Fault-Tolerant Scalable DCS - RTP

Fault-Tolerant Scalable DCS
2300 Family
Product Highlights
Costs Less
Runs Faster
Never Stops
Scalable DCS Overview
The unique RTP Fault-Tolerant Scalable Distributed
Control System (DCS) protects your process as well
as providing continuous access to process data with
a combination of multiple levels of redundancy and
data validation that can be configured to meet your
precise requirements.
Scalability: The use of a common set of hardware
and software throughout the 2300 family ensures
that any node can be scaled from a single-processor
node to a triple-redundant processor node, and any
single chassis node with a few I/O points to a
multiple chassis node with tens of thousands of I/O
points. Also, a single node control system can be
scaled to a distributed control system with an
unlimited number of nodes. There is never a need to
discard any hardware or software.
High-Integrity Validation: An RTP Scalable DCS is
perfectly suited for fault-tolerant applications.
Communications are validated using advanced builtin
CRC routines on both the host and the redundant
I/O networks. System information is validated in the
remote I/O chassis to ensure error-free performance,
and provide the assurance of hardware availability.
Error checking on the data transfers within I/O
chassis detects any data corruption. Field wiring to
an I/O card is supervised to ensure continuity to the
field. I/O card diagnostics perform readback of
outputs and even calibration checks on the A/D
converters! Lastly, validation of the output data is
performed in the remote I/O chassis, as close to the
process as possible to minimize the opportunity for
data corruption.
Scalable DCS Family
The RTP family of fault-tolerant DCS systems
combine peer-to-peer communications, a common
chassis design and the powerful RTP NetSuite
monitoring and control software.
2300-T Scalable Distributed Control System
• 2300-T: For the highest level of fault-tolerance
and dependability, the 2300-T Triple Modular
Redundant system features data validation and
communications validation. It includes three
2300 Node Processors installed in three physically
separate chassis, or optionally in one
chassis designed to accommodate all three
processors. It supports 32 chassis of tripleredundant,
dual-redundant or common I/O.
Tired of the rest – try the best!
RTP NetSuite includes all the tools you will ever
need to design, simulate, test, integrate, and
maintain your industrial control applications.
Following the IEC 61131 standard, NetSuite is a
fully integrated software workbench that
dramatically reduces the time it takes to develop,
deploy, commission and maintain your control
application.
RTP engineers each NetSuite module so it works
together seamlessly as a single solution: the
powerful, networked RTPView HMI; NetArrays
graphical configurator; data archives; alarms;
trending; and global tag management database–all
interact seamlessly. NetArrays includes advanced
controls (e.g. Fuzzy Logic, robust PID control
objects) and powerful online commissioning tools.
Favorite application or custom software? NetSuite
includes an OPC server for a common interface
to diverse process control applications.
RTP’s Hassle-Free Software Policy provides an
unrestricted site license with free upgrades for a
one-time registration fee, no maintenance fees,
regardless of tag count or number of seats.
Contact RTP at www.rtpcorp.com for your free
demonstration CD-ROM.
RTP Corp. • 1834 SW 2nd Street • Pompano Beach, Florida 33069
PHONE (954) 974-5500 • FAX (954) 975-9815 • EMAIL rtpinfo@rtpcorp.com • WEB: www.rtpcorp.com

• 2300-D: Built on the same components as the 2300-T,
the 2300-D provides a dual-redundant solution with
advanced diagnostics. The 2300-D features dual-redundant
processors, and up to 32 chassis of triple-redundant,
dual-redundant or common I/O.
• 2300-S: When TMR or dual-processor redundancy is not
a requirement, the 2300-S Single processor configuration
provides integrity and availability, featuring data validation
and redundant host communications. The 2300-S also
supports up to 32 chassis of common, dual-redundant or
triple redundant I/O.
• 2300-M: For small to medium sized systems, the 2300-M
provides a low cost solution using a single processor in a
single chassis. The 2300-M uses a subset of the same
components as the other 2300s, plus the same RTP
NetSuite.
• RTP NetSuite software: Windows-based control and
monitoring software for control logic development,
archiving, alarming, trending and HMI, a central tag
database; PC-based simulation and OPC and DDE
servers. Requires no keys or licenses. Powerful RTPView
HMI and SCADA system software included with every
copy of NetSuite.
Scalable DCS Architecture
Major components of an RTP Scalable DCS-based industrial
control system include the 2300 Target Node(s), an HMI
platform, a development platform, alarm and data archive
platform, and a communications network. With the ability to
support a virtually unlimited number of 2300 Target Nodes,
for simplicity only five 2300 Target Nodes are shown in the
above illustration. Any combination of 2300-T, 2300-D, 2300-
S and 2300-M Target Nodes can be used, allowing any level
of redundancy required for its intended application.
