Professional Documents
Culture Documents
Training Manual
Revision 3.0
August 2007
P/N 553099
ics triplex
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The information contained in this document is subject to change without notice. The reader
should, in all cases, consult ICS Triplex to determine whether any such changes have been
made.
Microsoft, Windows, Windows 95, Windows NT, Windows 2000, and Windows XP are
registered trademarks of Microsoft Corporation.
Disclaimer
The illustrations, figures, tables, and layout examples in this manual are intended solely to
illustrate the text of this manual. The user of, and those responsible for applying this
equipment, must satisfy themselves as to the acceptability of each application and use of
this equipment.
This document is based on information available at the time of its publication. While
efforts have been made to be accurate, the information contained herein does not purport to
cover all details or variations in hardware or software, nor to provide for every possible
contingency in connection with installation, operation, or maintenance. Features may be
described herein which are present in all hardware or software systems. ICS Triplex
assumes no obligation of notice to holders of this document with respect to changes
subsequently made. ICS Triplex makes no representation or warranty, expressed, implied,
or statutory with respect to, and assumes no responsibility for the accuracy, completeness,
sufficiency, or usefulness of the information contained herein. No warranties of
merchantability or fitness for purpose shall apply.
Table of Contents 3
Warning
Radio Frequency Interference
Most electronic equipment is influenced by radio frequency interference (RFI). Caution
should be exercised with regard to the use of portable communications equipment around
such equipment. Signs should be posted in the vicinity of the equipment cautioning against
the use of portable communications equipment.
Maintenance
Maintenance must be performed only by qualified personnel. Otherwise personal injury or
death, or damage to the system may result.
Caution
Static Sensitive Devices
Modules in the TMR system may contain static sensitive devices which can be damaged
by incorrect handling. The procedure for module removal is detailed in relevant product
descriptions and must be followed. All TMR systems must have labels fitted to the exterior
surface of all cabinet doors cautioning personnel to observe antistatic precautions when
touching modules.
ICS Triplex introduced a next-generation safety and control TMR product family named
Trusted in 1997. The Trusted system was build upon the proven technologies of the Regent
and Regent + Plus product families incorporating state-of-the-art microprocessor and
leading edge electronic technologies. The Trusted system is compatible with legacy Regent
and Regent + Plus systems allowing a direct migration path for existing systems.
Application programs for the Trusted system are written and monitored using the IEC1131
Toolset. The system supports a variety of communications configurations, including
Networked Systems, OPC, Modbus, and Peer-Links controlled and monitored using both
Engineering and Operator Workstations.
Table of Contents 5
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Chapter 1: Introduction
Course Goals ...................................................................................................................... 1-1
Who This Course is Intended For ...................................................................................... 1-2
Recommended Prerequisites .............................................................................................. 1-2
Course Length .................................................................................................................... 1-2
Other Trusted Training Courses......................................................................................... 1-2
Table of Contents 7
Chapter 4: Controller Assembly
Purpose............................................................................................................................... 4-1
Objectives........................................................................................................................... 4-1
Controller Chassis .............................................................................................................. 4-2
TMR Processor .................................................................................................................. 4-4
Processor Interface Adapter ............................................................................................. 4-10
Expander Interface ........................................................................................................... 4-12
Expander Interface Adapter ............................................................................................. 4-13
Communications Interface ............................................................................................... 4-15
Communications Interface Adapter ................................................................................. 4-17
Gateway Module .............................................................................................................. 4-18
Test Your Knowledge ...................................................................................................... 4-20
Table of Contents 9
Chapter 10: Loading, Monitoring & Controlling Applications
Purpose............................................................................................................................. 10-1
Objectives......................................................................................................................... 10-1
Loading an Application in a Controller ........................................................................... 10-2
Monitoring an Application............................................................................................... 10-6
Controlling Variables / Locking....................................................................................... 10-8
Locking Using the Dictionary.................................................................................. 10-10
Unlocking................................................................................................................. 10-11
Spying ............................................................................................................................ 10-12
Test Your Knowledge .................................................................................................... 10-13
Chapter 11 Troubleshooting
Purpose............................................................................................................................. 11-1
Objectives......................................................................................................................... 11-1
Self Test Cycle Times ...................................................................................................... 11-2
Troubleshooting ............................................................................................................... 11-3
LED Diagnostics ........................................................................................................ 11-4
Toolset Diagnostics.................................................................................................. 11-12
Microprocessor Log ................................................................................................. 11-13
Dumptrux ................................................................................................................. 11-14
Swapping / Installing Modules ...................................................................................... 11-15
Swapping Processor Modules .................................................................................. 11-16
Swapping Expander Interface Modules ................................................................... 11-20
Swapping Expander Processor Modules.................................................................. 11-22
Swapping I/O Modules ............................................................................................ 11-24
Swapping Smart Slot I/O Modules .......................................................................... 11-26
Test Your Knowledge .................................................................................................... 11-29
Appendix 1: Dumptrux
Purpose............................................................................................................................ A1-1
Objectives........................................................................................................................ A1-1
Dumptrux ........................................................................................................................ A1-2
Appendix 2: Puzzles
Purpose............................................................................................................................ A2-1
Objectives........................................................................................................................ A2-1
Hardware Crossword Puzzle ........................................................................................... A2-2
Software Crossword Puzzle ............................................................................................ A2-4
Introduction
Course Goals
To teach maintenance and instrumentation personnel:
What components make up the Trusted system.
