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1. 5 8 7 8 10 11 12 ATEX Certificate TYPE EXAMINATION CERTIFICATE Equipment or Protective System intended for use in Potentially Explosive Atmospheres Directive SEC Type Examination Certificate Number DEMKO 11 ATEX 1129711X Rev Equipment Programmable Logic Controllers Models 9110 Processor 9111 Processor 9401 Digital Input 9402 Digital Input 9431 Analog Input 9432 Analog Input 9451 Digital Output 9481 Analog Output 9482 Output Input 9100 Processor Backplane 9101 Dual Backplane 9300 I O Backplane 9801 Digital Input Termination Assembly 9802 Digital Input Termination Assembly 9803 Digital Input Termination Assembly 9831 Analog Input Termination Assembly 9832 Analog Input Termination Assembly 9833 Analog Input Termination Assembly 9851 Digital Output Termination Assembly 9852 Digital Output Termination Assembly 9881 Analog Output Termination Assembly 9882 Analog Output Termination Assembly 9892 Digital Output Termination Assembly Manufacturer Rockwell Automation Ltd Address Hall Road Maldon CM9 4LA United Kingdom This equipment and any acceptable variation thereto are specified in the schedule to this certificate and the documents therein refered to UL International Demko A S certifies that this equipment has been found to comply with the Essential Health and Safety Requirements that relate to the design of Category 3 equipment which is intended for use in potentially explosiv
2. e Use only finger pressure to manipulate and engage the clips Do not attempt to use a screwdriver or other tool as injury or equipment damage may result 96 Rockwell Automation Publication ICSTT RM448I EN P May 2015 Install the AADvance System Chapter 5 e Use two clips for each join 3 Mark off the panel to locate hole positions for three screws for each base unit You can place the assembly of base units onto the panel and use the assembly as a template or refer to the illustration to locate the holes e Mark and drill the panel and then secure the base units M5 screws are suitable 4 Mount power supply units e To install the power supply units refer to the instructions supplied with the units 5 Fit termination assemblies e Insert the retaining clip on the back of the termination assembly into the slot on the I O base unit Press the termination assembly onto the base unit and then slide the assembly upwards as far as it will go e Make sure the retaining tab clips over the printed circuit board to secure the termination assembly in position 6 Check coding pegs e Observe the legend on the 9100 processor base unit and repeated on some termination assemblies which defines the six possible positions for a coding peg The positions are numbered from 1 to 6 e Examine a coding peg fitted and identify the index recess on the hexagonal flange Rockwell Automation Publication ICSTT RM448I EN P
3. Base Unit 126 ia O Base Unit amp Termination Assemblies Processor Modules I O Modules 136 Table 4 Summary of Dimensions Attribute Value Base unit dimensions H x W x D 233 mm x 126 mm x 18 mm see text approx 9 14 in x 5 in x 34 in Module dimensions H x W x D 166 mm x 42 mm x 118 mm approx 6 in x 1 in x 4 in Rockwell Automation Publication ICSTT RM448I EN P May 2015 The AADvance Safety Controller Chapter 2 The depth of the base unit 18 mm excludes the parts of the backplane connectors that mate inside the module connectors Adding the depth of a module 118 mm to the depth of the base unit gives the overall depth of the controller assembly at 136 mm Module Dimensions All modules have the same dimensions Figure 1 Module Dimensions mm 166 a 118 Compact Module Design Each processor and I O module has a flame retardant and impact resistant plastic cover The cover is designed to help ventilation and heat dissipation occur naturally without the need for fan assisted cooling Processor and I O modules fit onto standardized base units Base units plug together by side connectors and are securely held in position by specially designed plastic clips which cannot corrode or seize up Modules are retained by a locking screw which is easy to access from the Rockwell Automation Publication ICSTT RM448I EN P May 2015 45 Chapter 2 The AADvance Safety Controll
4. AMBER Off Push the Fault Reset button on the processor module and the Run indication goes GREEN The module will now be on line with the following status indications GREEN GREEN GREEN Dependent on channel status If the module fails to educate and go on line replace the module You can check the firmware revision of you processor modules without removing them to read the label and you can upgrade the firmware revision of the processor modules Upgrading the firmware in the 9110 processor module is done in the Recovery Mode and is a two stage process Stage 1 Run the latest version of 350720 xxx ControlFLASH ms1 program to install the ControlFLASH firmware upgrade kit for the Recovery Mode on your PC Then run the ControlFLASH utility to upgrade your processor module and install the Recovery Mode If your module is delivered with the Recovery Mode installed then this stage 1s not necessary Stage 1 must be performed individually on each processor it does not matter if you download the Recovery Mode one at a time in a specific slot or in their own slots Stage 2 Reboot the processor and press and hold the Fault Reset button to enter the Recovery Mode Then run the latest version of 354400_xxxx_ControlFLASH msi program to install the ControlFLASH to upgrade your processor s OS FPGA LSP and BUSP When stage 1 is completed ControlFLASH can be used to upgrade three processor modules in the same processor base unit all at the
5. Digital Output Model Termination Assembly 16 Channel Simplex Digital Input Termination Assembly 16 Channel Dual Digital Input Termination Assembly 16 Channel TMR Digital Input Termination Assembly 16 Channel Simplex Analog Input Termination Assembly 16 Channel Dual Analog Input Termination Assembly 16 Channel TMR Analog Input Termination Assembly 8 Channel Simplex Digital Output Termination Assembly 8 Channel Dual Digital Output Termination Assembly 8 Channel Dual Digital Output Termination Assembly 8 Channel Simplex Analog Output Termination Assembly 8 Channel Dual Analog Output Circuit Number 151491 152181 151501 151421 151431 151421 151431 151441 151441 151751 151961 151441 151751 151631 151801 151791 151521 151531 151731 151711 151561 151721 151701 151551 151741 151691 152621 151821 151811 Board Number 130662 131022 130622 130642 130652 130642 130652 130682 130682 130772 130682 130682 130772 130842 130852 130842 130722 130732 130812 130802 130782 130812 130802 130782 130822 130792 131212 130872 130862 Model 9100 Processor Backplane and 9101 Dual Processor Backplane are for use with Model 9110 and 9111 Processors Model 9300 1 0 Backplane is for use with all other Models Subject devices are all marked Ex nA IIC T4 Ge Temperature range Models 9110 and 9111 The ambient temperature range is 25 C to 60 C All other M
6. Optional accessory Type of Protection Non Sparking nA Marking Ex nA IIC T4 Ge Approved for issue on behalf of the IECEx Paul T Kelly Certification Body Position Principal Engineer Global Hazardous Locations AG oF Tie Signature Vag LE wes for printed version ae Date 2014 05 28 1 This certificate and schedule may only be reproduced in full 2 This certificate is not transferable and remains the property of the issuing body 3 The Status and authenticity of this certificate may be verified by visiting the Official IEC Ex Website Certificate issued by UL LLC 333 Pfingsten Road Northbrook IL 60062 2096 United States of America Rockwell Automation Publication ICSTT RM448I EN P May 2015 The AADvance Safety Controller Chapter 2 IECEx Certificate of Conformity Certificate No IECEx UL 12 0032X Date of Issue 2014 05 28 Issue No 2 Page 2 of 4 Manufacturer Rockwell Automation Ltd Hall Road Maldon CM9 4LA United Kingdom Additional Manufacturing location S This certificate is issued as verification that a sample s representative of production was assessed and tested and found to comply with the IEC Standard list below and that the manufacturer s quality system relating to the Ex products covered by this certificate was assessed and found to comply with the IECEx Quality system requirements This certificate is granted subject to the conditions as set out in IECEx Scheme Rules IECEx 02 and O
7. tool accessible enclosure that has been evaluated to the requirements of EN 60079 0 2012 A11 2013 and EN 60079 15 2010 IEC 60079 0 Ed 6 and IEC 60079 15 Ed 4 Enclosure is to be marked with the following Warning Do not open when energized After installation of subject devices into the enclosure access to termination compartments must be dimensioned so that conductors can be readily connected Grounding conductor should have a minimum cross sectional area of 3 31 mm Subject devices are for use in an area of not more than pollution degree 2 in accordance with IEC 60664 1 Subject devices are to use conductors with a minimum conductor temperature rating of 85 C Subject devices are to be installed in the vertical orientation only AADvance meets the essential requirements of EN 60079 0 2012 A11 2013 amp EN 60079 15 2010 and IEC 60079 0 Ed 6 and IEC 60079 15 Ed 4 File Number E251761 The AADvance controller investigation and approval is contained in the following file certifications e NRAG E251761 Programmable Controllers for Use in Hazardous Locations Class I Division 2 Groups A B C and D The products have been investigated using requirements contained in the following standards Rockwell Automation Publication ICSTT RM448I EN P May 2015 25 Chapter 2 The AADvance Safety Controller Certifications for Safety System Applications in Hazardous Environments 26 e ANSI ISA 12 12 01 2013 Nonincendi
8. 2 Pages represents 9401 GA 2 2008 09 24 the Processors 9110 and 9111 and all I O Devices Model 9801 Construction Drawing 1 Page represents all 9801 GA 4 2013 07 30 termination assemblies Marking Label 9100 9300 1 Page 274850 F 2013 11 04 Marking Label 9300 1 Page 274070 B 2011 02 11 Marking Label 9100 1 Page 274680 D 2011 08 25 Marking Label All 1 0 Modules 2 Page 275750 D 2013 11 04 Marking Label 9110 9101 All I O Moduels 3 Page 275520 F 2012 02 14 Marking Label 9110 1 Page 273570 E 2013 11 04 Marking Label 9101 1 Page 276250 E 2012 08 02 Marking Label All Termination Assemblies except 9851 276210 C 2011 08 26 and 9852 1 Page Marking Label 9851 and 9852 1 Page 276260 C 2011 08 26 Marking Label Model Number only 9801 1 Page 274270 C 2011 02 15 Marking Label Model Number only 9802 1 Page 274280 E 2011 05 01 Marking Label Model Number only 9803 1 Page 274290 E 2011 05 03 Marking Label Model Number only 9831 1 Page 274300 C 2011 02 15 Marking Label Model Number only 9832 1 Page 274310 E 2011 05 01 Marking Label Model Number only 9833 1 Page 274320 E 2011 05 03 Marking Label Model Number only 9851 1 Page 274240 C 2011 02 11 Marking Label Model Number only 9852 1 Page 274250 D 2012 05 14 Marking Label Model Number only 9881 1 Page 275060 B 2011 02 15 Marking Label Model Number only 9882 1 Page 275070 C 2012 05 17 Marking Label Model Number only 9892 1 Page 276370 A 2011 12 14 00 IC
9. Allen key hex wrench 2 5 mm for plug and sockets assemblies used with extension cables Special Tools Long nosed pliers to remove the fuses on termination assemblies Digital voltmeter for troubleshooting activities Resistor 1k8 for troubleshooting analogue input modules Resistor 1k 1W for troubleshooting digital output modules Resistor 250R 1W for troubleshooting analogue output modules Rockwell Automation Publication ICSTT RM448I EN P May 2015 69 Chapter 4 Before You Begin Specifying an Enclosure 70 When the system is installed in an enclosure it must meet the UL508 requirements for the installation environment hold the modules securely provide mechanical protection and should not interfere with other system components The enclosure must also be able to handle the heat dissipated by the modules and other components devices included in the same enclosure Maximum Enclosure Air temperature CAUTION HEAT DISSIPATION AND ENCLOSURE POSITION The maximum air temperature rating in an enclosure where standard AADvance processor and I O modules are installed to ensure predictable reliability is 70 C 158 F for 1 0 Modules and 60 C 140 F for Processor modules System and field power consumption by modules and termination assemblies is dissipated as heat You should consider this heat dissipation during the design and positioning of your enclosure e g enclosures exposed to continuous sunlight will ha
10. Electrical Characteristics Supply voltage Redundant 24 Vdc nominal 18 Vdc to 32 Vdc range Channel isolation channel to channel and channel to chassis Maximum withstanding 1 5 kVdc withstand for 1 minute IMPORTANT Overall system power consumption heat dissipation and weight can be estimated using the values given in the heat dissipation and weight data tables shown in this manual Scan Times The controller processing scan times listed in the table are taken from a test system which used only production modules The tests which were used to measure the scan times did not measure the effects of logic complexity and communications loading Table 2 Typical Module Scan Times Module Scan Time 9402 Digital input module 24 Vdc 16 channel Simplex 0 924 ms Dual 1 676 ms Triple 2 453 ms 9432 Analogue input module 24 Vdc 16 channel Simplex 1 170 ms Dual 1 965 ms Triple 2 656 ms 20 Rockwell Automation Publication ICSTT RM448I EN P May 2015 The AADvance Safety Controller Chapter 2 9451 Digital output module 24 Vdc 8 channel Simplex 1 174 ms Dual 2 202 ms 9482 Analogue output module 24 Vdc 8 channel Simplex 0 981 ms Dual 1 761 ms Minimum cycle time overhead 39 3 ms Scan overhead for each module 0 04 ms The minimum overhead to the cycle time is a feature of the AADvance Workbench The scan time is Scan time 39 3 ms Sync time Total number of modules 0 04 ms Number of module groups x scan time show
11. ICSTT RM448I EN P May 2015 Install the AADvance System Chapter 5 System Security 4 Connect the signal ground not illustrated from the 0 V terminal to each slave device IMPORTANT Do not connect the signal ground to the AC safety ground Insert the connector into the 9100 processor base unit Serial networks are closed and local and have limited protocol functionality so they are immune to any external attack apart from local deliberate sabotage The AADvance system however with its workstations and DCS interfaces uses Ethernet networks which are frequently part of a larger corporate network and can expose the system to accidental or malicious infection or attack These steps help prevent such issues Network and workstation security must be used when installing and setting up the system As a minimum set up the following security measures AADvance must not be on a network with open unsecured access to the Internet The Firewall must be active on the Workstation preventing access to the relevant Ethernet ports on each communication interface Anti virus software must be installed and be kept updated IMPORTANT Firewalls have been known to change the operation of the AADvance Discover tool The workstation must be password protected If the workstation is a laptop it must be kept locked when not in use If the workstation uses a hardware license USB dongle it must be kept secure without it the workstation
