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AADvance System

PD Digital Output

AADvance System
Product Description
Digital Output

Number: 553558
Issue: 1.0
Date: 10 June 2008

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PD553558 Digital Output

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PD Digital Output

Digital Output
Introduction
The Digital Output interface consists of a combination of Digital Output Modules and Digital Output
Termination Assemblies.
Each Digital Output Module is an 8 channel isolated module which plugs into a single position of the
I/O Base Unit and a matched Termination Assembly. Digital Outputs can be configured as Simplex or
Dual by selecting the appropriate Termination Assembly and the number of Digital Output modules.
Termination Assemblies provide termination for input channels and mate with a Digital Input Module.
The field connections are made at the marshalling terminals, then to the terminal bock connectors on
the Termination Assembly.
The modules covered by this Product Description are:

9451 Digital Output Module, 24V DC, 8 Channel

9851 Digital Output Termination Assembly, 8 Channel, Simplex

9852 Digital Output Termination Assembly, 8 Channel, Dual

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Issue Record
Issue
Number

Date

Revised
by

Technical Check

Authorised by

9th June
2008

SB/RMG

Nick Owens

P. Stock

Modification

Copyright 2008 by ICS Triplex Technology Ltd.


All rights reserved. No part of this publication may be reproduced, or stored in a database or retrieval
system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording,
or any other media, without the prior written permission of ICS Triplex Technology.

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Disclaimer
This document is based on information available at the time of its publication; however, the document
contents are subject to change from time to time. After each update and release a new issue number
is recorded in the Issue Record page and is also shown at the foot of each page. The reader should
contact ICS Triplex Technology Ltd. Technical Support via e-mail (support@isctriplex.com) to check if
you have the latest version of this publication.
The information contained in this publication does not intend to cover every possible detail about the
installation, operation, or maintenance of a control system installation. The reader should refer to their
own (or supplied) system safety manual, installation instructions, and operator/maintenance manuals.

Precautionary Information
WARNING
Warning notices call attention to the use of materials, processes, methods, procedures or limits which
must be followed precisely to avoid personal injury or death.
CAUTION
Caution notices call attention to methods and procedures which must be followed to avoid damage to
the equipment.
NOTES
Notes point out to users important facts about the product.

WARNING
MAINTENANCE
MAINTENANCE MUST BE PERFORMED ONLY BY QUALIFIED PERSONNEL, OTHERWISE
PERSONAL INJURY OR DEATH, OR DAMAGE TO THE SYSTEM MAY BE CAUSED.

CAUTIONS
The module PCBs contains static sensitive components. Static handling precautions must be
observed. DO NOT remove the module housing or touch exposed connector pins. Return any
damaged units to your supplier.
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.

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Table of Contents
INTRODUCTION ......................................................................................................................................3
1. ARCHITECTURE ................................................................................................................................8
1.1. Simplex ........................................................................................................................................8
1.2. Dual .............................................................................................................................................8
1.3. Triple ............................................................................................................................................8
1.4. Digital Output Configuration ........................................................................................................9
1.5. Recommended Digital Output Field Loop Circuits ......................................................................9
1.5.1. Digital Output (Simplex or Dual) Field Loop Circuit ..........................................................9
2. 9451 DIGITAL OUTPUT MODULE ...................................................................................................10
2.1. 9451 Hardware ..........................................................................................................................11
2.2. Part Number ..............................................................................................................................11
2.3. Technical Overview ...................................................................................................................12
2.4. Installation Procedure................................................................................................................13
2.5. Module Set-Up and Configuration Data ....................................................................................13
2.6. Trouble Shooting _ About Fault Indications ..............................................................................13
2.6.1. Module Faults ..................................................................................................................14
2.6.2. Channel Faults ................................................................................................................14
2.6.3. System Faults..................................................................................................................14
2.6.4. Field Faults ......................................................................................................................14
2.6.5. User Application Fault Indications and Logging..............................................................14
2.6.6. Digital Output Module Status Indications ........................................................................15
2.7. Repair ........................................................................................................................................16
2.8. Maintenance ..............................................................................................................................16
2.9. Specifications.............................................................................................................................16
3. DIGITAL OUTPUT 8 CHANNEL TERMINATION ASSEMBLIES .....................................................18
3.1. Introduction ................................................................................................................................18
3.2. Description.................................................................................................................................19
3.2.1. Hardware .........................................................................................................................19
3.2.2. Part Numbers ..................................................................................................................20
3.2.3. Replacement Parts..........................................................................................................20
3.2.4. Technical Overview .........................................................................................................21
3.3. Installation Procedure................................................................................................................22
3.3.1. Field Connections............................................................................................................23
3.3.2. Set-up and Configuration ................................................................................................24
3.4. Servicing ....................................................................................................................................24
3.4.1. Trouble Shooting .............................................................................................................24
3.4.2. Repair Procedure ............................................................................................................24
3.5. Specifications.............................................................................................................................25

