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Technical Application Note #46, Revision 1

Subject: Remote I/O Communication for Trident/Tri-GP Systems using


Hirschmann OZD 485 G12 PRO (with Triconex Firmware)

Affected Products
All versions of Trident and Triconex General Purpose (Tri-GP) systems

Introduction
This Application Note explains how to set up remote I/O communication for Trident and
Tri-GP controllers using Hirschmann fieldbus repeaters (model OZD 485 G12 PRO with
Triconex firmware) and fiber-optic cables. Remote I/O communication is required if the
distance between the primary and remote I/O locations is greater than 650 feet (200
meters ), but not more than 4,000 feet (1.2 kilometers). For distances between 4,000 feet
(1.2 kilometers) and 62 miles (100 kilometers), you must use the Triconex Peer-to-Peer
protocol.

Any Trident/Tri-GP installation which includes two or more vertical columns of I/O modules
must use I/O Extender Modules and I/O bus cables to connect the columns. The Extender
Modules and cables carry I/O messages from one column to another and supply logic power
connections for each column. The standard I/O bus is made of copper wire, which limits its
length to 650 feet (200 meters). The total length of an I/O bus (column) includes the
length of all baseplates, Extender Modules, and I/O bus cables.

The data transmission rate is 2 megabits per second, whether you are using the standard
I/O bus or fiber-optic cables.

For general instructions on installing and configuring a Trident/Tri-GP controller, see the
appropriate Planning and Installation Guide.

For detailed information about the Hirschmann repeaters described in this Application Note,
see the Hirschmann document Startup Informations OZD 485 G12 PRO with Triconex F/W.
To obtain a copy of this document, contact Invensys Global Customer Support (GCS).

Required Hardware

Trident/Tri-GP remote I/O communication requires Triconex hardware, Hirschmann


hardware, and fiber-optic cabling, as well as redundant 24-volt logic power supplies and
termination resistors.

Invensys Global Customer Support (GCS) Center +1-866-746-6477 (toll-free, US & Canada)
http://support.ips.invensys.com +1-508-549-2424 (worldwide)

Technical Application Note 46 February 8, 2012 Part No. 9791005-46, Rev. 1


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Triconex Hardware

The Hirschmann OZD 485 G12 PRO with Triconex F/W is only compatible with Trident
systems v1.2 and later, and Tri-GP systems v2.1 and later. If you have a Trident v1.1
system, and would like to install the Hirschmann OZD 485 G12 PRO with Triconex F/W in
your system Invensys recommends upgrading to Trident system v1.2 or later.

Table 1 lists the Triconex hardware required for Trident/Tri-GP remote I/O communication.

Triconex
Model/Part Description
Number

2291 I/O Extender Module kit for IO baseplate (with terminators)

2292 I/O Extender Module kit for MP baseplate (with terminators)

3000678-100 I/O Extender Module

2921 I/O Interconnect Assembly

2296-6 Set of six Hirschmann repeaters and six 2-ft fanned-out cables

2296-1 Set of one Hirschmann repeater and one 2-ft fanned-out cable

3900064-003 Set of three terminating resistors

Table 1 – Triconex Hardware Model/Part Numbers

A typical remote I/O configuration has one column in the primary location and one I/O
column in the remote location, as shown in Figure 3 on page 8. In the example shown in
Figure 3, you must use the following parts (in addition to the MP, CM/CIM, and I/O
hardware):

Triconex
Qty Description
Model/Part Number

1 2292 I/O Extender Module Kit for MP baseplate

3 2291 I/O Extender Module Kit for I/O baseplate

2 3000678-100 I/O Extender Module

2 2921 I/O Interconnect Assemble

1 2296-6 Hirschmann Repeater Kit with Fanned Out Cables

Table 2 – Hardware Model/Part Numbers for One Remote I/O Drop as Shown in Figure 3
Components of an I/O Extender Module
Each I/O Extender Module includes the following components:

• Three DB-9 pin I/O bus connectors, one per channel.

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• Two 24-volt logic power input terminal blocks, each with fuse and blown-fuse indicators.

• One protective earth terminal block.

Hirschmann Hardware

Remote I/O communication with a single I/O location requires six Hirschmann Fiber Optic
Fieldbus Repeaters (model OZD 485 G12 PRO with Triconex F/W). The primary location and
the remote location each require three repeaters to carry signals for I/O channels A, B, and
C across triplicated fiber-optic cables.