12. Il 3G Ex nA IIC T4 Ge 11e DEMKO 11 ATEX 1129711X File E341697 IECEx UL 12 0032X A KCC REM RAA es 9000 MODULES l TUV Rheinland ID 0600000000 Battery Fitted polycarbon monofiuoride lithium coin battery 3V Size BR2032 Warning Explosion Hazard Batteries must only be changed in an area known to be non hazardous Pile install e Pile bouton au poly lithium carbonmonofiuoride 3V taille BR2032 Avertissement risque d explosion Les piles ne doivent tre remplac es que dans une zone r put e non dangereuse AS 7 248 SSe717 0 Ale SeBARL AAWHPSsS Gt a 7121080 BOAR SE ASAE O BS FHT Het 73e RIAA A BOE AS Soe SU Translation Class A device Broadcasting Communication Device for Office Use This device obtained EMC registration for office use Class A and may be used in places other than home Sellers and or users need to take note of this The AADvance software lets you design one complete control strategy and then target parts of the strategy to individual controllers Interaction between the resources is automatic significantly reducing the complexity of configuration in a multi resource system Programs can be simulated and tested on the workstation computer before downloading to the controller The workstation software is compliant with the IEC 61131 industrial standard and has several powerful features 37 Rockwell Automation Publication ICSTT RM448I EN P May 2015 Chapter 2 The A
13. L L L L L su SGC Se L LLELLLLLELLLELLLLL heme Ava ASOVONHOsLL XS Idle SI Termination Assemblies The AADvance system provides a range of termination assemblies to connect field wiring to the I O modules A termination assembly is a printed circuit equipped with screw terminal blocks for the field wiring and in some cases fuses and connectors for the plug in I O modules Termination assemblies give the system designer flexibility when configuring redundant and fault tolerant systems Termination assemblies come in three types simplex dual or triple to accommodate one two or three I O modules Each termination assembly provides connections for up to 16 channels but can accommodate 8 or 16 channel modules The version illustrated 1s a simplex termination assembly for a digital input module The field wiring connectors are located to the left the Rockwell Automation Publication ICSTT RM448I EN P May 2015 The AADvance Safety Controller Chapter 2 fuses have a cover shown open and the module sockets are to the right Each fuse cover has a label that identifies the fuse numbers Figure 7 Single Termination Assembly Rockwell Automation Publication ICSTT RM448I EN P May 2015 55 Chapter 2 The AADvance Safety Controller Figure 8 Top View TERMINAL BLOCK CABLE ENTRY THIS SIDE TH TES C f Baaa aaa al EE O k Fuse Cover i Polarisation e LI e
14. May 2015 97 Chapter 5 Install the AADvance System e Refer to the following table and verify each coding peg is fitted so its index recess is adjacent to the relevant numbered position Allocations of Coding Pegs Coding pegs are assigned to each module type as shown in the following table 9100 processor base unit 1 1 1 for 9110 processor module 9801 2 3 digital input termination assemblies 2 1 1 for digital input modules 9831 2 3 analogue input termination assemblies 2 1 3 for analogue input modules 9851 2 digital output termination assemblies 3 1 1 for digital output modules 9842 1 analogue output module 2 98 Rockwell Automation Publication ICSTT RM448I EN P May 2015 Install the AADvance System Chapter 5 This example shows pins set to positions 2 1 1 for a 9401 digital input module b k er Connect the AC Safet The T9100 processor base unit has a ground stud which must be y connected to the AC safety ground Connect the ground stud to the AC Ground Connection safety ground bus bar of the system or panel e Conductor wire must be a minimum of 12 AWG 3 31 mm with a temperature rating of 85 C e Use a M6 lug on the end of the ground wire e Place the lug below the second nut on the ground stud between two washers and use two 10mm wrenches to tighten the nuts to a torque of 1 2 Nm to 2 Nm 0 88 Ib ft to 1 48 Ib ft Refer to the photograph of t
15. Number 19110 Serial Number 504D4153 Current Revision 1 2 0 New Revision 1 22 0 lt Back Finish Cancel Help The continue message is displayed ControlFLASH Are you sure you want to begin 2 updating the target device ows L 7 Click Yes to continue with the update 156 Rockwell Automation Publication ICSTT RM448I EN P May 2015 System Start Up Chapter 6 e A progress bar is displayed Contr olFLASH 9 00 015 Progress Catalog Number 19110 Serial Number 504D4153 Curent Revision 1 2 0 New Revision 1 22 0 Transmitting block 164 of 4617 1o If the processor is not in the Recovery Mode the following error is displayed AB_ASA DLL Failed to begin update to the target device The target device b not in the proper mode to accept an update om Follow the procedure in Stage 1 to download the recovery Mode Rockwell Automation Publication ICSTT RM448I EN P May 2015 157 Chapter 6 System Start Up e After the progress bar reaches the end it may take several minutes for the next screen to appear i efx Control FLASH 9 00 015 Cangi TP a urim Le an pS Cod ess 1 A ss oe 1710 a SSS e Use the View Module Firmware Versions procedure to verify that the upgrade has worked The AADvance system uses Internet Protocol IP to carry S etting the Controller IP communications between the controller and the AADvance Workbench Address for
16. Park USA England Balgownie Road Bridge of Don Scotland Tel 44 1621 854444 Tel 44 1224 227780 Fax 44 1621 851531 Tel 1 713 353 2400 Fax 1 713 353 2401 Silvertech Middle East Rockwell Automation No 2 Corporation Road 04 01 to 03 Corporation Place Singapore 618494 ICS Middle East LLC Al Wahda Office Tower Office Numbers 1801 1802 1803 1804 Hazaa Bin Zayed Street 11th Street FZCO PO Box 17910 Jebel Ali Free Zone Dubai UAE PO Box 45235 Abu Dhabi UAE Tel 971 2 694 8100 Tel 971 4 883 7070 Tel 65 6622 4888 Fax 65 6622 4884 Rockwell Automation Publication ICSTT RM448I EN P May 2015 187
17. Publication ICSTT RM448I EN P May 2015 Install the AADvance System Chapter 5 Recommended Circuit for Analogue Outputs These circuits are suitable for simplex and dual configurations of analogue output modules All channels are isolated from each other but may be bridged at the terminal if fed by a common system mounted supply System powered devices Figure 20 Analogue output Circuit 24V Termination Assembly OV The above circuit is appropriate for devices that are powered by the system The channel will pass a requested current between 0 mA and 24 mA The field device could also be connected between the 24 V supply and the Loop Plus terminal IMPORTANT Ifthe 24 V supply is shared between channels or between modules the field loops will not be isolated from each other Rockwell Automation Publication ICSTT RM448I EN P May 2015 119 Chapter 5 Install the AADvance System Field powered devices V N Termination Assembly The above circuit is appropriate for devices that are powered locally and expect a current controlled signal loop Ensure that the loop is wired to pass current to the Loop Plus terminal and return it on the Loop Minus terminal Analogue Output Slew Tolerance Analogue output channels voltage slew is unconstrained with the limits set by the module s compliance operating voltage range To avoid spurious declaration of channel faults it is necessary to ensure that the field
18. Service of other aurswillance of the equipment The Maruteehunes be acey and Lily r agit i conformity of all equipment bo al applicable Standards specHicatons requinements or Directives The teal results maj nol be uad in whole oF in part in any other decumend witout UL a prise writen appris Date of issue 2011 09 02 Re issued 2014 06 03 UL International Demko A S Borupvang 54 2750 Ballerup Denmark Tel 45 44 85 65 65 info dk Eul com wew ul com OC IC FO0GO Issue 7 0 This cert icaie may only be reproduced in its entirety and wilhoul any change schedule included Page 1 of 5 Rockwell Automation Publication ICSTT RM448I EN P May 2015 27 Chapter 2 The AADvance Safety Controller 28 13 Schedule 14 TYPE EXAMINATION CERTIFICATE No DEMKO 11 ATEX 1129711X rev 2 Report 4786336921 15 Description of Equipment These devices are low power open type programmable logic controllers that are intended for installation in an ultimate enclosure The 9000 Programmable Logic Controller Series consist of the following Models 9111 9401 9402 9431 9432 9481 9482 9451 9801 9802 9803 9831 9832 9833 9851 9852 9892 9881 9882 Description Processor Backplane Dual Processor Backplane I O Backplane Processor Model Processor Model Digital Input Model Digital Input Model 16 Channel Analog Input Model Analog Input Model 16 Channel Analog Output Model Analog Output Model 8 Channel
19. address Controller ID displayed on a label on the processor base unit Install at least one 9110 processor module into the processor base unit Make sure the program enable key is inserted in the KEY connector on the processor base unit Rockwell Automation Publication ICSTT RM448I EN P May 2015 159 Chapter 6 System Start Up 160 3 Start the AADvance Discover tool from the Start menu e Start All Programs AADvance gt AADvance Discover The AADvance Discover utility scans the network for controllers and creates a list Configuration Name Res Num Status GR 00 A0 EC 40 02 6A PROJECT6 CONTROL Series Locked GB 00 A0 EC 40 02 F4 FELSA CONTROLLERI Series Locked GB 00 A0 EC 44 08 0A Series Configurable GB 00 A0 EC 44 25 4A Series Configurable GB 00 A0 EC 44 25 62 OPTIMDIVINPROGLD Series Locked GB 00 A0 EC 44 25 68 DRILLSHIPS FGS3 Series Locked U 00 A0 EC 44 25 74 Series 7 Configurable BR 00 A0 EC 44 25 7A Series Configurable MD 00 A0 EC 44 25 80 PROJECTSOE CONTR Series Locked GR 00 A0 C 44 25 A4 Series Configurable GR 00 A0 EC 44 25 AA PROJECTI CONTROL Series Locked OT R BA ja AF ms Rape EAn AA PAA A a ae 4 Locate the controller in the list and make sure that the status of the controller is Configurable 5 Double click the MAC address in the Controller ID field Rockwell Automation Publication ICSTT RM448I EN P May 2015 System Start Up Chapter 6 e The resource and
20. arbitrary fault and continue correct operation fault warning receiving station A location where corrective measures can be initiated Rockwell Automation Publication ICSTT RM448I EN P May 2015 9000 Series Glossary Chapter 10 fault warning routing equipment Equipment which routes a fault warning signal from control and indicating equipment to a fault warning receiving station field device An item of equipment connected to the field side of the I O terminals Such equipment includes field wiring sensors final control elements and operator interface devices which are hard wired to 1 0 terminals fire alarm device A component of a fire alarm system not incorporated in the control and indicating equipment which is used to give a warning of fire for example a sounder or visual indicator fire alarm receiving station A location from which fire protection or firefighting measures can be initiated fire alarm routing equipment Equipment which routes an alarm signal from control and indicating equipment to a fire alarm receiving station function block diagram An IEC 61131 language describing a function between input variables and output variables Input and output variables are connected to blocks by connection lines See limited variability language functional safety The ability of a system to perform the actions necessary to achieve or to maintain a safe state for a procedure and its related e
21. condition has been removed Faults in the I O modules are latched To clear them a fault reset signal 1s sent from the processor module by pressing the Fault Reset button on the processor module front panel Field faults are not latched and will clear as soon as the field fault is repaired When the Fault Reset button on each processor module is pressed it attempts to clear a fault indication immediately however the diagnostic 60 Rockwell Automation Publication ICSTT RM448I EN P May 2015 The AADvance Safety Controller Chapter 2 systems will report a serious problem again so quickly there will be no visible change in the fault status indications Remote Fault Reset Using the Workbench software you can set up a fault reset variable to mimic pressing the Fault Reset button on the front panel This feature 1s provided for systems located in inaccessible locations Refer to the AADvance Configuration Guide Doc No 553633 555063 for Workbench 2 0 for instructions on how to set up the variable On line updates 1 0 Configuration Changes The AADvance controller modular design makes it easy to create and change the I O configuration The on line update facility enables you to make changes to the I O configuration after the system is commissioned An on line update can be used for the following changes e Expand a system and add new I O modules base units and termination assemblies e Change the module type in a simplex or group ar
22. monitoring and control e Turbo machinery governor control and over speed protection not yet released An AADvance controller is particularly useful for emergency shut down and fire and gas detection protection applications as it offers a system solution with integrated and distributed fault tolerance It is designed and validated to international standards and is certified by TUV for functional safety control installations and UL for use in hazardous environments A controller is built from a range of compact plug in modules see illustration that are straightforward to assemble into a system A system can have just one or more controllers a combination of I O modules power sources communications networks and user workstations It can operate as a stand alone system or as a distributed node of a larger control system Rockwell Automation Publication ICSTT RM448I EN P May 2015 15 Chapter 2 The AADvance Safety Controller I O Base Unit Termination Assembly Blanking Panel Field Wiring Connectors Processor Base Unit mn monts mes NUNN IT _ wining on ee s ms wre s rs 8 t e t t fr i wi f Pid VO Module VO Module Processor module The printed circuit boards of all AADvance modules termination assemblies and backplanes are coated during manufacture The coating meets defense and aerospace requirements is approved to US MIL
23. non inverting Transmit receive data B non inverting 0 Instrument ground signal ground Instrument ground Transmit data B non inverting not used Transmit data A inverting not used 1 The line functions shown in the table receive and transmit are with respect to the processor base unit NOTE To connect to the external communication link you should terminate the receive end of the twisted pairs with a 120 Q resistor in series with a 68nF capacitor at the receiver ends Connecting Modbus Slave Devices to Serial Ports You can use a full duplex or a half duplex connection for a Modbus slave device on a serial port 102 Rockwell Automation Publication ICSTT RM448I EN P May 2015 Install the AADvance System Chapter 5 Connect a Slave Device Full Duplex You can use a full duplex serial connection to connect one Modbus slave device to the AADvance controller To make the physical connection do the following le Termination i Rd Note i Termination Termination 1200 68nF 9100 Processor Base part 1 Select an applicable cable We recommend 3 pair overall shielded cable 2 Remove the serial port connector from the 9100 processor base unit 3 Make the connections shown in the illustration Terminate the twisted pairs with a 120 Q resistor in series with a 68 nF capacitor at the receiver ends 4 Connect the signal ground not illustrated from the 0 V terminal to th