How the Trusted system functions as a fault tolerant
programmable logic controller.
How to load, monitor and control programs.
How to lock (force) inputs and outputs.
How to troubleshoot a Trusted system.
How to replace faulty modules.
Introduction 1-1
Who This Course Is Intended For
Electricians, maintenance, operations and
instrumentation personnel responsible for installation,
maintenance and troubleshooting of the Trusted system.
Recommended Prerequisites
A general knowledge of programmable logic controllers
(PLCs).
A background in troubleshooting industrial electronic
control equipment and field devices.
A level of competence using Microsoft Windows
operating systems and programs.
Course Length
2 days
Purpose
To define the various terms and concepts associated with fault
tolerance and the Trusted system.
Objectives
To be familiar with the terms associated with fault
tolerance and the Trusted system.
System Overview
Purpose
To provide an overview of the Trusted system and its
components.
Objectives
To understand the system architecture.
Power System
(4 Power Shelves + 12 Power Packs)
Fan Tray
Controller Assembly
(Chassis + TMR Processor +
Interfaces + I/O)
Fan Tray
Expander Assembly
(Chassis + Expander Processor +
I/O)
Fan Tray
Expander Assembly
Fan Tray
Expander Assembly
Grill
3x2
Expander Bus
Expander
Chassis
Backplane Bus 3
Expander I/O I/O
Processor
Expander
Backplane Bus 3 Chassis
Expander I/O I/O
Processor
I/O System
Different I/O modules have different point densities (with 40
being the most common). A controller assembly can contain up
to 8 I/O modules. A controller assembly can physically connect
to up to 28 expander assemblies (up to 4 pairs of expander
interfaces each with up to 7 connections). Expander assemblies
can house up to 12 I/O modules. This would equal 336 I/O
modules. 336 modules x 40 channels per module (typical)
would represent over 13,000 I/O.
However, the greater the number of I/O modules, the longer the
scan time of the system. (Scan time is roughly 4 msec per I/O
module.) Large systems can be broken down into smaller units,
each communicating with the others and sharing information
using safety certified peer to peer communications.
Communication Protocols
Modbus (Slave or Master)
TCP/IP
OPC
Communication Speed
Varies depending upon standard and protocol
Input Power
110-220 Vac 50/60 Hz
Controller Assembly
Purpose
To describe the components and functions of the controller
assembly in more detail.
Objectives
To understand the components that make up the
controller assembly.
The two left-most module positions are triple width and are
used to accommodate TMR processors. The first slot is
designated logical 0 and the adjacent slot logical 15. The
remaining module positions are designated logical 1 to 8 from
left to right. The modules occupying these slots are defined in
both the system and I/O configuration managers, as described in
Sections 10 and 11.
External Power
The voter circuits read the input data from the inter-module bus
and carry out a continuous 2oo3 vote of the data. The voting
and fault detection circuits enable the module to identify and
isolate transient, intermittent and permanent faults as they
occur. All faults are recorded in the systems fault history.
Permanent faults are also annunciated by an LED on the module
front panel.
The battery is built into System data, fault information and user program data are
the chip and cannot be retained in the TMR Processor non-volatile memory during
replaced. power off mode for up to 10 years (conservatively rated) via a
non-replaceable battery.