Hirschmann repeaters can be ordered using either Triconex model number 2296-6 (a kit
containing six repeaters and six fanned out cables) or 2296-1 (a kit containing one
repeater and one fanned out cable).

Figure 1 depicts the screw terminals for the 24V power, the switches, the screw terminals
for the RS-232 cable (Port 1), and the fiber-optic connector (Port 2) on the front panel of a
Hirschmann repeater. Note that the Analog Voltage Output screw terminal is not used for
the Trident/Tri-GP application.

Front Panel of the


Hirschmann Repeater

Connect to 24V
power supply
h HIRSCHMANN

System

P1 P2
LED indicators
1 2
DA/ STAT
0 1
S1
S2
S3
S4 Switch
RT+
K1+
K1+
K1-
IN Four of these screw
K1-
RT- Port 1 terminals connect to
RT- the Triconex Fanned
K 2-
K 2- Out cable to the
OUT
K 2+
K 2+ repeater
RT+

Ua2 Analog Voltage


GND
Ua3 Outputs – Not
Used

OZD 485 G 12 TRI This connector


Port 2 attaches the repeater
to the fiber-optic cable .
There is one for TX and
one for RX.

Figure 1 – Hirschmann Repeater Front Panel

Figure 2 depicts the screw terminals for the 24V power, the screw terminals for the RS-232
cable (Port 1), and the fiber-optic connector (Port 2) on the side panel of a Hirschmann

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repeater. Note that the Hirschman has a third port (Port 3), but it is not used for the
Trident/Tri-GP application.

Side Panel of the


Hirschmann Repeater

7-pin terminal block


to connect the two
24V power supplies

Four of these screw


terminals connect to Port 1
the Triconex Fanned
Out cable to the
repeater

Analog Voltage
Outputs – Not
Used

Port 2 Port 3
Attaches the repeater (unused)
to the fiber-optic cable.
There is one for TX and
one for RX.

Figure 2 – Hirschmann Repeater Side Panel

For detailed information, see the Hirschmann document Startup Informations OZD 485 G12
PRO with Triconex F/W.

Guidelines for Fiber-Optic Components

The selection and installation of fiber-optic components requires specialized knowledge,


training, and tools. In the United States, Canada, and Western Europe, fiber-optic
components are widely used in the telecommunications industry and are sold by many
vendors. Invensys recommends that, whenever possible, the services of a qualified vendor
be used for the selection and installation of fiber-optic cabling.

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Main Fiber-Optic Cable

For Trident/Tri-GP remote I/O communication, Invensys recommends using standard multi-
mode fiber-optic cables with ST connectors.

Vendors offer several types of cable core and sheath designs. Selection of the cable sheath
must be based on the physical and environmental requirements of the application. Indoor
cable is available for general usage, riser applications, and plenum applications. Outdoor
cable is available for cable tray, aerial, underground, directly buried, or underwater uses.
Outdoor cable with protective over-sheath coverings for lightning and rodent protection is
also available.

A Trident/Tri-GP configuration requires a total of six fibers (two per channel) between the
primary and remote locations. If you use a single cable, you should select a cable with six
main fibers plus spare fibers.

For critical applications, where loss of communication to the remote I/O column cannot be
tolerated and the physical integrity of the fiber-optic cables cannot be assured, use a
separate cable for each channel. In this case, a total of three main cables are required,
each having two main fibers plus spare fibers. For additional protection, route each cable
that runs between a primary I/O column and a remote I/O column along a different path.

In all cases, Invensys recommends installing cables with spare fibers. The cost of spare
fibers in a cable is small compared to the cost of installing a new cable if a single-fiber
cable is accidentally damaged.

Note: Invensys does not supply fiber-optic cables. You must make arrangements with local
vendors to purchase the cables. Make sure you follow the specifications described in
this document before purchasing the cables.

Junction Boxes

A junction box is typically used to terminate each end of the main fiber-optic cable. Each
fiber in the cable must be individually mated to an ST connector.

The type of junction box and the mounting location depends on the requirements of the
application.