24. now Choose the options you want below Yes want to view the README file _ Yes want to launch ControlF LASH Click Close to exit e ControlFLASH will launch and you can now upgrade the Processor Module firmware Upgrade the Processor This is the recommended procedure to upgrade the processor module Module Recovery Mode firmware using the ControlIFLASH Utility Firmware NOTE ControlFLASH can upgrade three processor modules at once when installed into a 9100 base unit and they are in the Recovery Mode To do this press and hold the Fault Reset button on all three processors when they are being powered up during a power on off cycle until the AUX LED goes Amber WARNING FIRMWARE UPGRADE DANGER TO A RUNNING SYSTEM Do not attempt to upgrade firmware on a running system ControlFLASH will not warn you that a system is running and you will lose control of the application when the system reboots 1 Run the ControlFLASH software by either e Launching from the installation Rockwell Automation Publication ICSTT RM448I EN P May 2015 147 Chapter 6 System Start Up e Double clicking the desktop icon e Launching from the Start button i ControlFLASH Untitled R KOD A NY se 9 00 015 Welcome to ControlFLASH the firmware update tool ControlFLASH needs the following information from you before it can s begin updating a device Contr al 1 The Catalog Number of the target device 2 The Net
25. on line and supplying data to receiving data from application Module is inserted into a running system but not on line Push the Fault Reset button on any processor module to set the module to go on line Module is prepared to go on line but no application is running Rockwell Automation Publication ICSTT RM448I EN P May 2015 131 Chapter 5 Install the AADvance System Channel 1 8 OFF Input module field switch is open Output module output is in its de energized condition Note If the run indicator is not green the module is not reporting channel values all channel indicators will be off GREEN Input module input is on Output module output is in its energized condition AMBER Field fault RED Channel fault Status Indicators on the 9110 Processor Module Indicator Healthy Ready 132 Healthy fc Ready Run System Healthy Farce Aux Serial 1 serial 2 Ethernet 1 Ethe rnet 2 Table 11 Status Indicators on the T9110 Processor Module OFF No power RED e Flashes RED briefly after being installed as the module is booting up e Continuous RED means a Module has a fault GREEN As the module boots up it goes GREEN this lasts for 10 to 20 seconds When the module is operational the LED stays GREEN When in the recovery mode and no faults are present the LED is GREEN Fault Indications e If Healthy is GREEN and all the other indicators on the module are OFF then the module has failed
26. power consumption of all the modules Use the following table to estimate the system power consumption Table 6 Module Supply Power Consumption Item Number of Power Subtotal W Modules Consumption T9110 Processor Module T9401 Digital Input Module 24 Vdc 8 channel T9402 Digital Input Module 24 Vdc 16 channel T9431 Analogue Input Module 8 channel PB BW T9432 Analogue Input Module 16 channel T9451 Digital Output Module 24 Vdc 8 channel T9482 Analogue Output Module 8 channel isolated IMPORTANT The above figures are worst case values calculated from the range of operating voltages and currents If your system is required to meet UL CSA standards the power consumption and the corresponding electrical ratings must not exceed the maximum electrical ratings given in the table included in the topic Backplane Electrical Ratings 82 Rockwell Automation Publication ICSTT RM448I EN P May 2015 Before You Begin Chapter 4 System Design Considerations for Heat Dissipation and Cooling Field Power Consumption To estimate overall controller power dissipation it is necessary to include the field power component dissipated within the controller Refer to the table Field Loop Power Heat Dissipation The field power requirements should be calculated separately and is dependent on the number and type of field elements Refer to the specifications for the Digital and Analogue output modules for details of the channel
27. reporting short circuit 110 Rockwell Automation Publication ICSTT RM448I EN P May 2015 Install the AADvance System Chapter 5 e All of the input circuits are applicable for simplex dual and TMR configurations e The F amp G circuit assumes that the devices are volt free contacts e For more information please refer to Application Note AN T90001 Field Loop Configuration This also includes advice for fire detectors which are not simple volt free contacts Digital Input SlewTolerance It is possible during sustained periods of abnormal input voltage slewing that channels can be declared faulted as a consequence of diagnostics otherwise designed to ensure the channels are operating within their designed safety accuracy To avoid spurious declaration of channel faults it is necessary to ensure that the input signal condition satisfies the maximum slew rate criteria defined in the Solutions Handbook Accordingly it may be necessary to condition the input signal such as by filtering or by appropriate choice of process safety time Connections to 9801 Non isolated Digital Input TA 16 Channel Simplex OV CH1 CH2 CH3 CH4 CH6 CH7 CHS CH9 CH10 CH11f CHI2 fcH FCHI4 CHI5 JCH16 ae ee ee DE 1 HE NE OL IDI IOI Ol OP LILI D QD OY O A EE PE e Apply a minimum tightening torque of 0 5 Nm 0 37 ft Ib to the terminal screws Rockwell Automation Publication ICSTT RM448I EN P May 2015 1
28. sure that installations satisfy and maintain their required safety integrity level Solutions Handbook This technical manual describes the features performance and functionality of the AADvance controller and systems It gives guidance on how to design a system to satisfy your application requirements System Build Manual This technical manual describes how to assemble a system switch on and validate the operation of your system Configuration Guide This software technical manual defines how to configure an AADvance controller using the AADvance Workbench to satisfy your system operation and application requirements Troubleshooting and This technical manual describes how to maintain Maintenance Manual troubleshoot and repair an AADvance Controller OPC Portal Server This manual describes how to install configure and User Manual use the OPC Server for an AADvance Controller PFH and PFDavg Data This document contains the PFH and PFDayg Data for the AADvance Controller It includes examples on how to calculate the final figures for different controller configurations 186 Rockwell Automation Publication ICSTT RM448I EN P May 2015 Additional Resources Chapter 11 Regional Offices Rockwell Automation Millennium House Campus 1 Rockwell Automation Rockwell Automation 4325 West Sam Houston Hall Road Parkway North Suite 100 Maldon Houston Essex Aberdeen Science amp Texas 77043 1219 CM9 4LA Technology
29. to boot up e If Healthy is GREEN and Ready and Run are RED then the module is in its shutdown state OFF No power RED e Module is booting up 10 to 20 seconds or not educated or synchronized with partners e Module is in the shutdown state Flashing GREEN The module is being educated or synchronized GREEN Module is educated and synchronized with partners Rockwell Automation Publication ICSTT RM448I EN P May 2015 Install the AADvance System Chapter 5 Run System Healthy Force AUX Serial 1 and 2 Ethernet 1 and 2 AMBER OFF RED GREEN Module is in Recovery Mode No power and stays off while the module is booting up 10 to 20 seconds e Module is not educated synchronized No application loaded the processor module is in the Recovery Mode and the base level firmware is running e Module is in the shutdown state The module contains an application and it is running Module is in Recovery Mode or The module contains the application but the application has stopped Press Fault Reset to start the application No power and stays off while the module is booting up 10 to 20 seconds There is a fault on one or more modules or The application has stopped because the module has entered Recovery Mode No system or module faults present or The system is in Recovery Mode No power and stays off while the module is booting up 10 to 20 seconds No variables are being locked force
30. tool from the Start menu e Start gt All Programs AADvance gt AADvance Discover e The AADvance Discover utility scans the network for controllers and creates a list e Itcan also be launched from within the Workbench under the View menu 4 Locate the controller in the list and make sure that the status of the controller is Configurable 5 Double click on the MAC address in the Controller ID field e The resource and IP address dialog box is displayed 162 Rockwell Automation Publication ICSTT RM448I EN P May 2015 System Start Up Chapter 6 Ethernet E1 1 Ethernet E1 2 Gateway El Ethernet E2 1 Ethernet E2 2 Gateway E2 1 Enter the IP Address and Subnet Mask into the fields for each Ethernet port 2 Enter the Gateway values for each processor module then click Apply e Returning to the main window of the utility the controller status will shows In Progress and then Configurable e The controller uses the new settings Rockwell Automation Publication ICSTT RM448I EN P May 2015 163 Chapter 6 System Start Up Page intentionally left blank 164 Rockwell Automation Publication ICSTT RM448I EN P May 2015 Chapter 7 Functional Acceptance Testing Functional acceptance testing also known as factory acceptance testing or integration testing tests the controller and its application software to make sure that it satisfies the requirements specified in the requirements for the i
31. will not run The application must be password protected Removable media such as USB storage devices and CDs must be virus checked before use in the system Rockwell Automation Publication ICSTT RM448I EN P May 2015 107 Chapter 5 Install the AADvance System Connecting Field Wiring 108 Connect the field wiring to the screw terminal blocks on the termination assemblies Use conductor wire with a cross section of 16 AWG The stripping length should be 6mm 1 4 in and a conductor temperature rating of 85 C Apply a tightening torque of 0 5 Nm 0 37 ft Ib to the terminal screws Digital Input Field Loop Circuits Recommended Field Loop Circuits This section contains recommended field loop circuits for line monitoring digital inputs used in Emergency Shutdown or Fire amp Gas applications Field Loop Circuit for Digital Input 24V de Controller DEN Termination Assembly 4K390 Terminal Blocks Where IE Independent earth Rockwell Automation Publication ICSTT RM448I EN P May 2015 Install the AADvance System Chapter 5 Field Loop Circuit for Line Monitored Digital Input for Emergency Shutdown Systems ESD 24V de Controller os Termination Assembly sf Ri l i i i i h i 4k990 Sac i i 1000 Shield i i i if used l i l The suggested values for R1 and R2 are as follows e R1I 15K Q 1 1W maximum power dissipa
32. 015 11 Table of Contents Functional Acceptance Testing Dismantling the AADvance System Parts List 9000 Series Glossary Additional Resources Processor Firmware Upgrades ccccccccccecceeeeeeeeeeaeeeeeesseseees 143 Stage 1 Install ControlFLASH for Recovery Mode and Secondary BOO UB iw ail C ercts seveassose IR eee nae ews 144 Upgrade the Processor Module Recovery Mode Firmware 147 Stage 2 Install ControlFLASH for System Firmwate 153 Upgrade Processor OS FPGA LSP and BUSP Firmwarte 153 Setting the Controller IP Address for AADvance Workbench COMMUNICATIONS nent diet 158 COMMON IPAddress ESS eer peer mnee arn eeeeient S 158 Troubleshooting AADvanceDiscover Communications 159 Configure the Controller Resource Number in the Controller 159 Configure the IP Address in the Controller cceeeeeeeeeeeees 162 Chapter 7 Devising tests for Functional Acceptance cccceeeeseeeeees 165 Test Environment for Functional Acceptance 165 Managing Functional Acceptance Testing 166 Chapter 8 About Dismantling a System 167 Chapter 9 Chapter 10 CHOSSAL OL T EMS ano ns nn once 173 Chapter 11 RE S10 tial ONCOS SR cn ne ne ed dies 187 Rockwell Automation Publication ICSTT RM448I EN P May 2015 Chapter 1 The AADvance System An AADvance system consists of an AADvance controll
33. 1 46058C standard and meets IPC CC 830 The coating is also UL approved NOTE A Key benefit of the AADvance system 1s its flexibility All of the configurations are readily achieved by combining modules and assemblies without using special cables or interface units System architectures are user configurable and can be changed without major system modifications Processor and I O redundancy is configurable so you can make a decision between fail safe and fault tolerant solutions There is no change to the complexity of operations or programming that the controller can handle if you add redundant capacity to create a fault tolerant solution They can be mounted onto DIN rails in a cabinet or directly mounted onto a wall in a control room Forced air cooling or special environmental control equipment is not necessary However important consideration must be given to the choice of cabinet or when the controller is installed in a hazardous environment Specific guidelines are given in this user documentation to help you choose an enclosure that will make sure that the system operates to its Rockwell Automation Publication ICSTT RM448I EN P May 2015 16 The AADvance Safety Controller Chapter 2 Safety Features full capability and reliability and that it also complies with the ATEX and UL certification requirements for use in hazardous environments The Ethernet and serial ports are configurable for a number of protocols in
34. 1 08 24 2011 08 25 2011 10 24 2011 08 24 2011 10 24 2012 02 09 2012 02 09 2012 02 09 2011 08 24 2011 08 25 2011 08 25 2011 08 24 2011 08 25 2011 08 25 2011 08 25 2011 08 25 2011 08 25 2011 08 04 2011 08 04 2013 12 23 2014 05 Subject devices are for use in an area of not more than pollution degree 2 in accordance with IEC 60664 1 Subject devices are to use conductors with a minimum conductor temperature rating of 85 C Subject devices are to be installed in the vertical orientation only 18 Essential Health and Safety Requirements Met by compliance with the standards EN 60079 0 2012 A11 2013 EN 60079 15 2010 00 IC F0060 Issue 7 0 Rockwell Automation Publication ICSTT RM448I EN P May 2015 This certificate may only be reproduced in its entirety and without any change schedule included Page 5 of 5 31 Chapter 2 The AADvance Safety Controller 32 IECEx UL Certificate IECEXx Certificate of Conformity INTERNATIONAL ELECTROTECHNICAL COMMISSION IEC Certification Scheme for Explosive Atmospheres for rules and details of the IECEx Scheme visit www iecex com Certificate No IECEx UL 12 0032X issue No 2 Certificate history Issue No 2 2014 5 28 Status Issue No 1 2014 1 30 Current Issue No 0 2012 8 27 Date of Issue 2014 05 28 Page 1 of 4 Applicant Rockwell Automation Ltd Hall Road Maldon CM9 4LA United Kingdom Electrical Apparatus Programmable Logic Controllers