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Figures
Figure 1 Simplex Configuration ................................................................................................................8
Figure 2 Example Dual Configuration ......................................................................................................8
Figure 3 Example TMR Configuration ......................................................................................................9
Figure 4 Digital Output Field Loop Circuit ................................................................................................9
Figure 5 9451 Digital Output Module Front Panel View......................................................................11
Figure 6 9451 Block Functional Diagram ...............................................................................................12
Figure 7 9851 Simplex Digital Output Termination Assembly................................................................19
Figure 8 9852 Dual Digital Output Termination Assembly .....................................................................20
Figure 9 9851 Simplex Output Connections ..........................................................................................21
Figure 10 9852 Dual Output Connections..............................................................................................22
Figure 11 Termination Assembly Installation .........................................................................................23
Figure 12 Digital Output Termination Assembly Field Wiring ................................................................24

Tables
Table 1 Part Number ..............................................................................................................................11
Table 2 Installation Procedure................................................................................................................13
Table 3 Module Status Indications .........................................................................................................15
Table 4 Digital Output Module Specifications ........................................................................................17
Table 5 Termination Assembly Part Numbers .......................................................................................20
Table 6 Replacement Part Numbers ......................................................................................................21
Table 7 Termination Assembly Installation Procedure..........................................................................23
Table 8 Trouble Shooting .......................................................................................................................24
Table 9 Repair Procedure ......................................................................................................................25
Table 10 Digital Output Termination Assembly Specifications ..............................................................26

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1. Architecture
The system architecture allows a scalable system to be configured using standard modules. Modules
and processors can be configured in Simplex, Dual or Triple arrangements, although output modules
are normally Simplex or Dual. Input and Output modules meet SIL 3 requirements as a single module
but are fitted in multiples to provide fault tolerance. Two Processor Modules must be fitted to achieve
SIL 3 and, if one of the Processors fails, then it must replaced within the Mean Time To Repair
(MTTR).

1.1. Simplex
An example configuration is shown in Figure 1. Each module will fail safe on the first detected fail
danger fault and the process will shutdown.

Figure 1 Simplex Configuration

1.2. Dual
An example configuration of dual input module and processor and single output module is shown in
Figure 2. An input module and/or processor will degrade to 1oo1D on first detected fail danger fault.
The processor must be replaced within the Mean Time To Repair (MTTR). An output module will fail
safe on first detected danger fault.

Figure 2 Example Dual Configuration

1.3. Triple
The configuration in Figure 3 shows triple input and processor and fault tolerant output. The input
modules and/or the processors will degrade to 1oo2D on the first module fault with no time limit to
repair. The input modules will degrade to 1oo1D on a second module fault with no time limit to repair.
The processor modules will degrade to 1oo1D on second module fault and must be replaced within
the MTTR.
The output modules will degrade to 1oo1D on first detected fail danger fault. The faulty module must
be replaced within the MTTR.

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Figure 3 Example TMR Configuration

1.4. Digital Output Configuration


Dependent upon the Termination Assembly installed, you can fit up to two output modules in a
Simplex or Dual.
A Simplex Output Module will fail safe on the first detected fail danger fault.
A Dual arrangement provides Output Module fault tolerance .

1.5. Recommended Digital Output Field Loop Circuits


The field loop circuit for a Digital Output is shown in Figure 4.