Jumper Cables

A general-purpose jumper cable is used with ST connectors on each end to make


connections between the junction box and the Hirschmann fiber-optic repeaters.

ST Connectors

Twelve ST connectors are required for each primary-remote connection. Connectors should
be the bayonet type with a ceramic tip plug.

Logic Power Supplies

Invensys recommends that you power the Hirschmann repeaters using the Trident/Tri-GP
logic redundant power supplies.

If separate power supplies are required, Invensys recommends two 24-volt DC power
supplies for each location where the Hirschmann repeaters are located.

All logic power supplies must be referenced to the Trident/Tri-GP signal ground reference.

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Setting Up a Remote I/O Configuration

This section provides the following information about setting up a Trident/Tri-GP remote
I/O configuration.

• Safety Guidelines on page 6

• Configuration Rules on page 6

• Installation Rules on page 7

• Guidelines for Installing Hirschmann Repeaters on page 8

• Typical Remote I/O Configurations on page 8

• Hirschmann Repeater Wiring Example on page 11

• Connecting a Fanned-out Adapter Cable on page 12

• Configuring a Hirschmann Repeater on page 14

• Recommended Procedure for Installation, Configuration, and Power Up on page 14

Safety Guidelines

For maximum safety, you must use Hirschmann repeaters only in the manner described in
this document and in the Hirschmann document Startup Informations OZD 485 G12 PRO
with Triconex F/W.

You should install Hirschmann repeaters only in locations that comply with the
environmental specifications described in the Hirschmann document and in the
Trident/Tri-GP Planning and Installation Guide.

The power supplies used with Hirschmann repeaters and Trident/Tri-GP I/O columns should
provide +24 volts DC. Refer to Startup Informations OZD 485 G12 PRO with Triconex F/W
and the Trident/Tri-GP Planning and Installation Guide for power supply specifications.

Configuration Rules

Every Trident/Tri-GP installation must include a Main Processor baseplate with three Main
Processor modules and may include a Communication baseplate with one or two
Communication Modules.

As an example, Trident system v1.5 supports up to 25 I/O baseplates, with a maximum of


13 Analog Input modules. You must use TriStation 1131 v4.0 or later to configure up to 25
I/O baseplates.

If Analog Output (AO) or Pulse Input (PI) modules are used, Trident system v1.5 is
restricted to five AO and five PI modules, with a maximum of 15 baseplates of other types
of I/O modules.

Refer to the latest Trident/Tri-GP Product Release Notice for details on the maximum
number of baseplates a specific Trident/Tri-GP system supports. Product Release Notices
are available on the Invensys Global Customer Support website.

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Installation Rules

The following rules apply to a Trident/Tri-GP controller that is configured for remote I/O
communication using Hirschmann repeaters and fiber-optic cables:

• The installation must comply with general Trident/Tri-GP rules for the maximum
number of baseplates and I/O modules described in the Product Release Notice and
the Planning and Installation Guide. Both of these documents may be found on the
Invensys Global Customer Support website.

• All modules connected to the Trident/Tri-GP primary or remote I/O bus (this
includes the Hirschmann’s) must be contained within a metal cabinet or multiple
metal cabinets connected by metal conduits. Note: This requirement is specifically
stating that all RS-485 I/O cables must be contained within the cabinet or in a
separate metal conduit. Only the I/O bus Fiber Optic cabling, power, I/O field and
communications cabling should enter/exit the cabinet.

• The Trident/Tri-GP remote I/O configuration has been tested and validated for a
maximum of one primary location and four remote locations in a star configuration.
Each remote location must originate from the primary location. If your application
requires more than four remote locations, please contact Invensys Global Customer
Support for assistance.

• A location can include one or more columns of baseplates. A string consists of one
or more columns in a given location.

o For the primary location, the total length of the I/O bus, including the length
of the columns, cannot exceed 328 feet (100 meters).

o For the remote location, the total length of the I/O bus, including the length
of the columns, cannot exceed 20 feet (6 meters).

• Terminating resistors must be installed on each end of the string in the primary
location and each remote location.

• The primary location and each remote location must have a dedicated Extender
Module for the fiber-optic connection with the Hirschmann repeaters.

o The dedicated Extender Module must be located at the end of the string,
adjacent to the Extender Module, with terminating resistors.

o Each dedicated Extender Module must be connected to three Hirschmann


fiber-optic converter repeaters – one for each I/O bus channel.

