Evolutéou User Manual 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. 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 on line, 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 your local area August Systems office (see inside front cover). Page 16 of 17 008-5102-01 (06/97)CS300E - Evotutéon User Manual Digital Output Module MDO32BNS APPENDIX 1 ‘When Digital Output Modules are used in cabinets without fan assisted cooling the following precautions are recommended. a) Wherever possible modules should be located in the lowest chassis in the cabinet to benefit from natural cooling. b) Modules, or module pairs, should preferably be spaced apart in the chassis and, if a module is used at more than 50% (8A) of maximum load, it is advisable to keep the right hand adjacent slot empty. 008-5102-01 (06/97) Page 17 of 17