1.5.1. Digital Output (Simplex or Dual) Field Loop Circuit

Figure 4 Digital Output Field Loop Circuit

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2. 9451 Digital Output Module


The 9451 24Vdc Digital Output Module has a flexible and fail-safe design with eight field output
channels. Each field device connected to the Output Module provides the 24Vdc field supply. The
module output can be up to 1A continuous for each device.
Dependent upon the Termination Assembly (9851 or 9852) installed you can fit one or two output
modules in a simplex or dual configuration. This provides a choice of a simple I/O output or a fault
tolerant I/O output configuration that can support a SIL3 level safety application.
The Output Module carries polarised key sockets, which mate with complementary pins located on the
Termination Assembly. The sockets and pins ensure only an Output Module can be connected to a
designated Termination Assembly

Features
8 isolated output channels per module
Fail-safe design and operation
Suitable for simplex and dual redundant connections for fault tolerant applications
Independent galvanically isolated system input commands and response signals
Dual series output switches with overload protection in each channel
Voltage and current monitoring on each channel and reverse current protection

Short circuit and open circuit line fault detection for on and off channels
Dual redundant field power feed capabilities without the need for external diodes
Module replacement in the dual configuration without live system interruption or relearning

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2.1. 9451 Hardware
The 9451 Digital Output Module (shown in Figure 5) is a 110 x 155 x 42 mm module enclosed in grey
flame-retardant plastic. The module is mounted onto an I/O Base Unit and a Termination Assembly,
where it is held in position by a locking screw, accessible from the front panel. The front panel of the
module carries a set of LEDs, by which the operator can determine the health of the Output Module
itself and the channels it controls.

Figure 5 9451 Digital Output Module Front Panel View

2.2. Part Number


Use the following part number and description to order a replacement module.
Part Number
9451

Description
24Vdc Digital Output Module, 8 Channel
Table 1 Part Number

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2.3. Technical Overview

Figure 6 9451 Block Functional Diagram


Refer to Figure 6. The field output channel is controlled by two independent data management and
output control FPGAs. The field output circuitry is galvanically isolated from the processor input
commands and response lines by an Isolated Interface circuit. This architecture protects the system
processors from faults in the modules output control circuits and possible field device faults.
Module power is produced by the internal isolated power supply, supplied by the Dual Redundant
system power inputs. Over- and under-voltage protection is applied to the module internal power
supply outputs.
Command packets are received from the processor module via a serial link. The FPGAs decode and
vote the output data addressed to them and set the output FET switches accordingly. The output
voltages are produced from the 24Vdc field power input voltages by a Power Combiner circuit. Each
output channel has a pair of FET switches arranged in series that are independently controlled. Load
current and voltage monitoring from the IMON and VMON circuits is provided for each switch. An
output channel protection circuit switches off the output when the channel load current exceeds a safe
limit.
A reverse voltage protection circuit, shown in the diagram being driven from the lower of the two
FPGAs, ensures that externally applied voltages to any output channel do not generate current flow
backwards into the module outputs.
In dual redundant mode, the two fail-safe output switches per channel are combined in a parallel
arrangement so that they automatically form a fault-tolerant output configuration. In this configuration,
removal and replacement of an output module is possible without any disruption to a live system.

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The module has a range of self-checking functionality. Short circuit and open circuit line monitoring is
provided on all outputs. In addition, the 9110 Processor Module initiates a test sequence on each
output channel, checking for stuck-on and stuck-off conditions on the output switch pairs.
Internal diagnostics carry out ongoing functionality checks, ensuring that the output channel command
data is correctly transferred to the output. A visual display of the module health and individual channel
status is provided on the front panel LEDs.

2.4. Installation Procedure


To install a module follow the procedure in Table 2.

Step

Task

1.

Check the polarisation keys on the module match the ones on the Termination
Assembly.

2.

Insert the I/O Module on to the Base Unit and Termination Assembly connectors and
push the module downwards until the connectors are fully mated.

3.

Turn the locking pin on the module front panel to the lock position.

4.

The I/O Module will now enter the start up sequence during which the module will
educate and provide the following status indications:

5.

Healthy

Flashing green (may be momentary)

Ready

Flashing green (may be momentary)

Run

Off

Channel 1 - 8

Off

If the module start-up sequence does not start automatically. Press the Fault Reset
button on the Processor Module(s).
Note: An automatic start-up command can be set-up in the application software.