• The primary and remote Hirschmann repeaters must be connected to each other
with fiber-optic cables that contain a minimum of two fibers each.

• The length of the fiber-optic cables connecting the primary and remote Hirschmann
repeaters cannot exceed 4,000 feet (1.2 kilometers).

• The Hirschmann repeaters must be powered by the same redundant logic power
supplies from the Trident/Tri-GP system. If separate power supplies are used to
power the Hirschmann repeaters, all power supplies must be referenced to the same
signal ground reference. The Trident/Tri-GP I/O baseplates and Hirschmann
repeaters installed at the remote locations should be referenced to the remote
location signal ground reference.

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Guidelines for Installing Hirschmann Repeaters

To setup remote I/O communication using Hirschmann repeaters, the following


considerations must be followed:

• Select a location for the primary repeaters that is less than two feet (61
centimeters) away from the bottom of the primary I/O column, as shown in Figure
3.

Two feet (61 centimeters) is the maximum length of the fanned-out cable which
connects an I/O Extender Module to the Hirschmann repeaters.

• Select a location for the remote repeaters that is less than two feet (61 centimeters)
away from the bottom of the remote I/O column, as shown in Figure 3.

• Allocate three repeaters for the primary I/O column and a DIN rail for mounting.

• Allocate three repeaters for the remote I/O column and a DIN rail for mounting.

• If the repeaters will not be powered from the Trident/Tri-GP 24-volt logic power:

o Select a location for redundant 24-volt DC power supplies to power the


primary repeaters.

o Select a location for redundant 24-volt DC power supplies to power the


remote repeaters.

Typical Remote I/O Configurations

A typical remote I/O configuration can have one column in the primary location and one
column in the remote location, as shown in Figure 3.

PS1 Terminators PS 3 Terminators


PS2 PS 4
CM/CIM I/O

MP I/O

I/O I/O

I /O 2 ft. DB9 2 ft. DB9


I/O
fan out fan out
cables cables

Terminators Terminators

24V Multi-Mode Fiber 24V


Power 1. 2KM max . Power
Lines
Lines

Hirschmanns
Hirschmanns
Primary Remote
Location Location

Figure 3 – Schematic for One Primary and One Remote Location

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Another typical configuration can have one column in the primary location and two remote
locations with one column on each location, as shown in Figure 4.

PS1 Terminators
PS2 PS3 Terminators PS 5 Terminators
CM/CIM
PS4 PS 6
I /O I /O
MP
I /O I/ O
I/O
I/O I /O
I/O
I/O 2 ft. DB9 I/ O 2 ft. DB9
2 ft. DB9 fan out fan out
fan out cables cables
cables

Terminators Terminators Terminators

Multi-Mode Fiber
1. 2KM max . 24V 24V
24V Power Power
Power Lines Lines
Lines

Remote Multi-Mode Fiber


Hirschmanns Location #1 1 .2KM max .

Primary Remote
Location Location #2

Figure 4 – One Primary Location and Two Remote Locations

A complex configuration can have one column at the primary location and more than one
column at each remote location, as shown in Figure 5.

DB9 to
PS1 Terminators DB9 cables
PS2 PS3 PS 5
CM/CIM
PS4 PS 6
I/O DB9 to I /O
I /O I /O DB9 cables
MP
I /O I/O I/ O I/ O

I /O
I/ O I /O I /O I/ O

I /O
I/ O I/ O I /O 2 ft. DB9 I /O
2 ft. DB9 fan out
fan out cables
cables Terminators

Terminators Terminators Terminators


2 ft. DB9
fan out
Multi-Mode Fiber cables
1.2KM max .
24V
Power
Lines

Remote
Hirschmanns Location #1

Primary Multi-Mode Fiber Remote


Location 1.2KM max . Location #2

Figure 5 – One Primary Location and Two Remote Locations with Two Columns on Each
Remote Location

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The following are typical complex configurations that are allowed in the Trident/Tri-GP
system.

