Triguard SC300E

MAO04NND

Analogue Output Module

(MAO04NND)
Issue 1 October 2005

INTRODUCTION

PURPOSE
The 4-Channel Analogue Output Module MAO04NND (Figure 1-1) provides analogue output
signals.

The module is a rack mounted, 9U high unit that provides the output control interface between
the SC300E processing environment and the user field environment. It has four current loop
output channels. All field outputs are galvanically isolated from the SC300E system but have a
common supply connection.

Circuit triplication and voting procedures make the module single-fault tolerant and latent
testing ensures that the failure of a channel will be recognised and reported to the SC300E
system. Front panel indicators show the state of the circuit ‘on-line’ status and the health of
the module. Sockets are provided on the front panel for monitoring the outputs.

The module, which is compatible with ‘dual slot hot repair’, can be fitted in any of the ten I/O
slots in the SC300E chassis. ‘Wrong slotting’ is prevented by physical coding. The SC300E
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. This document is intended to provide a general understanding of the function of the
module sufficient to enable basic maintenance operations to be effected in the field.

ASSOCIATED DOCUMENTATION
Reference No Title

008-5097 Chassis User Manual

008-5104 PDD24 Power Distribution Panel User Manual
008-5201 TPH44AIC 4-Channel Pulse Input and Analogue Output
Termination Card, User Manual

008-5203
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Mechanical coding
Block (Upper)

Links JP1 to JP4

Links LK1 to LK3

Connector J1

Common Interface (CI)

Module

Connector J2

Connector J3

Mechanical coding
block (Lower)

Figure 1-1 General view and front panel detail

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SPECIFICATION

Model MAO04NND
Channels 4
Architecutre TMR
Indicators Health, 3 x On Line
Test points 4 x signal, 1 x common
Output range 0 to 22mA
Maximum resistive field load 400 ohm
Resolution 6.25 µA steps

Accuracy @ 25°C +0.2% of full signal range

Maximum input ripple voltage @ 24V field supply 12V peak to peak
Maximum input frequency 120HZ
Stability (temperature coefficient) 15ppm/°C

Isolation 1KV between field and system, commoned

supply
Field power supply
Volgate range +18Vdc to 30Vdc

Module power consumption 5.5W

Overall size (mm) 400(9U)H x 397L x 28W
Overall size (inches) 15.75H x 15.63L x 1.1W
Weight 1.4kg

ENVIRONMENTAL SPECIFICATIONS
The maximum ambient temperature measured at the hottest point within the Triguard system
shall not be greater than 60 degrees centigrade.

Temperature operating: +5°C to +60°C

Temperature storage: -25°C to +70°C
Humidity 5% to 95% non-condensing at ambient <40°C
EMC/RFI Immunity Tested and certified to IEC 1131-Part 2 1994
Vibration/Shock Tested and certified to IEC 1131-Part 2 1994

Certification:
General Certification: Ref. SC300E TMR Product Guide (ref 008-5209).

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TRANSPORT AND HANDLING

The MAO04NND must be transported and stored in its original packing material which should
be retained for this purpose.

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TECHNICAL DESCRIPTION

PHYSICAL
The MAO04NND is a 9U high PCB with integral front panel and rear connectors. A plug-in
daughterboard carries the common interface circuits. Figure 1-1shows the general layout,
including the location of the connectors, covers and configuration links.

The front panel provides the following: Three ‘On-Line’ indicators A ‘Health’ indicator
An On/Off line request switch
Five test jacks (4 line and a common) for monitoring the output lines.

NOTE
Each monitor point gives 0 to 5.5Vdc negative with respect to common, determining the current
flowing in the corresponding 0 to 22 mA output. Each monitor point has a 10k ohm resistance
in series to prevent malfunction if the monitor point is short circuited - so a high input-
resistance meter is required for accurate readings.

MECHANICAL CODING BLOCKS

All Input/Output modules carry two mechanical coding 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 factory installed in a pattern determined by
the module and corresponding set screws are removed from the chassis coding blocks to
enable fitting. Unused holes are plugged with set screws. The chassis coding block
configuration for this module is shown in Figure 2-1 .