Processor Configuration
The diagnostic serial 1. Engineering workstation via the front panel diagnostics
port on the serial port. The diagnostics port has a serial data rate of
communications 19.2k bits/sec.
interface module cannot
be used for this purpose. 2. Engineering workstation via the communications
interface (module). The communications interface
supports serial and Ethernet communications, however
the toolset (workstation) software only operates with the
communications interface via Ethernet.
Firmware Upgrades
There are eleven status LEDs on the processor front panel; three
Healthy, one Active, one Standby, one Educated, one Run, one
Inhibit, one System Healthy, and two User. The Healthy
indicators are controlled directly by each module slice. All
LEDs are controlled by the processor module itself.
The processor module status LED states and their meanings are:
LED Indication
Overall health of each processor slice:
Healthy Steady green = healthy
Flashing red = slice failed
Steady green when the Processor is in the Active
Active
mode
Steady green when the Processor is in the Standby
mode.
Standby
Flashing green when the Processor has changed
from the Active to the Standby mode.
Steady green when the Processor is Educated.
Flashing green when being Educated.
Educated
Off when the Processor is not Educated, or the
application program has stopped.
Flashing green when the Processor is operating
normally with full integrity.
Run Steady green in Standby.
Off when the application program in the Active
Processor has stopped.
Flashing green when any input or output is locked
Processors cannot swap if (forced). Also flashes green if a changeover from
the inhibit indicator is Inhibit Active to Standby is attempted when the Standby
flashing! and Active Processors have different system
configurations.
System health:
Steady green = healthy
Flashing red = system boot-up, system fault,
System self-test fail, IMB error. I/O
Healthy module error, Active/Standby
module failing to respond, module
slice error, channel fault, or a
module is being simulated.
User 1 and General purpose LEDs for use under software
User 2 control.
Run
Maintain
Run
The configuration and Memory is locked in the Run position. Application programs
Toolset programs will and system configurations cannot be downloaded or updated.
not even communicate Command line interfaces (e.g., the Dumptrux diagnostic utility)
with the system with the
interact with the system through the processor with the key in
key in the Run position
prior to version 3.5.
the Run position.
Maintain
Application programs and system configurations can only be
downloaded from the engineering workstation with the
appropriate access permission with the keyswitch in the
Maintain position. Command line diagnostics are not possible
through the Processors front panel serial port with the
keyswitch in the Maintain position, but may be accessed
through the Communications Module front panel port or
through Ethernet.
The keyswitch does have The key does not need to be in the Run position in order for the
a momentary third processor to run. Likewise, the key does not need to be in the
position, but it serves no Maintain position in order to perform maintenance on the
function. system. Perhaps more meaningful names for the keyswitch
positions and their meaning especially as of version 3.5
might be secure / write access, or read only / read-write.
LED Indication
Three LEDs, one for each of the three slices, indicating
the overall health of each slice.
Healthy Steady green - a healthy slice.
Flashing red - a fault in the corresponding slice.
Active Steady green when the module is in the Active mode.
Standby Steady green when the module is in the Standby mode.
With the controller chassis dip switches set to ID #1, the first
seven expander chassis would have their dip switch ID #s set
from 2 to 8. Another interface adapter would be used to connect
to the next seven chassis. Those chassis also need their dip
switch ID #s set from 2 to 8, although they would be designated
9 to 15 in the software configuration (system.ini file) described
in Section 10.
The module has dual Ethernet and four serial ports accessible
from the rear using the T8153 communications interface
adapter, along with a diagnostic port accessible from the front
faceplate.
LED Indication
Module health.
Healthy Steady green - healthy module.
Flashing red - module failed.
This module does not Steady green when the module is in the Active
Active mode (application running, communications
operate in an active /
enabled).
standby pair. These
Steady green when the module is in the
LEDs are provided for Standby Standby mode (application stopped,
consistency. communications disabled).
Configuration loaded successfully from
Educated
Processor
Six tri-colored LEDs indicate data transfer
The green LED for activity on the four serial and two Ethernet
Ethernet is off with a ports. The LEDs flash red when transmitting
good connection, and on Communications
data, green when receiving and amber when
with no or a bad transmitting and receiving within close
connection. proximity.
LED Indication
Module health.