PS1 PS3
PS2 PS4
CM/CIM DB9 to I / O
I/ O DB9 to I / O
DB9 cables
DB9 cables

MP I /O
I/O I /O

I /O I /O
I /O I /O

I/O I/O 2 ft. DB9 I / O


2 ft. DB9 I/ O
fan out
fan out
cables
cables
Terminators Terminators
Terminators
Terminators

24V Multi-Mode Fiber


24V
Power 1.2KM max. Power
Lines
Lines
Hirschmanns
Hirschmanns
Primary Remote
Location Location

Figure 6A – One Primary Location and One Remote Location with More Than One Column
on Each Location

DB 9 to
PS1 DB 9 cables
PS2 DB 9 to PS3 PS5
CM/CIM DB 9 cables
I/O
PS4 PS6 DB 9 to
I/O I/O I/O I /O
DB 9 cables
MP I/ O
I /O I /O I/O I/O

I/O I/O
I/O I /O I/O I/O

I /O I/O
I/O 2 ft. DB 9
I/O I/ O I/O
2 ft. DB 9 fan out
fan out Terminators cables
cables Terminators

Terminators Terminators Terminators


2 ft. DB 9
fan out
Multi - Mode Fiber cables
1.2KM max.
24 V
Power
Lines

Remote
Hirschmanns Location #1

Primary Multi - Mode Fiber Remote


Location 1.2KM max. Location #2

Figure 6B – One Primary Location and Two Remote Locations with More Than One Column
on Each Location

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Hirschmanns
Hirschmanns

24V
Power 2 ft. DB9
24V 1.2KM max. Lines fan out
Power Multi-Mode Fiber cables
Lines
Terminators
Terminators
Terminators Terminators

CM/CIM I/O 2 ft . DB9 I/O I/O


fan out
cables
MP I/O I/O
I/O

I/O I/O
I/O I/O

I/O I/O
I/O I/O
DB9 to DB9 to
PS1 DB9 cables PS 3 DB9 cables
PS2
PS 4

Primary Remote
Location Location

Figure 6C – One Primary Location and One Remote Location with More Than One Column
on Each Location

Hirschmanns 1 .2 KM max .
Multi-Mode Fiber

24V Hirschmanns Hirschmanns


Power
Lines 24V
2 ft. DB9 24V
Power 2 ft. DB9
1. 2KM max . Lines fan out Power
fan out
Multi-Mode Fiber cables Lines
cables
Terminators

Terminators Terminators
Terminators 2 ft. DB9 Terminators Terminators
fan out
CM/CIM I/O cables I/O
I/O I/O I/O

MP I/O I/O I/O I/O


I/O

I/O I/O I/O I/O I/O I/O

I/O I/O I/O I/O I/O


I/O
DB9 to DB9 to DB99to
DB to
PS 1
DB9 cables PS 3 DB9 cables PS 5 DB
DB99cables
cable
PS 2 PS 6
PS 4

Primary Remote Remote


Location Location # 1 Location # 2

Figure 6D – One Primary Location and Two Remote Locations with More Than One Column
on Each Location

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Hirschmann Repeater Wiring Example

Redundant 24 Vdc Redundant 24 Vdc


Power Supplies Power Supplies
PS PS
1 EM Terminators EM Terminators
PS 1
G
3 PS 1
PS G
PS 2 PS PS 2
G G
2 4
CM/CIM I/O

MP I/O

I/O I/O

I/O I/ O

I/O I/O

EM EM
PS 1 PS 1
G G
PS 2 PS 2
G G
EM EM

Terminators Terminators

2 feet DB 9
Fanned out cables

24Vdc power
Supplies lines

1.2KM
max .

Hirschmann
Fiber optic
Fiber optic
repeaters cables

Primary Location Remote Location

Figure 7 – Wiring Example: Hirschmann Repeaters to the Extender Modules

Connecting a Fanned-out Cable

To link a Trident/Tri-GP controller to a Hirschmann repeater, you must connect a fanned-


out cable from an Extender Module to screw terminals on the repeater, as shown in Figure
8. The wiring connections in the diagram apply to a primary location in a remote I/O
configuration.

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Hirschmann
Screw Terminals

RT+
K1+ See table below
for wire colors
Triconex Fanned
K1+ Out 2 feet cable

K1-
To DB-9 connector on
the Extender Module
K1-
RT-

RT-
K2-
K2-
K2+
K2+
RT+

Figure 8 – Connecting the fanned-out Cable to the Hirschmann Repeater

Table 3 provides wiring details for connecting a Triconex fanned-out cable to screw
terminals on a Hirschmann repeater.