Redundant Host Network: A fast 100 MHz Ethernet network,
identified above as the Redundant Host Network,
provides the communication medium for application development,
operator interface, and data exchange among RTP DCS
Target Nodes. The 2300 Scalable DCS includes peer-to-peer
capability, allowing the direct transfer of data between target
nodes over the high-speed Ethernet link via TCP (Transmission
Control Protocol). Routing through a host computer, or
the need for slow non-redundant extra cabling, is eliminated.
Only detected changes are exchanged among target nodes,
optimizing overall peer-to-peer communications efficiency.
Use of Ethernet also permits easy connectivity with other
plant floor devices and enterprise systems.
Redundant I/O Network: I/O communications within a
2300 node occur over a dedicated Ethernet network referred
to as the Redundant I/O Network in the diagram. This
ensures that private, dedicated lines carry all data between the
Node Processor and the I/O chassis–ensuring secure transmissions
with the convenience of standard Ethernet connectivity.
Multiple I/O chassis can be placed throughout the plant,
close to field devices. The benefits of this approach are
reduced field wiring and installation costs.

Host Workstations: Under supervision of Microsoft Windows
operating systems, one or more Development Workstations
are used to run the NetSuite Developer Studio. Easy to
use and intuitive in use, its design and graphical layout make
configuration and programming simple. Control application
design and development is augmented with extensive testing
and debugging facilities, including the ability to simulate the
application logic prior to hardware integration. Once developed
and compiled, the control application is downloaded to
the Target Node for execution.
In addition to application development, NetSuite also includes
our human-machine interface application (RTPView) and our
alarm monitoring and data archiving application (RTPADA).
Target Node: A 2300 Scalable DCS Target Node consists of
one, two or three redundant Node Processors housed in any
of a possible 32 intelligent I/O chassis. Each I/O chassis
contains a Chassis Processor and up to 16 hot-swappable
analog, digital or special function I/O cards for almost
unlimited I/O possibilities.
Unique to RTP is the use of separate processor modules to
achieve unparalleled system flexibility and performance. The
2300 Node Processors are responsible for all system functions
with the exception of I/O scanning and results voting.
The Chassis Processor executes the I/O scanning, floatingpoint
conversion, and results voting. RTP places the results
voting at the I/O chassis to minimize the opportunity for data
corruption and maximize system response, which is so
critical in process control. This design allows RTP to take
advantage of an advanced multiprocessor (up to 105 microprocessors
in a 32-chassis system) parallel processing
architecture in a truly distributed fashion unlike prior generation
TMR systems.
Node Processor: The Intel-architecture Node Processor
includes nonvolatile (disk-on-chip) memory, which contains
the target node’s real-time run-time executive (Viking Engine)
and the downloaded control application. Upon power-up or
reset, the Node Processor initialization routines copy the
contents from the disk-on-chip memory into its executable
RAM before entering its run state.
The Node Processor utilizes advanced technology such as
parallel processing, math co-processors and synchronous
DMA mode support, resulting in high-speed logic solving
while simultaneously performing error checking and validation,
I/O calls, peer-to-peer communications and communicating
with the SCADA/HMI operator stations. All I/O values
are reported with each scan to provide a higher level of
integrity than report by exception routines. Peer-to-Peer
communications report by exception to reduce network
traffic; however, the user can define refresh time intervals
where all peer variables are reported. This allows the user to
manage network integrity by balancing network traffic and
data integrity.
The Node Processors contain four Ethernet processors that
are factory-configured to support secure high-speed communications,
such as host, interprocessor and I/O networking.
Each communications port is truly redundant, if a communications
interface fails, the network interface will use another
one of the multiple paths available. Additionally, RTP built
advanced error-checking routines in the host, interprocessor
and I/O network structure, ensuring secure and accurate
communications.
High Performance I/O: RTP’s specialized I/O cards support
high-integrity applications and/or line supervision for missioncritical
applications. Fast scan rates, true 16-bit A/D precision,
high CMRR (Common Mode Rejection Ratio), over
voltage isolation protection, and superior construction are
several of the advantages that are the hallmark of RTP I/O.
RTP allows tighter, more accurate control of the process,
with a positive impact on the quality of your product.
RTP I/O cards provide a full range of I/O choices: from 5V to
240V AC, 5V to 125V DC, low-level millivolt to +10V, 4-20
mA, thermocouples, RTDs, relays and others. Communications
cards support Modbus serial communications and
Modbus TCP communications for connectivity to devices and
other systems.