35. 11 Chapter 5 Install the AADvance System Connections to 9802 9803 Isolated Digital Input TA 16 Channel Dual TMR CHI CH2 CH3 CH4 CH5 CH6 CH7 CHB CH9 CH10 CH11 CHI2 CH13 CH14 CH15 CHI6 CHI CH2 J CH3 9 CHa J CH5 CH f CH7 9 CHE CH9 PCHIO 4 EH11 4 PCH12 D CH13 4 CH14 9CH154 9 CH 16 e Apply a minimum tightening torque of 0 5 Nm 0 37 ft Ib to the terminal screws Analogue Input Field loop Circuits These circuits can be used for simplex dual and triple configurations of analogue input modules Fit a fuse as shown in each circuit to protect the field wiring 112 Rockwell Automation Publication ICSTT RM448I EN P May 2015 Install the AADvance System Chapter 5 Recommended Field Loop Circuits 2 Wire Analogue Input Figure 15 2 Wire Analogue Input Field Loop 24 de Controller Termination i Assembly Shield if used l Terminal Blocks 3 Wire Analogue Input Figure 16 3 Wire Analogue Input Field Loop 24 de E Controller ooo PEE EO MT i i Termination i Assembly i 4 20 mA 1 l fl 50 mA Shield l i if used qer J ah 1200 Terminal Blocks i ee Rockwell Automation Publication ICSTT RM448I EN P May 2015 113 Chapter 5 Install the AADvance System 4 Wire Analogue Input Figure 17 4 Wire Analogue Input Field Loop W SOMA H I L i fi L H Wa io Controller Te
36. 2 2 GHz or higher CPU 1 024 MB or more RAM a 1 280 x 1 024 display and a 7 200 RPM or higher hard disk It is also recommended that the hard disk has at least 10 GB free space This provides sufficient space to hold the distribution zip file the unzipped source files and the installed program files and also enough space for Windows to operate reasonably quickly You can get back a lot of this space by deleting the source files after finishing the installation Maintenance Activities The design of the installation must allow preventive and corrective maintenance activities to take place Corrective maintenance tasks will embrace the identification and renewal of defective modules and other assemblies and when exhausted renewal of the back up battery within the T9110 processor module Fuses on the termination assemblies can be replaced so access to the fuses is required There are no user serviceable parts inside modules therefore repair 1s by replacement defective modules should be returned to Rockwell Automation for investigation and repair Rockwell Automation Publication ICSTT RM448I EN P May 2015 87 88 Chapter 4 Before You Begin WARNING EXPLOSION HAZARD Do not connect or disconnect equipment while the circuit is live or unless the area is known to be free of ignitable concentrations or equivalent AVERTISSEMENT RISQUE D EXPLOSION Ne pas connecter ou d connecter l quipement alors qu il est sous ten
37. 448I EN P May 2015 79 Chapter 4 Before You Begin 80 Power Supply and Power Distribution Requirements The power supplies and power distribution 1f incorrectly designed are a possible electrical or fire safety hazard and can contribute to common cause failure It is therefore necessary to e Establish the power philosophy specific earthing philosophy power requirements and the separation requirements where items of equipment are separately supplied for example system internal supplies and field loop supplies e Make sure that the chosen Power Supply Units PSUs are compatible with the power feeds supplied Alternatively measures must be put in place to make sure that the power feeds stay within the specifications of the PSUs e Define the power distribution requirements together with the protective philosophy for each distribution for example current limited at source or protective devices Where protective devices are used it is important to find out that sufficient current will be available to make sure their protective action and the protective device can break the maximum prospective fault current e Make sure that the power supplies are sufficient to meet the system load and for any foreseeable load requirements and load transients e Make sure that the power supplies have a minimum hold up time of 10ms e Make sure that the power distribution cabling is sized to allow the maximum prospective fault currents
38. 61 67 Pages Model 9481 and 9482 Schematic Board Nos 151631 and 130842 M10 2013 09 26 151791 41 Pages Model 9482 Schematic Board No 151801 56 Pages 130852 H4 2013 09 26 Model 9451 Schematic Board No 151521 42 Pages 130722 R2 201 1 05 31 Model 9451 Schematic Board No 151531 21 Pages 130732 O 2009 07 01 00 IC F0060 Issue 7 0 This certificate may only be reproduced in its entirety and without any change schedule included Page 3 of 5 Rockwell Automation Publication ICSTT RM448I EN P May 2015 29 Chapter 2 The AADvance Safety Controller 13 Schedule 14 TYPE EXAMINATION CERTIFICATE No DEMKO 11 ATEX 1129711 X Rev 2 Report 4786336921 Description Drawing No Rev Level Date Model 9801 and 9831 Schematic 6 Pages 130812 H 2009 01 22 Model 9802 and 9832 Schematic 7 Pages 130802 C 2008 04 09 Model 9803 and 9833 Schematic 7 Pages 130782 J 2009 04 23 Model 9851 Schematic 2 Pages 130822 C 2008 01 22 Model 9852 Schematic 2 Pages 130792 F 2008 01 23 Model 9402 and 9432 Schematic Board no 151751 62 130772 F1 2012 05 25 Pages Model 9881 Schematic 130872 A 2009 04 17 Model 9882 Schematic 130862 C1 2011 04 12 Model 9892 Schematic 131212 A 2011 10 17 Model 9100 Construction Drawing 2 Pages 151490 GA G1 2012 07 27 representative of Model 9101 Model 9300 Construction Drawing 6 Page 9300 GA 3 2013 10 18 Model 9110 Construction Drawing 3 Pages 9110 GA 3 2012 03 13 Model 9401 Construction Drawing
39. 8 CIP Produce amp Consume Rockwell Automation Publication ICSTT RM448I EN P May 2015 63 Chapter 2 The AADvance Safety Controller Page intentionally left blank 64 Rockwell Automation Publication ICSTT RM448I EN P May 2015 Programming Language Support Program Management Facilities Support for Variable Types Chapter 3 Application Resource Development The AADvance Workbench environment helps you with the task of automation during the life cycle of your system from system design to commissioning and the day to day operation and maintenance For application resource development the AADvance Workbench has powerful intuitive features and functionality to enhance simplicity This chapter introduces the AADvance Workbench and describes basic software features The AADvance Workbench is IEC 61131 3 compliant offering all five languages of the standard e Ladder diagram graphical e Function block diagram graphical e Structured text textual e Instruction list textual e Sequential function chart graphical Note Instruction List IL and Sequential Function Chart SFC languages are not supported by AADvance Workbench 2 0 The development environment is designed for collaborative working A group of engineers can work together with shared ownership of a project Each contributor can simply look at the part of the application on which they wish to work Program management features let you identif
40. AADvance The Next Step in Automation AADvance Controller System Build Manual ICSTT RM448I EN P May 2015 LISTEN Cone Rockwell Allen Bradley Rockwell Software Automation Page intentionally left blank ISIN a Ns Rockwell gt Allen Bradley Rockwell Software Automation PREFACE In no event will Rockwell Automation be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment The examples given in this manual are included solely for illustrative purposes Because of the many variables and requirements related to any particular installation Rockwell Automation does not assume responsibility or reliability for actual use based on the examples and diagrams No patent liability is assumed by Rockwell Automation with respect to use of information circuits equipment or software described in this manual All trademarks are acknowledged DISCLAIMER It is not intended that the information in this publication covers every possible detail about the construction operation or maintenance of a control system installation You should also refer to your own local or supplied system safety manual installation and operator maintenance manuals REVISION AND UPDATING POLICY This document is based on information available at the time of its publication The document contents are subject to change from time to time The latest versions of the manu
41. AADvance This chapter shows you how to set up the IP address in the controller It is convenient to set up the controller resource number at the same time Workbench Communications Controller IP Address The AADvance controller stores its IP address data in non volatile memory in the 9100 processor base unit The data is independent of the 9110 processor modules in the controller and so the controller keeps the address information when you remove a processor module You must set up the IP address data when you create a new system or if you fit a new processor base unit After having set up the IP address data in the controller you can configure the AADvance Workbench to find the controller on the network 158 Rockwell Automation Publication ICSTT RM448I EN P May 2015 System Start Up Chapter 6 Troubleshooting AADvanceDiscover Communications Configure the Controller Resource Number in the Controller This procedure describes how to activate communications using the Discover tool After completing the steps refresh the Discover tool s list of modules to test for communications l Ensure that the Ethernet cable is plugged into a socket above a fitted AADvance controller communications will not pass through unused slots Ensure that the controller is activated by turning the locking bar Wait for the Ready LED to go green before refreshing the Discover tool The communications tasks are not active until it is
42. ADvance Safety Controller 38 e the regulation of the flow of control decisions for an interacting distributed control system e providing for the consistency of data e providing a means for synchronous operation between devices e eliminating the need to have separate synchronous schemes e easing the development and maintenance of robust systems The Workbench is a software development environment for a controller It lets you create local and distributed control applications using the five languages of IEC 61131 3 Instruction List IL and Sequential Function Chart SFC languages are not supported by AADvance Workbench 2 0 Engineers can use one language or a combination that best suits their knowledge and programming style and the type of application The Workbench is a secure development environment There is also a Program Enable key that must be plugged into the processor base unit to allow the user to modify and download the application resource or access the AADvance Discover tool to set or change the controller IP address The Program Enable Key when it is removed protects the application from unauthorized access The development environment includes e tools for program development e program documentation e function block library management e application archiving e database configuration e import export utilities e on line monitoring e off line simulation and controlled on line changes e Programs can be simul
43. F0060 Issue 7 0 This certificate may only be reproduced in its entirety and without any change schedule included Page 4 of 5 30 Rockwell Automation Publication ICSTT RM448I EN P May 2015 The AADvance Safety Controller Chapter 2 13 Schedule 14 TYPE EXAMINATION CERTIFICATE No DEMKO 11 ATEX 1129711 X Rev 2 Report 4786336921 Description Marking Label Model Number only 9882 1 Page Marking Label Model Number only 9892 1 Page System Build Manual Installation Instructions 107 Pages Model 9100 and 9101 Critical Component List 2 Pages Model 9110 Critical Component List Circuit Number 151421 3 Pages Model 9110 Critical Component List Circuit Number 151431 4 Pages Model 9300 Critical Component List 2 Pages Model 9401 and 9402 Critical Component List 4 Pages Model 9402 Critical Component List 2 Pages Model 9431 and 9432 Critical Component List 3 Pages Model 9481 and 9482 Critical Component List 6 Pages Model 9482 Critical Component List 3 Pages Model 9451 Critical Component List Circuit Number 151521 4 Pages Model 9451 Critical Component List Circuit Number 151531 3 Pages Model 9801 Critical Component List 3 Pages Model 9802 Critical Component List 3 Pages Model 9803 Critical Component List 3 Pages Model 9831 Critical Component List 3 Pages Model 9832 Critical Component List 3 Pages Model 9833 Critical Component List 3 Pages Model 9851 Crit
44. Half Duplex 106 SV SUCH D CUPLL NS RN me en neNence 107 Connecting Field Wiring ss 108 Digital Input Field Loop Circuits 108 Analogue Input Field loop Circuits 112 Recommended Field Circuit for Digital Outputs 116 Recommended Circuit for Analogue Outputs 119 Install MOdUISS as nant tentent 121 Install a 9110 Processor Module 121 Replace a Faulty Processor Back up Battery 122 Set the Real Time Clock Manually cccececscsseeeeeeeeeeeees 125 Install TVO Modules rnesa e a nd munie 127 Install T9310 Expansion Cables cccccccccsnsesssssessccceseeeeensees 128 Fault Reporting Reference Information 131 Status Indicators on the 94xx Series Input and Output Modul arune se eee ne en Cee ent ee E Pee Ph cee one ere 131 Status Indicators on the 9110 Processor Module 132 Chapter 6 Recommendations to Manage Test Documentation 135 System Physical Desien Check ote tees 135 Procedure to Verify Build State cc ceeccccceeeceeeeeeeeeeeeeeeeaeees 136 Procedure to Conduct the Mechanical Inspection 00000000eenn 136 Procedure to Check Ground Bonding ccceeeseeeeeeeeeeeees 136 Procedure to Check Power Distribution Integrity 0 137 Power Distribution and First Power Up 137 Start Up PTOCESS nn de 138 Processor Module Start Up Process 139 VO Mod le Start Up Process Sen ne ess 142 Rockwell Automation Publication ICSTT RM448I EN P May 2
45. IP Address dialog box is displayed Series 9000 00 A0 EC 00 23 CC EUROTEST CONFIGI l Enable Ethernet Forwarding View MAC addresses 6 Enter the resource value into the Resource Number field then click Apply e Returning to the main window of the utility the controller status will show Pending Restart 7 To finish the update turn off the power to the controller 8 Start the controller Refresh the screen to make sure that the new resource number is shown in the resource field and that the controller status is configurable IMPORTANT The Resource Number must also be configured in the application in the Resource Properties Rockwell Automation Publication ICSTT RM448I EN P May 2015 161 Chapter 6 System Start Up Configure the IP Address in When you assemble a new AADvance controller or install a new 9100 processor base unit you have to configure the IP Address stored in the the Controller controller The procedure to configure the IP Address uses the AADvance Discover utility Changes occur immediately and you do not have to start the controller again To set the IP Address do the following 1 Write down the controller s MAC address the Controller ID displayed on a label on the processor base unit Install at least one 9110 processor module into the processor base unit 2 Make sure the program enable key is inserted in the KEY connector on the processor base unit 3 Start the AADvance Discover
