1. Introduction

• Function: TMR pulse generation + stepper motor control + position monitoring

• Motors: 2 independent stepper motors (damper rod actuators)

• Control: Bi‑directional fast/slow movement, emergency stop, hold

• Feedback: Rod position (%) + thyristor driver status

• Safety: IEC 61508 SIL 3 (TÜV)

• Architecture: 3‑2‑0 TMR (Hardware Implemented Fault Tolerance)

• Isolation: 2500 VDC opto/galvanic isolation

• ESD: Rod release on safety demand

• Hot‑swap: Supported (Companion Slot / SmartSlot)

2. Product Overview

• 2‑channel TMR pulse generator for stepper motors (damper rods)

• Bi‑directional fast/slow motion profiles (configurable)

• Emergency stop (E‑stop) and position hold functions

• Rod position feedback (0–100% movement)

• Thyristor driver fault detection (open/short/mismatch)

• ESD‑initiated rod release (safety demand)

• 2500 VDC opto/galvanic isolation (field ↔ system)

• TMR diagnostics + triplicated BIST (per channel)

• Front‑panel LED status (module + motors + faults)

• Hot‑swap & hot‑standby (companion slot)

3. Specifications

3.1 Mechanical

• Form Factor: T8000 chassis single‑width module, 6U height

• Dimensions (H × W × D): 266 mm × 31 mm × 303 mm

• Weight: Approx. 1.2 kg

• Mounting: T8100 / T8400 chassis slots 1–16

• Termination: Custom FTA for thyristor drivers + position sensors

3.2 Electrical

• System Supply: 20–32 VDC (nominal 24 VDC)

• Power Consumption: ≤ 20 W

• Pulse Outputs: TMR‑triplicated pulse trains (5–24 VDC)

• Output Current: ≤ 20 mA per channel

• Position Inputs: Analogue/digital feedback (0–10 V / 4–20 mA)

• Isolation: 2500 VDC opto/galvanic (field to backplane)

• Overcurrent Protection: Per‑channel automatic (fuse‑less)

3.3 Functional

• Redundancy: TMR (3 independent slices, 3‑2‑0 fault tolerance)

• Motor Control: 2 × stepper motors (bi‑directional, fast/slow)

• Position Range: 0–100% (rod movement)

• Response Time: ≤ 10 ms (motion command)

• Diagnostics:

  • Thyristor driver open/short circuit

  • TMR pulse mismatch

  • Position drift / range fault

  • On‑board BIST (periodic self‑test)

• ESD Action: Rod release on safety signal

• SOE Resolution: 1 ms (position events + faults)

3.4 Environmental

• Operating Temperature: –20 °C to +60 °C

• Storage Temperature: –40 °C to +85 °C

• Humidity: 5–95 % RH, non‑condensing

• Vibration: 10–57 Hz ±0.075 mm; 57–150 Hz 1.0 g

• Shock: 15 g, ½ sine wave, 11 ms

3.5 Safety & Certification

• Safety Standard: IEC 61508 SIL 3 (TÜV Certified)

• Approvals: CE, UL, CSA, ATEX, IECEx

• Fault Tolerance: TMR 3‑2‑0

• PFHd: < 1.0 × 10⁻⁹ / hour (SIL 3)

4. Front Panel Indicators

• PWR (Green): ON = module power healthy

• RUN (Green): ON = active; FLASHING = BIST/initialization

• FAULT (Red): ON = critical fault; FLASHING = minor fault

• COM (Green): FLASHING = backplane communication active

• M1/M2 LEDs: Motor 1/2 status + position/fault indication

5. Installation

• Chassis: Insert into any vacant slot in T8100 / T8400 chassis

• Hot‑Swap: Supported (Companion Slot / SmartSlot)

• Front‑Panel Screws: Torque 0.8–1.0 Nm

• Termination: Connect to custom FTA for thyristor drivers and position sensors

6. Wiring

• Pulse Outputs: To thyristor drivers (24 VDC pulses)

• Position Feedback: From rod sensors (4–20 mA / 0–10 V)

• ESD Input: From safety system (dry contact)

• Wire Gauge: 16–22 AWG stranded

• Terminal Torque: 0.5–0.6 Nm

7. Operation

• Power‑Up: PWR ON; RUN flashes during BIST (5–10 s)

• Normal: PWR/RUN steady green; FAULT OFF; COM flashing

• Motion: M1/M2 LEDs indicate direction/speed

• Faults:

  • FAULT ON: TMR mismatch, driver fault, position error

  • FAULT FLASHING: Single‑slice fault, minor mismatch

• ESD: Triggers immediate rod release (safety state)

• SOE: All position changes, faults, and ESD events time‑stamped at 1 ms

8. Ordering Information

• T8444: Standard TMR pulse generator (–20 °C to +60 °C)

• T8444C: Conformal coated (harsh environment)

• Custom FTA: Thyristor driver + position sensor termination assembly

• T8100 / T8400: Trusted chassis