6.

7.

The start up sequence will complete and the I/O Module will go on-line with the following
status indications:
Healthy

Green

Ready

Green

Run

Green

Channel 1- 8

Dependent on channel status

If the module fails to educate and go on-line, refer to the Trouble Shooting Section.
Table 2 Installation Procedure

2.5. Module Set-Up and Configuration Data


There is no requirement to configure the Digital Outputs from the Workbench toolset.

2.6. Trouble Shooting _ About Fault Indications


Faults are indicated by front panel LEDs and fault codes reported in the System Event Log. Faults
can also be reported provided by the application program, sourced from system variables or I/O
connection points available to the application.
Faults are classified as follows:

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2.6.1. Module Faults
A Module fault is indicated when a detected fault is isolated to the hardware of a specific module. The
Healthy LED turns red on the faulty module and, if it is an I/O module that is faulty, then the System
Healthy LED on the processor also turns red.

2.6.2. Channel Faults


A Channel fault is indicated when a detected faulty channel is isolated to a hardware fault on a
specific channel of a single I/O module. All channel faults are also reported as a module fault. This
means that the Channel LED will go red, the I/O module Healthy LED will go red and the System
Healthy LED on the Processor Module will also show red.
NOTE: If redundant processors are fitted then the System Healthy LED on all three processors will
simultaneously go red.

2.6.3. System Faults


A System fault is indicated when a detected fault cannot be isolated to a single module (i.e. could
therefore be a bus failure or backplane fault) or the fault is not the result of a hardware failure that
needs a module replacement (e.g. a software fault, calibration drift, etc.). When this type of fault
occurs in the system, only the System Healthy LED on the processor(s) will turn red.

2.6.4. Field Faults


A field fault is indicated when a detected fault condition is isolated to a field condition or field device
and the cause is not the hardware associated with the channel or output module. Examples are
an.open circuit field connection, no field power, or an out-of-range signal. These faults are indicated
by a Channel LED turning amber.

2.6.5. User Application Fault Indications and Logging


System variables or I/O connection points are available to the user application to indicate fault status.
The information available includes:
Module operational mode (i.e. OFF-LINE or ON-LINE)
An echo of the front panel indicators for each module
The total number of faults displayed
Fault codes for each fault recorded
Note: The actual fault indications available will depend on the application program.
The System Event Log will log fault codes. You can use the Workbench to view the fault codes in the
System Event Log Each entry in the log includes a fault code and is classified as a FAULT or
ERROR.

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2.6.6. Digital Output Module Status Indications
The module front panel LED indications are described in Table 3.
Indicator

Healthy

Status

Description

Provides an indication of the modules fault status and power-on


status.
OFF
RED

No power
Power-up/reset in progress
Processor is ON-LINE with a module fault
present
Processor is OFF-LINE

Ready

GREEN

I/O module is ON-LINE with no module faults


present

Flashing
GREEN

Start-up is in progress

Provides an indication of the modules education and synchronisation


status.
OFF

No power
Power-up/reset in progress
Processor is OFF-LINE

Run

RED

Module is not educated or synchronized with


partner I/O module(s)

GREEN

Module is educated and synchronized with partner


I/O Module(s)

Flashing
GREEN

Education and/or synchronisation is in progress

Provides an indication of the modules operational status


OFF

No power
Power-up/reset in progress
Module is OFF-LINE

RED

Module is not educated/synchronised


Module is not being driven by or reporting
values to the user application

GREEN
Channel 1 8

Module is reporting values and being driven by the


user application.

Provides an indication of the status of each digital input channel.


OFF

Input is OFF-LINE

RED

Channel fault(s) present

GREEN

Channel input is ON

AMBER

FIELD fault present


Table 3 Module Status Indications

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2.7. Repair
This module cannot be repaired. It must be replaced.

2.8. Maintenance
This module requires diagnostics tests to be run at specified intervals. These tests are generated by
the application running the controller.