46. Item Number of Module Power Heat Subtotal Modules Dissipation W BTU hr T9110 Processor Module x 8 0 W 27 3 BTU hr T9401 Digital Input Module 24 Vdc 8 channel x 3 3 W 11 3 BTU hr T9402 Digital Input Module 24 Vdc 16 channel x 4 0 W 13 6 BTU hr T9431 Analogue Input Module 8 channel x 3 3 W 11 3 BTU hr T9432 Analogue Input Module 16 channel x 4 0 W 13 6 BTU hr T9451 Digital Output Module 24 Vdc 8 channel x 3 0 W 10 2 BTU hr T9482 Analogue Output Module 8 channel isolated x 3 6 W 12 3 BTU hr Total Table 8 Field Loop Power Heat Dissipation The field loop power heat dissipation is generated from the input voltages and currents the output currents Item Number of Field Loop Power Heat Dissipation Subtotal Field loops W x 3 412 BTU hr Digital Inputs x Input Voltage V 5125 84 Analogue Inputs Digital Outputs Analogue outputs x Input current A x 135 x Output current A x 0 57 x Field voltage V x Output Current A load Resistance Q x Output current A Total The maximum field loop power heat dissipation for analogue outputs should be calculated at an output current corresponding to the smaller of the Maximum Channel Output Current OR Field Voltage 2 x Load Resistance Rockwell Automation Publication ICSTT RM448I EN P May 2015 T9100 T9110 T9401 T9402 T9431 T9432 T9451 T9482 T9300 T98x1 T98x2 T98x3 T9310 T9841 Informat
47. MA4BI EN P May 2015 35 Chapter 2 The AADvance Safety Controller Annexe for IECEx UL 12 0032 en EE Vdc 400mA per slot 400mA per slot 9300 I O Backplane 18 32 9 6A fe ie Er 9110 Processor Module 8 32 9111 Processor Module 18 32 380 1 380 24 mA 6 5 mA 6 5 mA Channel 24 mA 0 20mA Channel 0 20mA 0 5A Pilot Duty 16VA 1 5A Inrush Channel Simplex Digital Input Termination Assembly 16 6 5 Channel Dual Digital Input Channel TMR Digital Input Channel Simplex Analogue Input Channel Dual Analogue Input Channel TMR Analogue Input a al ES Simplex Digital Output Termination Assembly 8 Channel 18 32 Dual Digital Output Dual Digital Output Lo ll DS Simplex Analogue Output S out Anaogue Op Dual Analogue Output Module 9100 Processor Backplane and 9101 Dual Processor Backplane are for use with Module 9110 and 9111 Processors Module 9300 I O Backplane is for use with all other Modules Subject devices are all marked Ex nA IIC T4 Ge 36 Rockwell Automation Publication ICSTT RM448I EN P May 2015 The AADvance Safety Controller Chapter 2 Module Label KCC EMC Registration The AADvance Workbench and Software Development Environment The L following label information must be attached to each module Rockwell Automation Hall Road Maldon UK CM9 4LA IND CONT EQ FOR USE IN s HAZARDOUS LOCATIONS n CL I DIV 2 GP A B C D LISTED Tamb 25 C to 60 C Ej mek
48. O data and assists with fault containment Rockwell Automation Publication ICSTT RM448I EN P May 2015 59 Chapter 2 The AADvance Safety Controller Ethernet Serial Links a Bus 10 Bus 1 sg Bus 10 Bus2 i in Individual Response Bus s aT a Internal Diagnostics and Fault Reset The AADvance controller contains comprehensive internal diagnostic systems to identify faults that occur during operation and trigger warnings and status indications The diagnostic systems run automatically and test the system for faults related to the controller and field faults related to field I O circuits Serious problems are reported immediately but faults that are not on non critical items are filtered to prevent spurious alarms The diagnostic systems monitor such items at regular times and need a number of occurrences of a possible fault before reporting it as a problem The diagnostic systems use simple LED status indications to report a problem The LED indications identify the module and can also identify the channel where the fault has occurred There is also a summary system healthy indication for all of the controller The application software uses its variable structures to report a fault problem these variables give status reports and are configured using the AADvance Workbench Faults in the processor modules are none latching The controller will recover automatically and the fault indication will clear once the fault
49. Ready Do not use an office network Use an isolated hub or switch between the computer and AADvance controller Check that the hub switch has LEDs lit for the ports to both computer and controller showing that the ports are working Open the Network Connections window Open the Properties of the computer s network adapter as used for configuring AADvance Un tick all protocol items which are not immediately necessary especially Check Point SecuRemote and iPass Protocol Gf present You will need to leave Internet Protocol or IPv4 and IPv6 Client for Microsoft Networks File and Printer Sharing and Network Monitor Driver if present for normal Windows operation Disable the Windows Firewall or any third party firewalls and shields If you are using a laptop disable Wireless If you have more than one network connection disable the one you are not using The Discover tool installed with AADvance Workbench release 1 2 1 20 109 will not discover with more than one network connection available When assembling a new AADvance controller or install a new 9100 processor base unit you have to configure the resource number stored in the controller The resource number is a type of device address and it must also be configured in the application The procedure to configure the resource number uses the AADvance Discover utility To set the resource number do the following l Write down the controller s MAC
50. SES de ae nie 37 Operating Systems 32 or 64 bit 39 Importing and Exporting Data cccccccccccceeceeeeeeseeeeeeeees 40 AADvance Workbench Licensing cccccccccesseeeeeeeeeeeees 40 Corrective Maintenance and Module Replacement 40 TUV Approved Operating System 41 Main OM PON CIS nantes 41 PAYSICAL POALNTES sn a N 41 Environmental Specification 42 Product DIMENSIONS x nn en 44 Compact Module D S une 45 Module Polarization Keying cccccccccccceeceeeeeeeeseeeeeeeeeeeees 46 Module Locking Mechanism 47 Freid WIRE Re A ANNE 47 PROCESSOR Baso UN Cernere ue ct 49 External Ethernet Serial Data and Power Connection 49 Serial Communications Ports 50 Processor Back up Battery 51 Processor Maintenance Socket s00cececeeeeeccecencnnesseseees 53 VOBIS ESS nn hd ie none 54 Termination Assembl es tit nan tndes 54 Backplane Electrical Ratno S niie a T 57 Expansion Cable oerien aieia EA A EEES EN AE 59 Te CMI Cal EC AUS renie A sa ir 59 Controller Internal Bus Structure 59 Internal Diagnostics and Fault Reset 60 Remote Fault se latsasuctit cian ne 61 On line updates I O Configuration Changes 6l Hot Swap I O for Business Critical Channels 62 Table of Contents Application Resource Development Before You Begin 10 Processor Firmware Upgrad
51. TIONS OF CERTIFICATION YES as shown below Models 9110 and 9111 The ambient temperature range is 25 C to 60 C All other Models The ambient temperature range is 25 C to 70 C m Subject devices are to be installed in an IECEx Certified IP54 tool accessible enclosure that has been evaluated to the requirements of IEC 60079 0 Ed 6 and IEC 60079 15 Ed 4 Enclosure is to be marked with the following Warning Do not open when energized After installation of subject devices into the enclosure access to termination compartments shall be dimensioned so that conductors can be readily connected Grounding conductor should have a minimum cross sectional area of 3 31 mm Subject devices are for use in an area of not more than pollution degree 2 in accordance with IEC 60664 1 Subject devices are to use conductors with a minimum conductor temperature rating of 85 C m Subject devices are to be installed in the vertical orientation only Rockwell Automation Publication ICSTT RM448I EN P May 2015 The AADvance Safety Controller Chapter 2 IECEx Certificate of Conformity Certificate No IECEx UL 12 0032X Date of Issue 2014 05 28 Issue No 2 Page 4 of 4 DETAILS OF CERTIFICATE CHANGES for issues 1 and above Issue 1 Addition of Model 9892 and updated drawings Issue 2 Update to the latest edition of IEC 60079 0 Annex Annexe for IECEx UL 12 0032 Issue 2 pdf Rockwell Automation Publication ICSTT R
52. a length of cable 78 Rockwell Automation Publication ICSTT RM448I EN P May 2015 Before You Begin Chapter 4 System Power Requirements trunking or the equivalent be put above each set of base units for cable management Figure 12 Field Wiring Connections A controller s system power should be supplied from two different 24 Vdc Nominal power supplies with a common return path that is the 0 V return will be the same between the power feeds Each controller also requires an external field power source for the field loops A controller system must be installed with a power network that is designed to meet over voltage Category II see BS EN 60664 1 This means that a controller must be supplied with system power from a power source that complies with SELV and PELV standards e SELV safety extra low voltage is a voltage which is no larger than 30 Vrms 42 4 Vpeak and 60 Vdc between conductors or between each conductor and earth in a circuit which is isolated from the line voltage by a safety transformer e PELV protected extra low voltage is an extra low voltage circuit with a protective partition from other circuits which has a protective earth connection To satisfy SELV and PELV requirements the power source must have a safety transformer with a protective partition between the primary and secondary windings so that the windings are galvanic and electrically isolated Rockwell Automation Publication ICSTT RM
53. additional user licences for use with T9084U IEC 61131 Workbench 2 Part Description OPC portal server AADvance DTM for use with HART Pass Through feature Demonstration Unit Part No T9141 Part Description AADvance Demonstration Unit Including HMI Miscellaneous Items Part No Part Description T9901 No 396 TES 50 mA time lag fuse UL 248 14 125 V Leadfree manufactured by Littelfuse T9902 SMF Omni Block Surface Mount Fuse Block 154 010 with a 10 A 125 V Fast Acting Fuse Littelfuse gt T9905 Polycarbon monofluoride Lithium Coin Battery BR2032 20 mm dia Nominal voltage 3 V Nominal capacity mAh 190 Continuous standard load mA 0 03 Operating temperature 30 C to 80 C supplied by Panasonic Rockwell Automation Publication ICSTT RM448I EN P May 2015 171 Chapter 9 Parts List Page intentionally left blank 172 Rockwell Automation Publication ICSTT RM448I EN P May 2015 Glossary of Terms A accuracy The amount of closeness of a measurement of a quantity to the true value of the quantity See also resolution achievable safe state A safe state that is achievable Sometimes a safe state cannot be achieved An example is anon recoverable fault such as a voting element with a shorted switch and no means to bypass the effect of the short actuator A device causing an electrical mechanical or pneumatic action to occur in a plant component Examples are va
54. als are available at the Rockwell Automation Literature Library under Product Information information Critical Process Control amp Safety Systems DOWNLOADS The product compatibility and download center is www rockwellautomation com rockwellautomation support pcdc page Select the Find Downloads option under Download In the Product Search field enter AADvance and the AADvance option is displayed Double click on the AADvance option and the latest version is shown Select the latest version and download the latest version AADVANCE RELEASE This technical manual applies to AADvance Release 1 34 Rockwell Automation Publication ICSTT RM448I EN P May 2015 3 LATEST PRODUCT INFORMATION For the latest information about this product review the Product Notifications and Technical Notes issued by technical support Product Notifications and product support are available at the Rockwell Automation Support Center at http rockwellautomation custhelp com At the Search Knowledgebase tab select the option By Product then scroll down and select the ICS Triplex product AADvance Some of the Answer ID s in the Knowledge Base require a TechConnect Support Contract For more information about TechConnect Support Contract Access Level and Features please click on the following link https rockwellautomation custhelp com app answers detail a_1d 5087 1 This will get you to the login page where you must enter your login detail
55. ance criteria over the safety life cycle protocol A set of rules that is used by devices such as AADvance controllers serial devices and engineering workstations to communicate with each other The rules encompass electrical parameters data representation signaling authentication and error detection Examples include Modbus TCP and IP PST Process Safety Time The process safety time for the equipment under control denoted PSTeuc is the length of time a dangerous condition can exist before a hazardous event occurs without a safety system as a protection Rockwell Automation Publication ICSTT RM448I EN P May 2015 9000 Series Glossary Chapter 10 real A class of analogue variable stored in a floating single precision 32 bit format redundancy The use of two or more devices each performing the same function to increase reliability or availability better resolution The smallest value measurable by an instrument the level of detail which can be represented For example 12 bits can distinguish between 4096 values RS 422 RS 485 Standard interfaces introduced by the Electronic Industries Alliance covering the electrical connection between data communication equipment RTC Real time clock RTU Remote terminal unit The Modbus protocol supported by the AADvance controller for Modbus communications over serial links with the ability to multi drop to multiple slave devices Rockwell Auto
56. and tolerable voltage losses This is specifically important where floating supplies are employed and other power sources can cause high prospective fault currents if multiple earth faults occur Controller Power Supply Requirements A controller requires the following power supply sources e A dual redundant power supply of 24 Vdc with an operating range of 18 Vdc to 32 Vdc The AADvance controller is designed to accept supply transient and interference according to IEC 61131 part 2 An over current fault in the controller must not cause the system to lose power Consequently the power sources must be able to supply the peak current to open any over current protection devices such as fuses without failing The power supply protection of the controller is in the modules the power distribution arrangement must have a circuit breaker on the input Rockwell Automation Publication ICSTT RM448I EN P May 2015 Before You Begin Chapter 4 side of each power source The controller is designed to be resistant to a reverse polarity connection without permanent damage The power sources must come from a commercially available industrial un interruptible power supply UPS system An applicable UPS must have the capacity sufficient to satisfy the entire system load including field devices and the controller and an applicable contingency allowance for projected future expansion The power supplies must satisfy the electrical requirement