Extender
Hirschmann
Module Hirschmann
Primary
Pin on Fanned-out Wire Color Remote Screw
Screw
DB-9 Terminal
Terminal
Connector
1 White wire with green stripes K2- K1-

2 Green wire with white stripes K2+ K1+

3 White wire with orange stripes K1- K2-

4 Orange wire with white stripes K1+ K2+

9 Blue wire with white stripes RT- RT-

Table 3 – Fanned-out Cable Wiring Details and Pin Assignment

Connecting Redundant 24 VDC Power

Connect the redundant logic power supplies from the Trident/Tri-GP controller to the
Hirschmann repeater as shown in Figure 9. The middle screw terminal can be connected to
the ground of the switch cabinet (optional).

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Side Panel of the


Hirschmann Repeater

Power Supply 2 Power Supply 1


from Trident from Trident
GND GND

Not Used
+24 Vdc +24 Vdc

Not Used
7-pin terminal block
to connect the two
24V power supplies

Figure 9 – Connecting the Redundant 24VDC Power Supplies from the Trident/Tri-GP
controller to the Hirschmann Repeater

Configuring a Hirschmann Repeater

You must configure both the primary and remote Hirschmann repeaters by setting the DIL
switches on the front panel to the “0” position, as indicated in Figure 10.

Figure 10 – Hirschmann DIL Switch Setting

Setting Up Remote I/O Communication Using Hirschmann Repeaters

Invensys recommends the following procedure for setting up remote I/O communication
using Hirschmann repeaters.

Note: Before beginning this procedure, the Trident/Tri-GP baseplates should be installed,
but the 24-volt logic power supplies should be disconnected.

1. Connect the wires of the fanned-out cables to the screw terminals on the primary
and remote repeaters. For details, see Figure 8.

2. Set the DIL switches (S1 to S4) on the front panels of the primary and remote
repeaters to the “0” position.

3. Attach the Extender Modules to the top and bottom of all I/O columns.

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4. Attach the fanned-out cables to the DB-9 pin connectors on the Extender Modules
that are dedicated to the fiber-optic connection.

5. Install terminating resistors on the unused DB-9 pin connectors on the Extender
Modules at each end of the I/O string.

6. Connect redundant 24-volt power supplies to each I/O string. For details, see
Figure 9.

7. Mount the Hirschmann repeaters on the DIN rails you have allocated for them.

8. Connect redundant 24-volt power supplies to the repeaters.

9. Connect the fiber-optic cables to the repeaters.

10. Connect the other fiber-optic components that are specific to your application, such
as junction boxes, jumper cables, and ST connectors.

11. Verify that the fanned-out cables are properly connected to the repeaters and the
Extender Modules.

12. Start the redundant 24-logic power supplies that are connected to each I/O string.

13. Start the redundant 24-logic power supplies that are connected to the repeaters.

14. Verify that the P/F indicator on each repeater turns green.

If the P/F indicator does not turn green, the fiber-optic cable is improperly
connected or the DIL switches on the repeater are improperly set. Refer to the
Troubleshooting section in this document, or the Startup Informations OZD 485 G12
PRO with Triconex F/W for details.

15. From TriStation 1131, download and run your Trident/Tri-GP control program.

16. Verify that the Pass indicator on each Trident/Tri-GP module turns green.

17. Verify that the TxD and the RxD (transmit and receive) indicators on the repeaters
are solid yellow.

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Remote I/O Bus Black Channel

The Trident/Tri-GP controller uses an end-to-end data integrity verification process for the
I/O bus sub-system between I/O columns, and as such does not make any assumptions
about the type of device used to extend the length of the I/O bus. In other words, the
Trident/Tri-GP controller considers the extension of the I/O bus and the associated
communication hardware as a black channel.

PS 1 Terminators PS3 Terminators


PS 2 PS4
CM/CIM I/O

MP I/O

I/O I/O

I/O I /O

Terminators Terminators

Black
Channel

Primary Remote
Location Location

Figure 11 – Trident/Tri-GP Remote I/O Bus Black Channel

The I/O bus sub-system includes data integrity verification to ensure that the message sent
between I/O columns is valid. If all parts of the message are verified, the Main Processors
provide the data to the control application. If there is a problem in the black channel, the
receiving end will either not receive the message, or will receive a corrupted message. In
this way, the integrity of the message is independent from the communication channel and
the communication hardware used in the channel; for example, fiber optic repeaters and
I/O bus extenders.