Fault Tolerance
To provide the highest level of fault-tolerant operation, the
2300 can be configured with redundant Node Processors,
redundant I/O and dual power supply chassis.
Data Integrity: Each 2300 Node Processor solves the logic
and sends the resultant outputs to the associated I/O chassis.
Within the I/O chassis, the Chassis Processor performs data
validation checking and then performs independent voting for
its associated outputs. If the systems outputs are located in
multiple I/O chassis, the voting is distributed over these
chassis.
Distributed voting, performed as close as possible to the
process, enhances integrity by moving potential fault variables
out of the response. Furthermore, results voting at the I/O
chassis level results in a much more responsive, high-speed
system. High-speed processing means more data adjudications
per second, resulting in higher resolution and greater
integrity.
High Availability: If any hardware or network fault occurs,
the operator is notified immediately and the offending Node
Processor is taken offline. Meanwhile, the application continues
to run unaffected on the remaining Node Processor(s).
RTP’s hot-swappable components and “easy out” power
supplies, coupled with additional layers of available redundancy,
allow for a quick return to a fully-functional operating
mode.

When the error condition is cleared through online
maintenance activities, non-intrusive reinitialization of
the restored Node Processor takes place, and the
2300 system returns to normal operation.
Signal Validation: Signal validation routines are
supported in all members of the RTP Scalable DCS
family, from the 2300-T to the 2300-M. RTP signal
validation routines allow for the control of one
logical input produced from up to four redundant
inputs (three hardware and one additional logic).
There are six algorithms that the user can select to
calculate the logical variable from the three physical
field variables. The 2300 DCS supports both I/O
card redundancy and sensor redundancy, which is
field-configurable.
Triple Redundant I/O: I/O option cards may have
their inputs or outputs identically configured with
their field wiring connected to the same physical
point, or to identical redundant input sensors. The
Chassis Processors determine which redundant I/O
card is the primary. Only the primary redundant I/O
card drives its analog outputs, the outputs on the
secondary and tertiary cards are armed but isolated
from the field device. Input channels are monitored
from all redundant I/O cards.
Superior Reliability
RTP products are designed and are being qualified
under the demanding IEC 61508 standard for
superior reliability, minimal downtime and
maintenance, and a high return on investment.
Specifications
Node Processor
2300-T, -D, -S:
Chassis Processor
2300-T, -D, -S or
Node Processor
2300-M:
Ethernet Cable Type:
Sequence Of Events:
Temperature Ranges
Operating:
Storage:
Humidity Range:
Power Requirements
AC Input Option:
DC Input Option:
Dimensions
16-Slot Chassis:
12-Slot Chassis:
8-Slot Chassis:
Weight
16-Slot Chassis:
12-Slot Chassis:
8-Slot Chassis:
Mobile Intel® Celeron Processor with integrated Intel floating point unit and the
440MX single-component chipset with support for synchronous DMA
2 PCI-based 100 MHz full duplex Ethernet controllers for Host/Inter Processor
communications (2300-T, -D) or redundant Host communications (2300-S)
32 MBytes RAM, 8 MBytes Flash
2 PCI-based 100 MHz full duplex Ethernet controllers for I/O communications
Dedicated processor (PLD) to perform I/O scanning
RISCore 32300 implements Enhanced MIPS-II instruction set
2 PCI-based 100 MHz full duplex Ethernet controllers
32 MBytes RAM, 4 MBytes Flash
STP Category 5 (EIA 568B, Cat 5) shielded Ethernet cables
SOE processing available as an option on all models
–20° to +60°C (–4° to +140°F)
–25° to +85°C (–13° to +185°F)
10% to 95% non-condensing
115V AC @ 2.1A or 230V AC @ 1.1A (External 24V DC input available for I/O cards)
24V DC @ 8A
9.04 inches (22.9 cm) x 19.0 inches (48.3 cm) x 11.3 inches (28.7 cm)
9.04 inches (22.9 cm) x 19.0 inches (48.3 cm) x 11.3 inches (28.7 cm)
8.8 inches (22.4 cm) x 10.0 inches (25.4 cm) x 11.3 inches (28.7 cm)
23 lb. (10.4 kg)
24.7 lb. (11.2 kg)
15.1 lb. (6.8 kg)
Trademark acknowledgments: RTP is a registered trademark of RTP Corp. All other product or service names mentioned herein are trademarks of their
respective owners. Specifications subject to change without notice.
© 2005 RTP Corp. Not for reproduction in any printed or electronic media without express written consent from RTP Corp.
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