57. ase units and modules to further expand the I O system Hot Swap 1 0 for Business Critical Channels You can add a hot swap capability for business critical data channels By installing a single I O module into a dual TA When a dual TA is configured you are leaving an empty spare slot for a replacement I O module when a fault occurs You can insert a new I O module into the spare slot and restore a failed channel without interrupting the operation of the other channels TIP Configure this hot swap arrangement when you configure your system at installation and set up time Processor Firmware Upgrades You can check the firmware revision of you processor modules without removing them to read the label and you can upgrade the firmware revision of the processor modules Upgrading the firmware in the 9110 processor module is done in the Recovery Mode and is a two stage process e Stage 1 Run the latest version of 350720 xxx ControlFLASH ms1 program to install the ControlFLASH firmware upgrade kit for the Recovery Mode on your PC Then run the ControlFLASH utility to upgrade your processor module and install the Recovery Mode If your module is delivered with the Recovery Mode installed then this stage 1s not necessary Stage 1 must be performed individually on each processor it does not matter if you download the Recovery Mode one at a time in a specific slot or in their own slots e Stage 2 Reboot the processor and press and hold th
58. ased Frequency Input Module TA TMR Passive not yet released Expansion Cable Assembly Expansion cable assembly comprising expansion cable and two adapters Part No T9310 02 Part Description Backplane expansion cable 2 metre Blanking Covers Part No T9191 T9193 Spares amp Tools Part No T9901 T9902 T9903 T9904 T9905 T9906 T9907 T9908 Software Part Description Blanking cover tall for 1 0 positions with no TA fitted Blanking cover short for 1 0 positions with TA or a Processor Part Description Replacement input fuse 50 mA for T9801 2 3 and T9831 2 3 pack of 20 t Replacement output fuse 10A for T9851 2 pack of 20 Replacement coding pegs pack of 20 Replacement backplane clips pack of 20 Replacement processor 3 V lithium cell pack of 20 3 Replacement program enable key Installation tool kit Fuse Extractor Tool Part Description Part No Rockwell Automation Publication ICSTT RM448I EN P May 2015 Parts List Chapter 9 T9082U T9082D Part No T9083U T9083D Part No T9084U T9085 T9087 Part No T9030 T9033 IEC 61131 Workbench USB key single user single controller IEC 61131 Workbench hard disk key single user single controller Part Description IEC 61131 Workbench USB key multiple controllers IEC 61131 Workbench hard disk key multiple controllers Part Description IEC 61131 Workbench 5 user USB key multiple controllers 5
59. ated and tested on the computer before downloading to the controller hardware Also supplied are a set of configuration tools that enables you to define the hardware architecture in the software set up the processor functionality and connect application variables to the Workbench application resource program that will monitor processor and I O module status information and report I O channel data values to the Workbench Resource Control applications can be distributed across several hardware platforms communicating with each other through secure networks Rockwell Automation Publication ICSTT RM448I EN P May 2015 The AADvance Safety Controller Chapter 2 Operating Systems 32 or 64 bit The minimum workstation requirements for the application development software are as follows e Microsoft Windows XP Service Pack 3 fi CAUTION Do not use XP Professional x64 Edition e Windows Vista e Windows 7 e Microsoft Windows Server 2003 e Microsoft Windows Server 2008 IMPORTANT For Workbench 1 3 Network Licensing Windows 64 bit version will only work with the USB license key and will not recognize a Workbench software license key Hardware e 1 6 GHz CPU e 1 GB RAM 32 bit or 2 GB RAM 64 bit add 512 MB if running in a virtual machine e DirectX 9 capable video card running at 1024 x 768 resolution display e 5 400 RPM hard disk e 3 GB available hard disk space e DVD drive or network connection to read software di
60. before installation make a record of the location of the module and the details shown on the label e Ifyou are installing more than one processor module make sure they all have the same firmware build Rockwell Automation Publication ICSTT RM448I EN P May 2015 121 Chapter 5 Install the AADvance System 122 Installation 1 Examine the coding pegs on the 9100 processor base unit and make sure they complement the sockets on the rear of the processor module b ks wa AS AU 2 Place the processor module on to the coding pegs Make sure the slot on the head of the module locking screw 1s vertical and then push the module home until the connectors are fully mated 3 Using a broad 9mm flat blade screwdriver turn the module locking screw clockwise to lock NOTE The locking screw acts as a power interlock device and must be locked or the module will not boot up Replace a Faulty Processor Back up Battery Use the following official Rockwell Automation battery or one of an equivalent specification Part No and Description T9905 Polycarbon monofluoride Lithium Coin Battery BR2032 recommended type 20 mm dia Nominal voltage 3 V Nominal capacity mAh 190 Continuous standard load mA 0 03 Operating temperature 30 C to 80 C supplied by Panasonic Rockwell Automation Publication ICSTT RM448I EN P May 2015 TIP Install the AADvance System Chapter 5 Battery design life is based on operati
61. both simplex and redundant configurations for connection to other AADvance controllers or external third party equipment Communications internally between the processors and I O modules uses a proprietary communications protocol over a custom wired harness The AADvance system supports transport layer communication protocols such as TCP and UDP for Modbus CIP IXL Telnet and SNTP services A secure network communications protocol SNCP developed by Rockwell Automation for the AADvance system permits distributed control and safety using new or existing network infrastructure while ensuring the security and integrity of the data Individual sensors and actuators can connect to a local controller minimizing the lengths of dedicated field cabling There is no need for a large central equipment room rather the complete distributed system can be administered from one or more PC workstations placed at convenient locations The AADvance controller is developed and built for IEC 61131 compliance and includes support for all five programming languages Instruction List IL and Sequential Function Chart SFC languages are not supported by AADvance Workbench 2 0 Program access is secured by a Program Enable key that you can remove Simulation software lets you prove a new application before reprogramming and downloading again maximizing system uptime Additional security functions are also included to prevent unauthorized access The AADvance
62. cation ICSTT RM448I EN P May 2015 Before You Begin Chapter 4 This illustration shows the minimum recommended clearances for a flat panel or DIN rail mounting MIN 440mm 7 ee Note Add DIN rail depth i if mounted on DIN rails N Base Unit s wG l O Base Unit Front Door MIN SOmm i MIN SOrrm wN DIN Rail T 35 MIN S0rnm Rockwell Automation Publication ICSTT RM448I EN P May 2015 75 Chapter 4 Before You Begin The flat panel drilling holes are shown in the illustration Figure 10 Flat Panel Mounting mm SPACE FOR CABLE TRUNKING S MIN 57 MIN 256 al DIMENSION Ga DRILL THREE HOLES PER BASE UNIT TO SUIT MS SCREWS HOLE A IS DATUM SET DIMENSION x TO SUIT NUMBER OF BASE UNITS MIN 157 FOR 1 BASE UNIT MIN 283 FOR 2 BASE UNITS MIN 409 FOR 3 BASE UNITS ADD 126 mm FOR EACH ADDITIONAL BASE UNIT CAUTION HEAT DISSIPATION AND ENCLOSURE POSITION The maximum air temperature rating in an enclosure where standard AADvance processor and I O modules are installed to ensure predictable reliability is 70 2C 158 F for 1 0 modules and 60 C 140 F for processor modules System and field power consumption by modules and termination assemblies is dissipated as heat You should consider the effect of heat dissipation on the design and positioning of your enclosure e g enclosures exposed to continuous sunlight will have a higher internal temperature that could increase
63. ce The communications request timed out 1 Click OK e Wait another couple of minutes and the same message will appear again 2 Click OK e The following message now appears ControlFLASH 4 Manually reset module and retry update 3 Click OK and another error message is displayed Update Status Catalog Number ICSAAdvance Sens Number 50004153 Current Revisor 1 25 6 NewRevaor 1 1 3 4 Click OK then Cancel to Exit ControlFLASH 152 Rockwell Automation Publication ICSTT RM448I EN P May 2015 System Start Up Chapter 6 5 Reboot the processor module by switching the power OFF then ON and hold in the Fault Reset button as the module reboots until the Aux LED goes amber The processor module s will reboot into the Recovery Mode indicated by the following LED states on the processor module Healthy Green dependent on Module health Ready Amber Run Amber System Health Green dependent on system health Force Amber Aux Amber Stag e 2 Install This procedure describes how to upgrade the system firmware for the 9110 processor module ControlFLASH for System Firmware The procedure that follows is basically the same as for stage 1 1 Run the 354400 102 ControlFLASH msi file 2 Click NEXT 3 Read and agree the License 4 Click Browse to select the location of the installation or Next to choose the default location 5 Click Next to confirm the installation e ControlFLASH installs and shows the p
64. cess Check system status indications show the system is on line and operating as expected System Configuration and application programming When the hardware is installed and running you need to set up the system configuration using the AADvance Workbench 138 Rockwell Automation Publication ICSTT RM448I EN P May 2015 System Start Up Chapter 6 e For Workbench 2 0 refer to the AADvance Configuration Guide Doc No 553633 for the detailed instructions on configuring a system e For Workbench 1 3 refer to the AADvance Configuration Guide Doc No 555063 for the detailed instructions on configuring a system Processor Module Start Up NOTE When inserting more than one processor module they MUST be inserted one at a time and the module be Process allowed to educate in the case of a 2 and 3 processor Table 12 Single Processor Module Installation Procedure New Processor Module Step Task 1 With the power switched on place the processor module into slot A on the Base Unit connectors and push the module home until the connectors are fully mated Turn the locking screw and lock the module in position All LEDs are off and after applying power the processor will show the following status indications Healthy Flashes RED for a second then goes GREEN as the module boots up 10 20 seconds Ready Will stay OFF as the module boots up 10 to 20 seconds then goes RED Run Will stay OFF as the Module boots up 10 to 20 secon
65. controller meets non safety business requirements and SIL 2 and SIL 3 safety related system requirements The system has comprehensive built in redundant capabilities that improve system availability The AADvance safety system features are e Easily transformed from a simplex non safety system to a fault tolerant safety related system e An AADvance platform provides a set of components that can be configured to meet a range of safety and fault tolerance user requirements within a single system such as fault tolerant topologies lool 1002D and 2003 e IEC 61508 certified reviewed and approved for safety systems up to SIL 3 by TUV e The scalable characteristics of the system enables independent safety functions within the same system to be configured with Rockwell Automation Publication ICSTT RM448I EN P May 2015 17 Chapter 2 The AADvance Safety Controller different architectures to meet a user specific safety and availability requirements The main components that provide the safety architecture are the processor and I O modules the remaining components provide secure external interfaces and connectivity between the field elements and the main components and add to the safety functionality AADvance processor modules are designed to meet the requirements for SIL 2 in a simplex configuration and SIL 3 ina dual or triplicated configuration Individual input modules are designed to meet the requirements for SIL 3 in si
66. ctionary The set of internal input and output variables and defined words used in a program discrepancy A condition that exists if one or more elements disagree DITA Digital input termination assembly DOTA Digital output termination assembly element A set of input conditioning application processing and output conditioning energize to action An output circuit for a safety instrumented function where the devices are usually de energized Application of power activates the field device 176 EUC Equipment under control The machinery apparatus or plant used for manufacturing processing transportation medical or other activities expansion cable assembly A flexible interconnection carrying bus signals and power supplies between AADvance base units available in a variety of lengths Used with a cable socket assembly at the left side of a base unit and a cable plug assembly at the right side of a base unit fail operational state A condition where a fault has been masked See fault tolerant fail safe The ability to go to a pre determined safe condition when a specified malfunction occurs fault reset button The momentary action push switch on the front panel of the 9110 processor module fault tolerance The ability of a system to operate correctly with a specified number of hardware and software faults fault tolerant The ability of a system to accept the effect of one
67. d Module is in the Recovery Mode or An operating controller has at least one variable being locked forced No power and stays off while the module is booting up 10 to 20 seconds or under application control The module is under application control Module is under application control or The module is in the Recovery Mode No power and stays off while the module is booting up 10 to 20 seconds Serial port pulse stretched Tx Serial port pulse stretched Rx Quickly alternating Tx and Rx activity No power and stays off while the module is booting up 10 to 20 seconds Ethernet link present Tx or Rx activity on Ethernet Port Rockwell Automation Publication ICSTT RM448I EN P May 2015 133 Chapter 5 Install the AADvance System Page intentionally left blank 134 Rockwell Automation Publication ICSTT RM448I EN P May 2015 Chapter 6 System Start Up This chapter describes a structured approach to the start up of a controller system When the checks and module installation and start up is completed successfully the system is ready for you to configure your system using the AADvance Workbench see AADvance Configuration Guide for set up and configuration procedures and then carry out Functional Acceptance Testing Recommendations to It is important that the system is documented when it is installed and this documentation is maintained throughout the testing process system Manage Test Documentation 1 Ob