Healthy Steady green module has passed self-test.
Steady red module has failed self-test.
Steady green when successful connection with
Active the communications interface module has been
established.
Steady green when the module is in the
Standby Standby mode otherwise off.
This LED is provided for consistency only. Set to
Educated steady green at power-up.
Ethernet Ports: LEDs flash amber to indicate
link activity and off if no activity.
RS-232 serial port: LEDs flash red when
Communications
responding, green when receiving, off if no
activity.
Ethernet FP: currently unused.
Flashing green when hard drive is active.
Disk Flashes red when secondary IDE is in use.
Status Reserved for future use.
Expander Assembly
Purpose
To describe the components and functions of the expander
assembly in greater detail.
Objectives
To understand the components that make up the
expander assembly.
Slot Positions
External Power
Figure 5-3:
Expander
Processor
LED Indication
Three LEDs, one for each of the three slices, indicating
the overall health of each slice.
Healthy Steady green - a healthy slice.
Flashing red - a fault in the corresponding slice.
Active Green when the module is in the Active mode.
Standby Steady green when the module is in the Standby mode.
Three LEDs, one for each of the three channels,
indicating the communications activity on each
processor channel.
the LED will appear When the module is active:
amber when both receive TxRx Green - Receive activity
and transmit activities Red - Transmit activity
are occurring. Off - no activity or failed
When the module is in standby, no Transmit activity (red
LED) will be observed.
I/O Modules
Purpose
To describe the input and output modules in greater detail.
Objectives
To understand the various I/O modules that are
available.
There are no user- The following information summarizes some of the more
serviceable parts or popular I/O modules. More complete details on all modules can
switch settings inside be found in their respective product description documents.
any modules.
There are six module status LEDs on the module front panel;
three Healthy, one Active, one Standby, and one Educated. The
module status LED states and their meanings are:
Figure 6-1:
24Vdc Digital
Input Module
There are input channel status LEDs on the module front panel,
one for each field input. The input status LED mode is
dependent upon the voltage level of the field I/O signal. Each
field input voltage is measured and compared to six threshold
levels (four configurable and two fixed) which produce seven
threshold bands, as described in Section 10. Each threshold
band can be defined to have a particular indicator mode: off,
green, red, flashing green, or flashing red.
Figure 6-2:
Analog Input
Module
The input status LED mode is dependent upon the voltage level
of the field I/O signal. Each field input voltage is measured and
compared to six threshold levels (four configurable and two
fixed) which produce seven threshold bands, as described in
Section 10. Each threshold band can be defined to have a
particular indicator mode: off, solid or flashing green, or solid
or flashing red. One example of LED indications for analog
inputs would be:
The two slots are joined at the rear of the chassis with a double-
wide I/O interface cable that connects both slots to common
Processor and Expander field wiring terminations. During normal operations, the
Modules may only utilize primary slot contains the active module as indicated by the
Companion Slot.
Active indicator on the front panel of the module. The secondary
slot is available for a spare module that will normally be the
standby module as indicated by the Standby indicator on the
front panel of the module.
Miscellaneous
Components
Purpose
To describe I/O field terminations and system cabling in greater
detail.
Objectives
To understand the types of I/O termination assemblies
that are available.
FTAs connect to the I/O cable by one hood which slots into the
FTA and may be locked into place, as shown in Figure 7-1. The
FTA contains fuses, resistors and other components as
appropriate, along with a set of field terminals.
Power for the field is supplied from dual 24 Vdc feeds which
are commoned via diodes on the FTA. Indication of power is
provided by a green LED.
Power for the field is supplied from dual 24V dc feeds which
are commoned via diodes on the FTA. Indication of power is
provided by a green LED.
Figure 7-5: Single Channel Schematic for Non-Incendive Digital Input FTA
Power for the field is supplied from dual 24V dc feeds which
are commoned via diodes on the FTA. Indication of power is
provided by a green LED.
Power for the field is supplied from dual 24V dc feeds which
are commoned via diodes on the FTA. Indication of power is
provided by a green LED.
Figure 7-7: Single Channel Schematic for Non-Incendive Analog Input FTA
The cable linking the 40 channels on the input module to the FTA
is terminated at the 96-way socket SK1.