The use of bus extenders and repeaters to increase the length of the I/O bus is a method
used in many critical process control applications to minimize I/O wiring costs. The
alternative of using commercial-off-the-shelf fiber optic repeaters is considered an
approach that is approved for use in safety critical applications by third party certification
agencies.

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Troubleshooting

Because of the number of components that make up a Trident/Tri-GP I/O remote


communication configuration, identifying a fault on the I/O communications link can be
difficult and time-consuming.

The architecture of the Trident/Tri-GP system is designed to allow the controller to continue
to operate even when there is an I/O communications failure. This type of failure is
characterized by all I/O modules in the remote location being in the fault state, indicating
that at least one I/O leg on each module is unable to communicate with the main processor
modules in the primary location.

In the event of intermittent I/O bus failures on the Trident/Tri-GP remote I/O system, a
systematic approach to troubleshooting a fault, combined with process of elimination, can
help diagnose, identify, and correct the problem more effectively and in a timely manner.
One approach is to start from the Trident/Tri-GP I/O bus, followed by the Hirschmann
repeaters, and finally the fiber-optic cabling.

The following recommendations assume that all I/O modules in the remote locations are
reporting a Fault condition and all modules in the primary location are in the Pass/Active
condition with a control program downloaded and in the RUN state. Make sure you have
installed the Trident/Tri-GP system following the installation guidelines described in the
appropriate Planning and Installation Guide.

• Trident/Tri-GP RS485 I/O Bus

Extender Modules on the Trident/Tri-GP I/O Bus allow the expansion of the I/O bus
into additional I/O columns, as well as the connection of the I/O bus to the
Hirschmann repeaters and I/O baseplates via an I/O interconnect assembly.
Properly terminating the I/O bus and providing a stable ground reference
guarantees good communication across the I/O bus.

• I/O Interconnect Assembly

These assemblies connect the Extender Module to the I/O baseplate at the end of
the I/O string, as well as connecting two I/O baseplates in a column. Ensure that
the I/O interconnect assemblies are properly installed and firmly secured.

• Terminating Resistors on the Extender Modules

To ensure that the I/O bus signal is not degraded across the RS485 I/O bus, 120-
ohm terminating resistors must be installed on these Extender Modules at the
remote location. These resistors come in a package kit of three DB9 connectors and
are plugged into the DB9 connectors on the Extender Module at the end of the I/O
string. These connectors have two sets of built-in resistors on the connector itself.

You can verify their impedance by removing the DB9 connector from the Extender
Module and measure 120-ohm across pins 1 and 2 and 120-ohm across pins 3 and
4. If they do not measure 120-ohms, it is possible that they might be out of
tolerance or damaged and they need to be replaced.

• I/O Bus Ground Reference

I/O bus signal quality depends not only on the bus being properly terminated with
resistors, but also on how good its ground reference is. The I/O bus uses signal
ground as the ground reference. An unstable signal ground caused by noise or an

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elevated reference can cause errors in the data transmission and therefore,
intermittent faults.

If proper grounding and installation guidelines are followed, the I/O bus ground
reference and the Hirschmann ground reference should be at the same ground
potential. To ensure that these two are at the same ground reference, first remove
power to the Trident/Tri-GP I/O column and the Hirschmann repeaters. Then
measure the impedance across the I/O bus, located on the DB9 pin 9 of the
Trident/Tri-GP Extender Module and the Hirschmann 0-volt signal ground reference.
They both should be at the same ground potential. If they are not, it is possible that
both ground connections are tied to separate references.

• Hirschmann Repeater

LED indicators on the front panel of the Hirschmann repeater identify the state and
operating conditions of the repeater. Table 4 lists these conditions, possible causes,
and recommended actions.