68. d T9402 Digital input module 24 Vdc 16 channel isolated T9451 Digital output module 24 Vdc 8 channel isolated commoned T9431 Analogue input module 8 channel isolated T9432 Analogue input module 16 channel isolated T9481 Analogue output module 3 channel isolated T9482 Analogue output module 8 channel isolated Special Application Modules Part No Part Description Frequency Input Module Product not yet released Contact Sales for T9441 more information Termination Assemblies Part No Part Description T9801 Digital input TA 16 channel simplex commoned T9802 Digital input TA 16 channel dual T9803 Digital input TA 16 channel TMR T9831 Analogue input TA 16 channel simplex commoned T9832 Analogue input TA 16 channel dual T9833 Analogue input TA 16 channel TMR Rockwell Automation Publication ICSTT RM448I EN P May 2015 169 Chapter 9 Parts List 170 T9851 T9852 T9881 T9882 T9844 T9845 T9846 T9847 T9848 T9849 Digital output TA 24Vdc 8 channel simplex commoned Digital output TA 24Vdc 8 channel dual Analogue output TA 8 channel simplex commoned Analogue output TA 8 channel dual Frequency Input Module TA Simplex Active not yet released Frequency Input Module TA Dual Active not yet released Frequency Input Module TA TMR Active not yet released Frequency Input Module TA Simplex Passive not yet released Frequency Input Module TA Dual Passive not yet rele
69. ding e An AC safety ground sometimes called the dirty ground to protect people in the event of a fault The ground stud on the T9100 processor base unit and all exposed metalwork such as DIN rails will be bonded to the AC safety ground e An instrument ground sometimes called the clean ground or the OV dc ground to provide a good stable OV reference for the Rockwell Automation Publication ICSTT RM448I EN P May 2015 85 Chapter 4 Before You Begin Specifying the Workstation PC 86 system Every signal return will be referenced to the instrument ground The instrument ground will be isolated from the AC safety ground The AC safety ground and the instrument ground will usually be made available through bus bars Bus bars must be of copper they may be nickel plated For a small application you may use ground studs instead of bus bars Some field wiring such as communications cables will need shielded screened cable There may be a shield ground in addition to the AC safety and instrument grounds to provide a common point to terminate shields of such cables The shield ground will usually be connected to the AC safety ground or more rarely to the instrument ground In practice the continuity of the shield connections will be more important than the goodness of the ground connection provided The controller input and output modules incorporate galvanic isolation Nevertheless it is possible that a part
70. ds then goes RED System Healthy Will stay OFF as the Module boots up 10 to 20 seconds then goes GREEN Force Will stay OFF as the Module boots up 10 to 20 seconds then stays OFF until the module has educated Aux Will stay OFF as the Module boots up 10 to 20 seconds then depends on data connection Serial 1 Will stay OFF as the Module boots up 10 to 20 seconds then depends on data connection Serial 2 Will stay OFF as the Module boots up 10 to 20 seconds then depends on data connection Ethernet 1 Will stay OFF as the Module boots up 10 to 20 seconds then depends on data connection Ethernet 2 Will stay OFF as the Module boots up 10 to 20 seconds then depends on data connection Install a Program Enable Key Download a correct application and push the FAULT RESET button When a valid application is downloaded the module shows the following indications Valid application downloaded Healthy GREEN Ready GREEN Rockwell Automation Publication ICSTT RM448I EN P May 2015 139 Chapter 6 System Start Up Step Task Run RED to GREEN Flashes GREEN as the module educates System Healthy GREEN Force GREEN Aux Off Depends on application Serial 1 Depends on data connection Serial 2 Depends on data connection Ethernet 1 Depends on data connection Ethernet 2 Depends on data connection Procedure for Installation of a Second and Third Processor The second and third processor modules must have the same firmware v
71. dules AADvance 9110 9801 9803 9831 9833 9851 9852 9892 9881 et 9882 un sectionneur adapt a l environnement ou ils sont install s devra tre fourni pour couper l alimentation en amont des fusibles avant leur remplacement Rockwell Automation Publication ICSTT RMA4BI EN P May 2015 73 Chapter 4 Before You Begin 74 Controller Mounting An AADvance controller and I O bases can be mounted using one of two methods e A pair of parallel TS35 DIN rails e Panel mounted using three holes on each base Free Space around the Controller Whichever mounting method is used the minimum depth from the rear mounting panel to the front panel and space around the base units are shown in the illustration if you wish to mount the controller on DIN rails increase this allowance by the increased depth of the DIN rails The DIN rails must be TS35 rail which is a 35mm x 7 5mm standard symmetric rail You must have sufficient free space around the base units to allow for the following e Space above to adjust and install field wiring e Space below to let modules fit and to be able to hold a module during removal e Space to the right of the last base unit in the row to move an I O base unit during assembly or if you are installing a new base unit If an expansion cable is to connect to the left most base unit the controller also needs space to the left to fit the expansion cable adapter Rockwell Automation Publi
72. e Fault Reset button to enter the Recovery Mode Then run the latest version of 354400_xxxx_ControlFLASH msi program to install the ControlFLASH to upgrade your processor s OS FPGA LSP and BUSP Rockwell Automation Publication ICSTT RM448I EN P May 2015 The AADvance Safety Controller Chapter 2 When stage 1 is completed ControlFLASH can be used to upgrade three processor modules in the same processor base unit all at the same time NOTE Detailed information and procedures on firmware revision are given in the AADvance Configuration Guide Doc No 553633 and AADvance Configuration Guide Doc No 555063 for Workbench 2 0 Tools and Resources You will need the ControlIFLASH firmware upgrade kit e Quick Start and RSLinx Classic Lite software or better e ControlFLASH programming tool along with its required support drivers and on line HELP e Firmware for the processor modules being upgraded Ethernet Communication Protocols AADvance Ethernet ports are used to support several transport layer services these services are listed in the following table Protocol Purpose TCP 502 Modbus Slave TCP ISaGRAF application downloads debug SoE TCP Transparent Communication Interface Serial Tunnelling TCP CIP Produce amp Consume TCP N A Telnet diagnostic Interface UDP 1123 1124 IXL Bindings UDP 2010 Discovery and configuration Protocol UDP 2222 CIP Produce amp Consume I O UDP 5000 Trusted peer to peer UDP 4481
73. e atmospheres These Essential Health and Safety Requirements are given in Annex Il to the European Union Directive SEC of 23 March 1854 The examination and test results are recorded in confidential report no 4786336921 Compliance with the Essential Health and Safety Requirements with the exception of those listed in the schedule of this certificate has been assessed by reference to Standards EN 60079 0 20124 411 2013 EN 60079 15 2010 Ithe sign X is placed after the certificate number t indicates that the equipment or protective system is subject to special conditions for safe use specified inthe schedule to this certificate This Type examination certificate relates only to the design of the specified equipment and not to specific items of equipment subsequently manufactured The marking of the equipment or protective system shall include the following 13G Ex nA IIC T4 Gc Tha alo certify ihal Ibe sample e of ie Equipment described herein Certiied Equipment hat been 3 _ investigated and found in compliance wih ihe Standardie indicated on this Cartficala in pecerdance wih the Certification Manager ATEM Equipment Cerificaten Program Requirements This ceriteate and test resus obtained apply only to 7 equipment samples submitted by he Manufacturer UL did mot select he samples of delermine whehe Jan Erik Storgaard 8 damplejti phiided were representative of other manudactured equipenent UL haa ral enteliched Flea p
74. e module installation or the first module of a redundant group installation Install the 1 0 module and turn the locking screw to the lock position The input module will show the following status indications Healthy GREEN Ready RED Run RED Channel 1 8 Off The input module will follow its start up sequence and the module will educate After approximately 3 seconds the module will now show the following status indications Healthy GREEN Ready GREEN Run AMBER Channel 1 8 Off Push the Fault Reset button on the processor module and the Run indication goes GREEN The module will now be on line with the following status indications Healthy GREEN Ready GREEN GREEN gt u Channel 1 8 Dependent on channel status If the module fails to educate and go on line replace the module Table 14 Second or third Module of a Group Installation Procedure Task This procedure applies to a second or third module of a redundant group installation Install the Input Output Module and turn the locking screw to the lock position The module will provide the following status indications Healthy GREEN Ready RED Rockwell Automation Publication ICSTT RM448I EN P May 2015 System Start Up Chapter 6 Processor Firmware Upgrades RED Off The input module will follow its start up sequence and the module will educate After approximately 3 seconds the module will now make the following status indications GREEN GREEN
75. e slave device IMPORTANT Do not connect the signal ground to the AC safety ground 5 Insert the connector into the 9100 processor base unit Rockwell Automation Publication ICSTT RM448I EN P May 2015 103 Chapter 5 Install the AADvance System Connect Multiple Slave Devices Full Duplex You can use a full duplex serial connection to connect multiple Modbus slave devices to the AADvance controller To make the physical connection do the following Slave 1 Termination I Termination Termination Note Termination 1200 68nF G o fl o00o O o000 te 51 2 9100 Processor Base supplied N G part 1 Select an applicable cable We recommend 3 pair overall shielded cable 2 Remove the serial port connector from the 9100 processor base unit 3 Make the connections shown in the illustration Terminate the twisted pairs with a 120 resistor in series with a 68 nF capacitor at the locations shown 4 Connect the signal ground not illustrated from the 0 V terminal to each slave device 104 Rockwell Automation Publication ICSTT RM448I EN P May 2015 Install the AADvance System Chapter 5 IMPORTANT Do not connect the signal ground to the AC safety ground 5 Insert the connector into the 9100 processor base unit Connect a Slave Device Half Duplex You can use a half duplex serial connection to connect a single Modbus slave device to the AADvance controller To make the physical connection do the
76. e state is an output configured to go to a specific value or configured to hold last state Safety System Certification T V is the safety certifying authority for an AADvance controller and they have certified the AADvance system to the following standards IEC 61508 Part 1 7 1998 2000 EN 50178 1997 IEC 61511 1 2004 EN 61131 2 2007 EN 61326 3 1 2008 EN 61000 6 2 2005 EN 61000 6 4 2007 EN 50156 1 2004 EN 54 2 1997 A1 2006 NFPA 72 2007 NFPA 85 2015 NFPA 86 2015 The AADvance Analogue Output modules are not certified to EN 54 2 NOTE You can download a copy of the TUV certificate from their web site at www fs products com Performance and Table 1 Controller Performance and Electrical Specifications Electrical Specifications Attribute Performance Characteristics Safety Integrity Level Safety level Degradation Processor Modules supported Rockwell Automation Publication ICSTT RM448I EN P May 2015 Value IEC 61508 SIL 2 IEC 61508 SIL 3 depending on processor and I O module configuration 1001D 1002D 2003D Three 19 Chapter 2 The AADvance Safety Controller I O Modules supported 48 8 or 16 channels modules Safety Accuracy Limit Digital inputs 1 0 Vdc Analogue inputs 200 uA Sequence of Event Resolution e Processor Module for internal Variables 1 ms Event Resolution Application Scan Time Stamp Accuracy e Digital Input Module 1ms Event Resolution 10 ms Time Stamp Accuracy
77. ed so its index recess is adjacent to the relevant numbered position Allocations of Coding Pegs Coding pegs are assigned to each module type as shown in the following table Application Key B 9100 processor base unit for 9110 processor module 9801 2 3 digital input termination assemblies 2 1 for digital input modules 9831 2 3 analogue input termination 1 assemblies for analogue input modules Rockwell Automation Publication ICSTT RM448I EN P May 2015 95 Chapter 5 Install the AADvance System 9851 2 digital output termination assemblies for digital output modules 9842 1 analogue output module This example shows pins set to positions 2 1 1 for a 9401 digital input module i LL i p F 7 L on L jt 1 tI Mount the Power Supply Units 1 Mount power supply units onto the DIN rails e To install the power supply units refer to the manufacturers instructions supplied with the units Install Base Units and Flat panel assembly secures the AADvance controller directly onto a Termination Assemblies panel without the use of DIN rails Do the following Flat Panel Assembly NOTE Remove the black protection covers when joining base units together 1 The base units carry latches which are intended to secure the base units to DIN rails 2 Assemble the base units Place the base units on a workbench and use the backplane clips supplied to join adjacent base units together
78. ed connector pins or attempt to dismantle a module Rockwell Automation Publication ICSTT RM448I EN P May 2015 ISSUE RECORD Issue Date Comments 01 First Issue 02 Update for Product Titles 03 Update for Release 1 1 04 Update for Release 1 1 1 05 Updates for UL Certification 06 Updated for Release 1 2 07 Updated for UL Requirements 08 Updates for release 1 3 and 1 31 09 Updates for UL ATEX IECEx Certification and T9892 information 10 Updates for Release 1 34 11 Correct Documentation Feedback URL and Issue Record Rockwell Automation Publication ICSTT RM448I EN P May 2015 7 Page intentionally left blank Rockwell Automation Publication ICSTT RM448I EN P May 2015 PREFACE The AADvance System The AADvance Safety Controller Table of Contents Chapter 1 Chapter 2 AMC yO AU O Sites ieateenia dr dm de 17 Sae COMIC ITAL ONS Reine teint 18 Safety System C eTLHCAUONM ennemie 19 Performance and Electrical Specifications ccccecssseeeeeeeeees 19 D CAN LIM S Sn ra disent ohne ner 20 System Installation Environment 22 Environment Standards sas en E a sit 23 Installation Requirements for Non Hazardous Environment 23 Installation Requirements for Hazardous Environment 24 Certifications for Safety System Applications in Hazardous A OBC AUS SR E 26 Module Labels ss ner nr RO leet nn st 37 KO CABMC REGIS ATOM dan eine 37 The AADvance Workbench and Software Development Environment