Standard cables are 15 feet for internal grade and 28 feet for
external grade, but other lengths may be specified. Lengths over
15m are not recommended to minimize voltage drop,
interference and measurement error. Cables are also available
with a flying lead at one end to allow connection to conditioned
terminals.
All I/O cables are available with the cores covered by nylon
braid but no overall sheath. These are internal cables and are
suitable for mounting in trunking or cable trays inside a panel
where they are unlikely to be disturbed or damaged. Some
cables are also available with a protective sheath for most of the
cable. These cables may be mounted in floor or ceiling voids
and trays between panels. Although these are described as
external they are not armored and are not suitable for use
outside buildings or in trenches.
Companion slots are used when partner I/O modules are side by
side. Figure 7-10 shows both ends of a typical companion slot
cable. The single wide hood connects to the FTA. The double
wide hood connects to the rear of the chassis. Figure 7-11
shows a companion slot cable.
Figure 7-15 shows a typical cable for inputs. Figure 7-16 shows
a typical cable for outputs. Note the additional connections
coming from the output chassis hood to the T8290 output power
distribution unit (described in section 9).
The fiber optic units are small DIN rail mounted boxes that
accept dual power. Each unit has connectors for separate
transmit/receive single mode, fiber cables. There are no other
requirements or differences between any of the I/O modules,
expanders or chassis for remote I/O.
A total of six fiber optic units are required for each expander
chassis (three at each end), as shown in Figure 7-22.
There are no glass fibers Figure 7-19 shows a TC-303 fiber optic communications cable.
in the 302 and 303 The large hood connector on the left is metal, double-wide, and
cables. See Figure 7-22 connects to the back of an expander chassis and its expander
for more details. processor(s). The right three connectors plug into three fiber
optic TX/RX units.
TC-301
TC-302
Fiber TC-303
x6
x3 x3
Circuit
Breaker
24V
110V
White
24Vd 0V connector 0V
Circuit 0V
Breaker
24V
110V
Orange
connector
24Vd 0V
0V
0V return
Power System
Purpose
To further describe the components and functions of the power
system.
Objectives
To understand the components that make up the power
system.
The power port is an accessory that fits onto the rear of the
power shelf. It consists of a PCB fitted with connectors, relays
The alarm contacts are and miscellaneous electronic components. It converts alarm
typically wired to digital signals produced by the power packs and power shelf into volt-
input modules. free alarm contacts for use by the system.
Application Programs
Purpose
To review the steps required to open and review a project, the
dictionary, the I/O configurations and application programs.
Objectives
To be able to open projects.
Analog I/O have 12-bit resolution, although they are held within
32-bit long integers.
The text-input field on the left of the button bar can be used to
search for a variable name. The search is case insensitive.
[EDIT]
NwAddrDecimal=1
Trusted does not force you to assign I/O to these addresses. For
example, if you wish to only read (and not write to) outputs,
you could assign them to the 10,000 series addresses.
Program Cycle
Scan Execute
Inputs Programs
Write
Overhead Outputs
Click the (all) button in the dialog box that will appear, as
shown in Figure 9-11, in order to view all variable names in the
project, as shown in Figure 9-12.
The combo box in the editor toolbar can be used to select the
type of objects viewed, rather than all of them at once.
Purpose
To review the steps required to connect, load, monitor and
control applications in the Trusted controller.
Objectives
To be able to connect to Trusted.
All time values are given in milliseconds. Time values are not
displayed when debugger is used in simulation mode.
The dialog box will close From here, you may lock (force) the variable and then change
when you first click on the its state in order to see the impact in the program.
lock button and must be
re-opened to change the
variables value.
Locked inputs are shown with the input field status displayed in
parenthesis and the locked logic value displayed to its left.
Locked outputs are shown with the locked output field value
displayed in parenthesis and the logic value displayed to its left.
This will display the Locked I/O variables dialog box, as shown
in Figure 10-13. From here, you can Unlock All variables.
The lists can be stored on the disk and opened again during
other debug sessions. Different variable types, both global and
local, may be mixed in the same list. Lists are dedicated to one
particular project. A list may contain up to 32 variables,
although there is no limit to the number of lists contained in a
project. Figure 10-15 shows an example of a spy window.
Troubleshooting
Purpose
To review basic troubleshooting of the Trusted system.
Objectives
To be familiar with the fault detection capabilities of the
Trusted system.