2.9. Specifications
Attribute

Value

Electrical Specification
Number of Output Channels

Channel Isolation (channel to channel and


channel to chassis):
Sustained Working

250Vdc

Maximum Withstand

1.5kV dc

Output Voltage
Operating field supply voltage

0 to +50Vdc

Maximum voltage without damage

1 to +60Vdc

Nominal Range

18 to 36Vdc

Output Current

1A continuous

Output Off Resistance (effective leakage)

50k

Output Channel Equivalent On Resistance

400m

Voltage Monitoring Accuracy

0.5Vdc

Current Monitoring Accuracy

10mA

Minimum Required Load For No-Load Detection

5k

Power Consumption

<2W (from system 24V supply)

Sample Update Interval (no filter)

1ms

Self-Test Interval

1 application scan period

Output Overload Protection


Surge

10A for 50ms

Continuous

1.5A

Fusing

10A per 24V field power feed

Intrinsic Safety

Fails Safe

Circuit Type

1oo1D, 1oo2D

Mechanical Specification
Dimensions (H x W x D)

162mm x 45mm x 120mm

Weight

290g

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Attribute
Casing

Value
Plastic, non-flammable

Environmental Specification
Temperature:
Operating

20C to 70C

Storage and Transport

40C to 70C

Humidity
Operating

10% to 95% RH, non-condensing

Storage and Transport

10% to 95% RH, non-condensing

Vibration
Functional Stress

5Hz to 9Hz

Continuous

1.7mm amplitude

Occasional

3.5mm amplitude

Withstand
Acceleration
Endurance
Acceleration
Shock

10Hz to 150Hz
0.1g in 3 axes
10Hz to 150Hz
0.5g in 3 axes
15g peak, 11ms duration, sine

Altitude
Operating

0 to 2000m

Transport

0 to 3000m
This equipment must not be transported in
unpressurised aircraft flown above 3000m

EMI

The modules are designed to meet EN50081/82


and EN55011/55022
Table 4 Digital Output Module Specifications

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3. Digital Output 8 Channel Termination Assemblies


3.1. Introduction
There are two types of Digital Output Termination Assembly.

A 9851 Simplex Termination Assembly that provides termination for 8 isolated digital
output channels and mates with a single 9451 Digital Output Module. This arrangement
provides a 1oo1D output.

A 9852 Dual Termination Assembly that provides termination for 8 isolated digital output
channels and mates with two 9451 Digital Output Modules. This arrangement provides a
1oo2D output.

FEATURES
A 9851 or 9852 Termination Assembly has the following features:
Provides connections for 8 output channels
Industry standard field device connections
24Vdc operation
Provides a fused field voltage supply to the module

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3.2. Description
3.2.1. Hardware
The 9851 Simplex Termination Assembly (Figure 7) simply routes 8 digital output channels from the
module connector to the field connections at the terminal blocks.
The 9852 Dual Termination Assembly (Figure 8) routes, in parallel, the 8 digital output channels from
the two module connectors to the field connections at the terminal blocks.
The 24V dc field voltages VFIELD 1 and VFIELD 2, used by the output module for the output field
voltages, are connected at the terminal blocks and routed via two replaceable 10A fuses, F1 and F2.
The fuse cover should be closed during normal operation.

Figure 7 9851 Simplex Digital Output Termination Assembly

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Figure 8 9852 Dual Digital Output Termination Assembly

3.2.2. Part Numbers


Use the part numbers and descriptions listed in Table 5 to order a replacement Termination Assembly.
Part Number

Description

9851

Simplex 8 Channel Digital Output Termination Assembly

9852

Dual 8 Channel Digital Output Termination Assembly


Table 5 Termination Assembly Part Numbers

3.2.3. Replacement Parts


The only serviceable parts on this module are the fuses. To order fuses use the part numbers listed in
Table 6.