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LED
Condition Description Recommended Actions
Indicator
Solid
Operating normally No action
Green
Verify that voltage supply is within
Not Lit Supply voltage failure
specifications.
Fault on the incoming optical link.
Possible causes:
Verify attenuation is within repeater’s
Attenuation too high
specifications.
System
Fiber-optic cable broken or Fix, replace, or reconnect fiber-optic
disconnected cable.
Red
Ensure cables are properly connected
Transmit and receive cables
from transmit to receive and from
are cross-wired
receive to transmit.
Incorrect transmitter Set DIL switch S4 at 0 position on
identifier set (both repeaters primary repeater and 1 position on
DIL S4 at 1 or 0) remote repeater.
Solid
Power Supply 1 is ok No action
Green
Power Supply 1 is not Check wire connections to screw
connected terminals.
P1
Power Supply 1 is off Turn on power supply 1
Not lit
Check the voltage of power supply 1
Power supply is low and ensure it is within the required
voltage.
Solid
Power Supply 2 is ok No action
Green
Power Supply 2 is not Check wire connections to screw
connected terminals.
P2
Power Supply 2 is off Turn on power supply 2.
Not Lit
Check the voltage of power supply 2
Power Supply 2 is low and ensure it is within the required
voltage.
Solid Operating normally and data
No action
Yellow receiving at Port 1
Verify the following:
• Fiber-optic cables are properly
installed
• Repeater on the other location is
powered up
DA/STAT 1
Repeater is not transmitting • Fanned-out cable is properly
Not Lit
data installed
• Trident/Tri-GP I/O column is
powered up on the other location
• I/O interconnect assembly between
the Extender Module and the I/O
column is installed
Green Input power at Port 2 ok No action
Operating normally and
Solid
optical data receiving at Port No action
Yellow
DA/STAT 2 2
Verify the following;
• Fiber-optic cables are properly
Not Lit Repeater is not receiving data
installed
• Repeater on the other location is

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powered up
• Fanned-out cable is properly
installed
• Trident/Tri-GP I/O column is
powered up on the other location
• I/O interconnect assembly between
the Extender Module and the I/O
column is installed
LED not used for this
DA/STAT 3 Not lit No action
application
LED not used for this
RM Not lit No action
application

Table 4 – Hirschmann Front Panel LED Indicator Conditions

• Fiber-Optic Cable

I/O module failure or intermittent fault symptoms could be due to a number of


factors, including cable mishandling. Table 5 lists the most common causes typically
found in the field when installing fiber-optic cables.
Cause Recommended Actions
Use cable tester to measure dB loss and attenuation. Fix or use spare
Poor slicing
cable
Cable Use cable tester to measure dB loss and attenuation. Fix or use spare
crimping cable
Bend radius Fix and adjust according to fiber-optic cable manufacturer’s
exceeded specifications.
Contaminated Clean with approved materials and substances. Replace connector if
connectors necessary.

Table 5 – Fiber-Optic Cable Problems, Common Causes, and Recommended Actions

• Trident/Tri-GP I/O Modules

I/O modules located in the remote location may still experience intermittent faults
even if all the components described above have been properly installed and
configured. If this is the case, the problem might be the I/O modules. In order to
identify the nature of the intermittent fault, diagnostic events should be collected
(using the Triconex Diagnostic Monitor or the Enhanced Diagnostic Monitor) and
sent to Invensys customer support for analysis.

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If you have any questions regarding this Application Note, please contact the Global
Customer Support Center, or your local Invensys office.

Changes from Initial Release (Rev. 0)

Section Description

• Included Tri-GP whenever Trident is mentioned.


Throughout • Changed CM to CM/CIM in figures that reference the CM designation for the
communication baseplate.

Required Hardware • Under Triconex Hardware, changed text from “CM” to “CM/CIM”.

The third bullet under Installation Rules, the text has been changed to read:
• The Trident/Tri-GP remote I/O configuration has been tested and validated
Setting Up A Remote I/O for a maximum of one primary location and four remote locations in a star
Configuration configuration. Each remote location must originate from the primary location.
If your application requires more than four remote locations, please contact
the Global Customer Support Center for assistance.

© 2008, 2012 Invensys Systems, Inc. All rights reserved. Invensys, Invensys logo, Triconex, Tricon, and TriStation are trademarks of Invensys plc,

its subsidiaries and affiliates. All other brands may be trademarks of their respective owners.

Technical Application Note 46 February 8, 2012 Part No. 9791005-46, Rev. 1