Troubleshooting 11-1
Self Test Cycle Times
Trusted diagnostics tests occur at different intervals. Some
faults cause an immediate error. Others can take hours before
they are reported.
Each test has a set of filter values which govern when a fault is
reported. In some cases a fault is reported on its first detection.
In cases where other conditions may cause a false report, a
counter is incremented by a set number on detecting the fault. If
a later test does not detect a fault, the counter is decremented by
a different set number. If the counter exceeds a threshold, the
fault is reported as permanent, as shown in Figure 11-1.
Troubleshooting 11-3
LED Diagnostics
A steady red LED indicates that the fault has forced the system
to isolate the slice. The slice I/O hardware is powered down
Pressing the Reset (OFFLINE) and will remain so until power is removed and
button will not clear returned. No diagnostic information is available from an
this type of fault. OFFLINE slice.
LED Flowchart
Is the Processor
Yes
Inhibit LED
flashing green?
The Inhibit LED flashes green when any input or output is locked, as a
warning. This LED also flashes green when the current Standby
No Processor has an incompatible system configuration. A changeover from
the Active to the Standby processor will not work if the Inhibit LED is
flashing. In this second case, remove and reinsert the Standby processor
Next page to load the system configuration. Then open the ejectors on the Active
processor to force a hot swap.
Troubleshooting 11-5
From
previous
Page
Is the Processor
System Healthy No
LED steady
green?
The System Healthy LED is steady green when the complete
Yes Trusted system is healthy. The LED flashes red when there is a fault
in the system or the processor is not yet initialized. This may be
caused by: system boot-up, system fault, self-test fail, inter-module
The processor is healthy bus error, I/O module error, active/standby module failing to respond,
and can see no system slice error, channel fault, a module is being simulated, or a module is
faults. failing to respond.
Next page
Is the Comms
Module Healthy No
LED steady
green?
Suspected module fault. If the Healthy LED is flashing red, the
Yes module has halted. Remove and reinstall the module. If it still fails,
obtain a replacement module of a compatible build. Remove the
comms module and insert the replacement (they do not hot swap).
Return the faulty module for repair.
Are the Comms
Module Active No
and Educated
LEDs green?
Recent versions illuminate the Active LED when the application is
Yes running and illuminate the Educated LED when a configuration has
been loaded. Note that communications modules do not hot-swap, they
automatically load a new configuration without needing a reboot.
Next page
Troubleshooting 11-7
From
previous
Page
Next page
Next page
Troubleshooting 11-9
From
previous
Page
A slice of the triplicated module has been set OFFLINE and has
No been disconnected. Obtain a replacement module of a compatible
build. Change over to the replacement module. Remove the faulted
module and continue.
I/O Digital Input Modules Analog Input Module (T8431) Digital Output Modules
LED (T8403, T8423) (T8451, T8461, T8471)
Color
Off Field signal into module good Good connection Load connected, commanded off
Switch open Input signal below 3.5 Volts Output voltage ~ 0.5 Volts
No module fault No module fault No module fault
No field fault No field fault No field fault
Green Field signal into module good Good connection Load connected, commanded on
Solid Switch closed Input signal above 3.5 Volts Output voltage and current good
On No module fault No module fault No module fault
No field fault No field fault No field fault
Green Field signal into module under-range Good connection Load not connected, commanded
Flash Input signal below 0 Volts Input signal above 6.0 Volts on/off
No module fault No module fault Output voltage field supply good
Field voltage under-range Field voltage over-range No module fault
Field load not detected or too
small
Red Input signal above 36 Volts Bad FTA connection or field No field supply voltage
Flash No module fault signal too high Module fault / No module fault
Field voltage over-range Input signal greater than 10V Module field supply lost,
Module fault / No module fault check field power on module
Field voltage high or bad FTA
connection
Red Not used Not used Over-current or external voltage
Solid (may be user selectable) (may be user selectable) supplied
On Module fault / No module fault
Check field connections
Troubleshooting 11-11
Toolset Diagnostics
Fault codes for each slice are shown in decimal on the last three
channels of the HKEEPING board. The document listing all
fault codes and their meaning is on your CD. Note that fault
codes are listed in hex in this document. The Windows
calculator can be used to convert from one number format to
another.
mp:?
Troubleshooting 11-13
Figure 11-9 is an example of a processor log file.