Figure 2-1 Chassis mechanical coding block configurations

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EXTERNAL CONNECTIONS
All connections to the MAO04NND are made via DIN 41612 connectors.

The upper connector is the system triple I/O bus connector. The middle connector is for the
field inputs and outputs. The lower connector is electrically in parallel with the middle
connector.

System interface
This MAO04NND acts as a slave to the MPP masters, and communication between three
MPPs and the MAO04NND takes place over the triplicated 16 bit parallel I/O - MPP buses that
run along the chassis mounted backplane. The three I/O - MPP buses are connected via the
module’s upper system interface DIN 41612 connector.

Field interface
The MAO04NND outputs and feedback connections are wired via one of the connectors (J2 or
J3) to the termination card TPH44AIC.

Current loop outputs

Four 0 to 22mA with common return. The termination card has a precision resistor for each
channel to control the current. This allows two modules to be used for dual-slot hot repair
purposes using the same termination card.

CONFIGURATION LINKS
The module contains a hardware identity circuit that enables system identification of the
module, and seven manual configuration links, JP1 to JP4 and LK1, LK2 and LK3.

Links JP1 to JP4 and LK1 to LK3

Links JP1 to JP4 enable undercurrent and overcurrent monitoring from a special termination
card giving galvanically isolated outputs. Links JP1 to JP4 must be set to the Off position.
Links LK1 to LK3 are described in Section 2.6, Theory of operation.

POWER SUPPLIES
The MAO04NND operates from dual power inputs supplied by the system’s dual redundant
PSUs, that each supply voltages of approximately 5.4Vdc and 12Vdc.

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THEORY OF OPERATION
The module has four 0-22mA current output channels using a common 24V supply via
termination card TPH44AIC.

The circuits are triplicated except for the final combining of the analogue output stages into a
single voted output.

Common functions
Power supplies and monitoring
The 5V and 12V dual-redundant supplies from the backplane are diode-OR’ed to the three
channels plus an auxiliary section. The analogue output section is isolated by dc/dc converters
providing +5V and ±15V. All the supplies and fuses are monitored by the CI.

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 or returned on-line.

Mode settings
The module contains a hardware identity circuit that enables system identification of the
module, and seven configuration jumper links (JP1to JP4 and LK1 to LK3). The jumper links
JP1, JP2, JP3 and JP4 must be set to the Off position. The operation of and settings links LK1
to LK3 is described below:

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 maintained. In
321 mode the system will continue to function with one out of three serviceable circuits. If that
fails the last read data is maintained 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 3 is always set to HW.

Latent fault detection (LFD) on outputs

The voted analogue voltage outputs from each channel are compared in turn with the D-to-A
outputs. The LFD scheme employed is to change each channel’s output in turn by 0.4V for
1ms, first negatively then positively, leaving the other channels unchanged. At each change,
the discrepancy between every channel and the common output is tested by a window
comparator. If a difference is detected on the deviated channel and the other two are 'same'
then no latent fault is detected and the Health LED is illuminated.

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Voting operates so that the LFD deviations do not appear on the combined output. If a fault
causes health to fail, no further LFD testing is performed.

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Figure 2-2 Analogue output section - Schematic block diagram

Analogue outputs
Five test-sockets are provided for monitoring the output lines: one common terminal via 2.2k
ohm to the +24V field supply, and the other four via 10k ohm to the current-determining
resistors on the termination card. These resistors are 250 ohm, so 20mA of loop-current
corresponds to 5V across them.

The four analogue voltage outputs use 12-bit DACs to produce +0.4V to –6V with respect to
field +24V common, applied across resistors on the termination card. The outputs from the
three channels go through a voting scheme using FETs to select the middle-value output, so
that if one channel fails high or low, one of the other two outputs will be selected (see Figure 2-
2).

The resultant current of 0 to 22mA determined by the voltage and resistor is fed to the field
device, then returns to the supply negative via the termination card.

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Common interface
The three discrete control circuits in the common interface (A, B, and C) (Figure 2-3 ) are each
responsible for the control of the corresponding one third of the I/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 I/O signal processing, signal path diagnostics, on-line/off-line
status and signal status read/write cycles to and from the SC300E processors 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 on each microcontroller
extinguishes the Health LED on the I/O module front panel in the event of a microcontroller
failure, LFD failure or a voting discrepancy.