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Part Number
3AV201

Description
FS SMF Omni-Block Fuse Holder + 10A Fuse
Table 6 Replacement Part Numbers

3.2.4. Technical Overview


The 9851 Digital Output 24Vdc Simplex Termination Assembly provides termination for 8 output field
connections. It mates with a single 9541 Digital Output Module. The Termination Assembly simply
routes the module output channels from the module connector to the field connection at the terminal
blocks.
The 9852 Digital Output 24Vdc Dual Termination Assembly provides termination for 8 output field
connections. It mates with two 9541 24Vdc 8 Channel Digital Output Modules. The Termination
Assembly routes, in parallel, the 8 output channels from the module connectors to the field connection
terminal blocks.
The 24Vdc field voltages VFIELD 1 and VFIELD 2, used by the output module for the output field
voltages, are connected at the terminal blocks and routed via two replaceable 10A fuses, F1 and F2.
These fuses give protection for the output module against field faults. Field 0V (VFIELD RTN) is also
routed from the output module connector(s) to the terminal block.

Figure 9 9851 Simplex Output Connections

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Figure 10 9852 Dual Output Connections

3.3. Installation Procedure


The installation of a Termination Assembly is shown in Figure 11. To install a Termination Assembly
follow the procedure in Table 7.

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:
Figure 11 Termination Assembly Installation

Step

Task

1.

Insert the retaining clip on the rear of the Termination Assembly into the
slot of the I/O base unit.

2.

Press and slide the Termination Assembly upwards as far as it will go.

3.

Ensure the plastic retaining tab clips over the TA circuit board to secure the
Termination Assembly in position.
Table 7 Termination Assembly Installation Procedure

3.3.1. Field Connections


The field connections to both the 9851 and 9852 Termination Assembly are the same and are shown
in Figure 12.

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Figure 12 Digital Output Termination Assembly Field Wiring

3.3.2. Set-up and Configuration


The Termination Assembly does not require any set-up or configuration.

3.4. Servicing
3.4.1. Trouble Shooting
The trouble shooting procedure is shown in Table 8.

Step

Task

1.

A ruptured field supply feed fuse will be indicated on the I/O module Channel LEDs.

2.

Investigate the cause of the field supply feed excess current.

3.

Repair the field supply feed and replace the ruptured fuse.
Table 8 Trouble Shooting

3.4.2. Repair Procedure


The fuse can be changed with the Termination Assembly still installed and you do not need to remove
it.The repair procedure is shown in Table 9.

Step

Task

1.

Lift the plastic cover that covers the fuse.

2.

Using a fuse removal tool, lever the fuse out of the fuse holder and replace with a new fuse.

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3.

Refit the plastic cover.


Table 9 Repair Procedure

3.5. Specifications
The specifications for both the 9851 and 9852 Termination Assemblies are shown in Table 10.

Attribute

Value

Electrical Specification
Number of Output Channels

8 Channels

Number of modules supported


9851

One

9852

Two

Supply voltage

Redundant 24Vdc nominal, 18 to 36Vdc.

Supply fuses

10A for each supply

Output current

1A continuous for each channel

Mechanical Specification
Dimensions (H x W)
9851

132mm x 42mm

9852

132mm x 84mm

Environmental Specification
Temperature:
Operating

20C to 70C

Storage and Transport

40C to 70C

Humidity
Operating

10% to 95% RH, non-condensing

Storage and Transport

10% to 95% RH, non-condensing

Vibration
Functional Stress

5Hz to 9Hz

Continuous

1.7mm amplitude

Occasional

3.5mm amplitude

Withstand
Acceleration
Endurance
Acceleration
Shock

10Hz to 150Hz
0.1g
10Hz to 150Hz
0.5g
15g peak, 11ms duration, sine

Altitude
Operating

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Transport

0 to 3000m
This equipment must not be transported
in unpressurised aircraft flown above
3000m

EMI

Designed to meet EN50081/50082 and


EN55011/55022
Table 10 Digital Output Termination Assembly Specifications

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ICS Triplex technologies and services are available worldwide.


Regional Headquarters:
Americas:
4325 West Sam Houston
Parkway North, Suite 100
Houston
Texas 77043-1219
USA
Tel: +1 713 353 2400
Fax: +1 713 353 2401
Europe, ME & Africa:
Hall Road
Maldon Essex
CM9 4LA
UK
Tel: +44 1621 854444
Fax: +44 1621 851531
Asia Pacific:
Unit 2/12 Keegan Street
OConnor
Western Australia
Tel: +61 89 314 7787
Fax: +61 89 314 7786

www.icstriplex.com
For technical support email: support@icstriplex.com
Sales enquiries: sales@icstriplex.com

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