Rather than a full processor log, one can simply poll a single
I/O module slice for its fault code using the following
procedure:
Dumptrux
Using anything other than 1) Insert the special release key to disengage the two
the plastic key can damage ejector levers on the top and bottom front faceplate of
the lever mechanism or the the module.
switches behind the levers.
2) Rotate the two ejector levers outward to fully disengage
them.
3) Hold the module and ejector levers and insert the
module into its chassis slot. The modules are self-
aligning.
4) Slide the module into the chassis and press it firmly in
place.
5) Press the two ejector levers flush with the module
faceplate.
Troubleshooting 11-15
Swapping Processor Modules
Troubleshooting 11-17
Transfer When Standby Processor Is Installed
Troubleshooting 11-19
Swapping Expander Interface Modules
Troubleshooting 11-21
Swapping Expander Processor Modules
Troubleshooting 11-23
Swapping I/O Modules
Troubleshooting 11-25
Swapping Smart Slot I/O Modules
There are two types of smart slot jumper cables, one for input
modules (DI or AI) and one for output modules (DO).
Troubleshooting 11-27
Figure 11-22: View of SmartSlot Connectors
Troubleshooting 11-29
Appendix 1
Dumptrux
Purpose
To review the use of the Dumptrux.
Objectives
To be able to use the Dumptrux utility to extract
diagnostic information from a Trusted system.
Dumptrux A1-1
Dumptrux
The Trusted system offers a wealth of diagnostic information.
The processor and I/O modules all hold their own log files
which can be used to diagnose field problems and internal
module faults.
3) Running Dumptrux
Dumptrux A1-3
5) Select Method of Communication (cont)
Dumptrux A1-5
8) Enter Your Name or Initials
Dumptrux A1-7
Once the log file is created, you will be prompted for a
confirmation, as shown in Figure A1-9. Click the OK
button.
Dumptrux A1-9
Appendix 2
Puzzles
Purpose
To review and reinforce the material.
Objectives
To remember the names of Trusted hardware and
software components.
Puzzles A2-1
Crossword Puzzle for Day 1 of Trusted Classes
1 2 3
4 5
6 7 8
9 10 11
12
13 14 15
16 17
18
19 20 21
22
23 25
24
Across
1) Status indicators
3) Internal system bus
5) Spare module arrangement where a single slot can be used for multiple module types
6) Expander ___ modules are located in expander assemblies
9) Power ___
11) Spare module arrangement where adjacent modules share the same function
12) Keyswitch position
13) Trusted is a fault ___ system
14) Triple ___ Redundant
16) Pushbutton on the processor
20) Keyswitch position
22) What modules plug in to
23) A common protocol used to communicate with other systems
24) Most circuits in Trusted are ___
Down
2) What a processor needs to be before it can become active
3) Expander ___ modules are located in controller assemblies
4) Switches used to set chassis number
7) Triple Modular ___
8) The assembly where the main processor is located
10) Acronym for assemblies that interface to field devices
15) Trusted has extensive ___
17) Not a controller assembly, but an ___ assembly
18) What output modules dont need
19) Acronym for Random Access Memory
21) A module that is not active is in ___
25) 4-20mA field circuits come in to what sort of input module?
Puzzles A2-3
Crossword Puzzle for Day 3 of Trusted Classes
1 2
3 4 5 6
7 8 9
10
11
12 13
14
15 16
17
18
Across
3) The name used in the Toolset for forcing
4) A group of programs make up an ___
7) I/O modules can detect ___ circuits
10) Variables that can only be used within one program
11) I/O and global variables must be defined in the ___
12) I/O modules can detect ___ circuits
14) Input modules can be configured to respond to specific voltage levels using the ___
template
15) The number of configurable voltage levels for an input module
16) Programs can be tested on a PC using the ___
17) The programming environment is called the Trusted ___
18) The operation of I/O modules (in terms of voltage thresholds and LED operation) is
defined using ___
Down
1) What programs must be before they are downloaded
2) Another name for bit variables
5) There are six programming ___ available in the Toolset
6) I/O tag names are associated with their physical location using the I/O ___ editor
8) The initialization file is created in the System ___ Manager
9) Variables that can be shared between programs
13) The name of the system
16) The initialization file that is downloaded into the controller has a default name of
___.ini
Puzzles A2-5