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Figure 2-3 Common interface - Block diagram

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SUPPLEMENTARY INFORMATION
Connector J1 is the I/O bus.
Field output connectors J2 and J3 are in parallel.
The Channel connections are shown in Table 2-1.

Table 2-1. Current loop sensing connections to Connector J2

DIN41612 Connector J2
Channel Current-loop Current-loop Current-loop Current-loop
positive output sensing common

1 J2-10a J2-10c J2-18a J2-18c

2 J2-12a J2-12c J2-20a J2-20c
3 J2-14a J2-14c J2-22a J2-22c
4 J2-16a J2-16c J2-24a J2-24c

J2-1c : Cable screen from earth on chassis backplane

The J2 connectors that are reserved for future use are shown in Table 2-2.

Table 2-2. Connections reserved for future use

Channel DIN41612 Connector J2

Under-range Over-range
logic input logic input

1 J2-2a J2-2c
2 J2-4a J2-4c
3 J2-6a J2-6c
4 J2-8a J2-8c

J2-1a : System 0V

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SERVICING

SCOPE
Repair is by module replacement. Faulty modules are not repairable in the field. They should be
replaced by new modules and returned for repair.

CAUTION 1
Before fitting a new module ensure that the setting of all links is the same as that on the old
module.

CAUTION 2
The module contains components that may be electrostatically sensitive, it should be
transported and stored in its original packaging.

DIAGNOSIS
The TriBuild workstation is used for fault diagnosis. In the case of an Output fault the Health
LED on the faulty module will be extinguished.

PREPARATION
To ascertain whether the chassis I/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 TriBuild workstation.

Where there is a hot repair partner allocation, use the ‘Dual-slot hot repair’ procedure,
otherwise use the ‘Single-slot hot repair’ procedure.

CONFIGURATION
Before fitting a new module ensure that all link setting are the same as that on the old module.

CAUTION 3
Registers must be initialised to 100 Hex, 256 Decimal.

Ladder logic must be used to prevent a value of less than 256 being written to the outputs or
the module will lose health indication.

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REMOVAL AND REPLACEMENT

CAUTION 4
Failure to take the faulty module off-line before removing it from the chassis could trigger a fault
alarm.
CAUTION 5
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.

Single-slot hot repair

CAUTION 6
Field loop current will not be supplied during changeover.

1. Operate the On/Off Line Request switch on the faulty module. The three On Line LEDs
should all extinguish to indicate that the MPPs have recognised the request and taken
the module off-line.

2. Slacken the two module securing screws and use the black ejection levers (top and
bottom) to draw the module from its slot.

3. Insert the new module ensuring that it engages properly in the upper and lower guides
in the chassis. The top and bottom chassis rails carry alignment marks to assist. Pull
out the ejection 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.

4. Operate the On/Off Line Request switch and check that the three On Line LEDs
illuminate for one second, extinguish for one second and then illuminate permanently
to indicate that the module has been put on-line. If the LEDs do not illuminate either
the first or second time or fail to remain illuminated, then the module must be
considered faulty.

Dual-slot hot repair

1. Insert the new module into the vacant hot repair slot ensuring that it engages properly
in the upper and lower guides in the chassis. The top and bottom chassis rails carry
alignment marks to assist. Pull out the ejection 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.

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2. Operate the On/Off Line Request switch on the new module. Ascertain that the three
On Line LEDs on the new module illuminate for one second, extinguish for one second
and then illuminate permanently as the LEDs on the old module extinguish. 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 illuminate either the first or second
time or fail to remain illuminated, the new module must be regarded as faulty. The old
module’s LEDs should remain illuminated indicating that it is still on line.

3. If the new module is serviceable slacken the screws on the old module and use its
ejection levers to remove it from the chassis.

PREVENTIVE MAINTENANCE
No preventive maintenance is necessary.

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SERVICE SUPPORT

SPARES
Spare parts and technical advice can be obtained from your local area offices.

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