79. elopment correcting or prompting the user with the correct use of the language There is also extensive on line help which includes a cross referenced explanation of the IEC 61131 3 standard Rockwell Automation Publication ICSTT RM448I EN P May 2015 67 Chapter 3 Application Resource Development Page intentionally left blank 68 Rockwell Automation Publication ICSTT RM448I EN P May 2015 Chapter 4 Required Tools Standard AADvance Before You Begin This chapter lists important information that should be read before starting to build the system It covers preparatory information that you should read tasks you should complete for a successful installation The installation and maintenance of the AADvance controller requires the following tools and test equipment Standard Tools Screwdriver flat 0 8 mm x 9 0 mm 1 25 inch x 3 8 inch for the module clamp screws and blanking covers Screwdriver flat 0 6 mm x 3 0 mm 1 40 inch x 1 8 inch or a similar that will open fuse covers on termination assemblies Screwdriver cross head number 0 for battery cover on 9110 processor module Screwdriver flat 0 8 mm x 4 0 mm 1 25 inch x 5 32 inch for screws on extension cables Torque screwdriver flat 0 6 mm x 3 0 mm 1 40 inch x 1 8 inch for dc power wiring terminals Torque screwdriver flat 0 4 mm x 2 0 mm 1 64 inch x 5 64 inch for field wiring terminals 2 x wrench open end 10 mm for ground stud nuts
80. ence e Pollution Degree 2 Only non conductive pollution occurs except that occasionally a temporary conductivity caused by condensation is to be expected e Pollution Degree 3 Conductive pollution occurs or dry non conductive pollution occurs which becomes conductive due to condensation which 1s to be expected e Pollution Degree 4 Continuous conductivity occurs due to conductive dust rain or other wet conditions The AADvance controller has been investigated and approved by UL for use as Industrial Control Equipment in hazardous locations Class I Division 2 Groups A B C and D in North America The AADvance controller has been assessed for ATEX compliance The UL Certification No is DEMKO 11 ATEX 1129711X Rev 1 UL report number is 4786144521 The ATEX marking is Ex nA HC T4 Ge Rockwell Automation Publication ICSTT RM448I EN P May 2015 The AADvance Safety Controller Chapter 2 Additionally the AADvance controller is approved under the IECEx certification scheme The certificate number is IECEx UL 12 0032X Installation Requirements To comply with the standards the following conditions must be applied to the installation Special conditions for safe use e Model 9110 The ambient temperature range is 25 C to 60 C 13 F to 140 F e All other Models The ambient temperature range is 25 C to 70 C 13 F to 158 F e Subject devices are to be installed in an ATEX IECEx Certified IP54
81. entation of the configuration settings for a Modbus master or for its related slave links in the AADvance Workbench The settings include communication settings and messages module clamp screw The AADvance latch mechanism seen on the front panel of each module and operated by a broad flat blade screwdriver Uses a cam action to hold the module to its base unit NFPA 85 The Boiler and Combustion Systems Hazards Code Applies to some boilers stokers fuel systems and steam generators The code helps to prevent uncontrolled fires explosions and implosions NFPA 86 A standard for ovens and furnaces Provides the requirements for the prevention of fire and explosion hazards related to heat processing of materials in ovens furnaces and related equipment 0 on line The condition of a controller that executes the application software OPC A series of standards specifications for open connectivity in industrial automation 179 Chapter 10 9000 Series Glossary output Workbench variable In the context of an AADvance Workbench variable this term describes a quantity passed from the Workbench to a controller peer to peer network One or more Ethernet networks connecting together a series of AADvance or Trusted controllers enabling application data to pass between them pinging In Modbus communications sending the diagnostic Query Data command over a link and by receiving a reply to ensure that the l
82. er 46 front Figure 2 An AADvance Module NOTE at Yie Wa 4 t x EI AAA Standard AADvance modules have a plastic casing and are rated IP20 Protected against solid objects over 12 mm 1 2 in for example fingers There is no specific protection against liquids Module Polarization Keying For each I O Module there is a matched termination assembly The controller incorporates module polarization keying to make sure that they are correctly mated when installed Sockets on the rear end plate align and mate with coding pins found on the termination assembly The Rockwell Automation Publication ICSTT RM448I EN P May 2015 The AADvance Safety Controller Chapter 2 alignment of the sockets and pins make sure that only the matched I O modules and termination assemblies can be mated Figure 3 Coding Sockets Module Locking Mechanism Figure 4 Locking Screw Each module carries a locking mechanism which secures the module onto its base unit The locking mechanism is in the form of a clamp screw which can be seen on the front panel of the module and engaged by a quarter turn of a flat blade screwdriver The module senses the locking mechanism position and notifies the controller accordingly This acts as an interlock device and prevents the module from going on line when it is not in the locked position Field Wiring Field device wiring connections are made to industry standard scr
83. er an external operator s workstation field connections power sources and external network connections The flexibility of the design means that a system can meet a wide variety of business needs An AADvance system is assembled to a scale and configuration that 1s applicable to your initial requirements and can be easily changed to meet your changing business requirements in the future A system is built from an approved range of modules and assemblies This chapter introduces the primary components that can be used to assemble an AADvance controller Rockwell Automation Publication ICSTT RM448I EN P May 2015 13 Chapter 1 The AADvance System Page intentionally left blank 14 Rockwell Automation Publication ICSTT RM448I EN P May 2015 Chapter 2 The AADvance Safety Controller The AADvance controller is specifically designed for functional safety and critical control applications it gives a flexible solution for smaller scale requirements The system can also be used for safety implemented functions as well as applications that are not related to safety but are nevertheless critical to a business process This AADvance controller offers the ability to make a cost effective system to a customer s specification for any of the following applications e Emergency shutdown system e Fire and gas installation protection system e Critical process control e Burner management e Boiler and furnace control e Distributed process
84. ersion as the first processor If the firmware revision is different upgrade the firmware using the ControlFLASH utility IMPORTANT When inserting a second and third processor module they MUST be inserted one at a time and allowed to educate before inserting the next one Step Task 1 Place the processor module on slot B on the Processor Base Unit connectors and push the module home until the connectors are fully mated Turn the locking screw with a flat bladed screwdriver and lock the module in position All the Module LEDs are OFF until the module is installed As soon as the module receives power it will boot up then educate and show the following indications Healthy Flashes RED for a second then goes GREEN as the module boots up 10 to 20 seconds Ready Will stay OFF as the module boots up 10 to 20 seconds then goes RED for 10 seconds then flashes GREEN as it educates and lastly it goes to steady GREEN Run Will stay OFF as the module boots up 10 to 20 seconds then goes RED until educated and then it goes AMBER System Healthy Will stay OFF as the Module boots up 10 to 20 seconds then goes GREEN Force Will stay OFF as the Module boots up 10 to 20 seconds then stays OFF until the module has educated and the application is running Aux Will stay OFF as the Module boots up 10 to 20 seconds then is depends on data connection Serial 1 Will stay OFF as the Module boots up 10 to 20 seconds then is depends on data connecti
85. es ccccccccccceceeeeeeeeeeeeeeeeeeees 62 Ethernet Communication Protocols cccccccccccsseeeeeeeeeeeees 63 Chapter 3 Programming Language Support 65 Program Management Facilities 65 Support tor Variable Ty pes san cs ne ps 65 I O Connection Addressing of Physical I O 66 Off line Simulation and Testing c cc ceessessssseseeeeeceeeeeeeeeeeeaaas 66 Application Resource Program Security 67 Aids to Software Development 67 Chapter 4 Required Tools Standard AADvance cccccccceccceceeeeeeeeeeeaeees 69 Speci ymo aE NClOSUIC 8er nie 70 Maximum Enclosure Air temperature ccccccccccceeeteeeeees 70 Enclosure Requirements for a Non hazardous Environment 71 Enclosure Requirements for a Hazardous Environment Class I Division 2 Groups A B C and D 71 Controller Mounto Rene dti us 74 Free Space around the Controller ccececcccccceeeeeeeeeeees 74 Base Units Rows and Expansion Cables cccceccceceeeeeeeees 71 Adding Field Cable Management cc ccccccsesseseeeeeeeeees 78 System POWer Reg uIremmenis se r Ra ne tn 79 Power Supply and Power Distribution Requirements 80 Controller Power Supply Requirements cccccceeeeeees 80 Power Arrangements for Field Devices 81 Estimating Power Consumption ccccccccccceeeeeeaesseeeseeeees 82 System D
86. es Data for retained variables is stored at the end of each application scan in a portion of RAM backed up by the battery On restoration of power the retained data is loaded back into the variables assigned as retained variables for use by the application e Diagnostic logs The processor diagnostic logs are stored in the portion of RAM backed by the battery The battery has a design life of 10 years when the processor module is continually powered for processor modules that are un powered the design life is up to 6 months Battery design life is based on operating at a constant 25 C and low humidity High humidity temperature and frequent power cycles will shorten the operational life of the battery Low Battery Alarm A variable is available in the Workbench that can be set up and report the battery status It will give an alarm and set a warning light on the processor front panel when the battery voltage is low Disabling the Low Battery Alarm For applications that do not require Real Time Clock functionality or there are specific constraints for example the controller is in an inaccessible location that make it necessary to remove the battery when the system is installed and set up the battery failure alarm can be disabled at the Workbench Rockwell Automation Publication ICSTT RM448I EN P May 2015 51 Chapter 2 The AADvance Safety Controller Battery Location The battery is supplied separately and inserted i
87. es modules AADvance sont utilisables dans Class I Division 2 A B C et D pour un environnement dangereux OU pour un environnement non dangereux ou quivalente The AADvance system has been investigated to United States National Standard s ULSO8 17th Edition and Canadian National Standard s C22 2 No 142 Ist Edition The investigation covers the following modules and provides requirements for compliance to the standards for use in a non hazardous and hazardous environments The AADvance controller has been investigated and approved by UL for use as Industrial Control Equipment in hazardous locations Class I Division 2 Groups A B C and D in North America The AADvance controller has been assessed for ATEX compliance The UL Certification No is DEMKO 11 ATEX 1129711X Rev 2 UL report number is 4786144521 The ATEX marking is Ex nA IIC T4 Ge Additionally the AADvance controller is approved under the IECEx certification scheme The certificate number is IECEx UL 12 0032X Investigation File Number E341697 Products Covered The products investigated and approved Programmable Logic Controller Models 9110 Processor Module 9401 Digital Input Module 9402 Digital Input Module 16 Channel 9431 Analogue Input Module 9432 Analogue Input Module 16 Channel 9451 Digital Output Module 9481 Analog Output Module 9482 Analogue Output Module 8 Channel Listed Accessories for use with PLCs 9100 Processor Backplane 9300 I O Backpla
88. es of the AADvance Workbench It is applicable for applications with one or more controllers e The demo license is a like a full license but with a time limit You can use all of the features of the AADvance Workbench for up to 30 days after first running the AADvance Workbench is first run A demo license is supplied free of charge for a first installation on a computer You change the demo license to a single controller license or a full license by purchasing an unlock code from Rockwell Automation and entering the code into the software When you use the demo license the AADvance Workbench displays a Demo License window each time you try to open a project The window includes the contact details at Rockwell Automation required for purchasing a license If you try to use the demo license for more than 30 days the license expires You cannot open a project or create a new one until you purchase a license Corrective Maintenance and Module Replacement Scheduled maintenance consists of checking the I O Module calibrations and proof tests Detailed scheduled and corrective maintenance information is given in the AADvance Troubleshooting and Maintenance Manual Doc No 553634 Corrective maintenance is by module replacement and where required fuse replacement in Termination Assemblies In dual and triple modular redundant configurations you can Rockwell Automation Publication ICSTT RM448I EN P May 2015 The AADvance Safety Controller C
89. esign Considerations for Heat Dissipation and Cooling 83 Estimate Heat Dissipation 228 nine 83 Estimate AADvance Controller Weight 85 Estimating Center of Gravity Information 85 Design Considerations for Electrical Grounding 85 Specifying the Workstation PC 86 Design Considerations for Maintenance Activities 87 Connecting the AADvance Controller to the Network 89 Rockwell Automation Publication ICSTT RM448I EN P May 2015 Install the AADvance System System Start Up Table of Contents Chapter 5 Unpacking and Pre assembly Checks ccccccccccccceeeeeeeeeeeeeees 9 Install Base Units and Termination Assemblies Enclosure DIN Rail Assembly Neon his 92 Allocations of Coding Pegs cccccccccccccceeeeeeeeeeeeeeseeeseeeeees 95 Install Base Units and Termination Assemblies Flat Panel ASSIS na Na a 96 Allocations of Coding Pe s cccccceeccccceeceeeseeeeeessseeeees 98 Connect the AC Safety Ground Connection 99 Connect the 24 V dc System Power to an AADvance Controller 100 Procedure to Connect Serial Communications Cabling 101 Connecting Modbus Slave Devices to Serial Ports 102 Connect a Slave Device Full Duplex 103 Connect Multiple Slave Devices Full Duplex 104 Connect a Slave Device Half Duplex ee eeceeeeeees 105 Connect Multiple Slave Devices
90. ew terminal blocks on the termination assemblies Terminals are easy to access without needing to dismantle assemblies The specification for the Rockwell Automation Publication ICSTT RM448I EN P May 2015 47 Chapter 2 The AADvance Safety Controller 48 field wiring sizes is given in the topic Power and External Connector Wiring Requirements This illustration shows field wiring connections at the termination assemblies Figure 5 Field Wiring Connections NOTE The recommended torque for termination assembly screw connectors is 5 Nm Rockwell Automation Publication ICSTT RM448I EN P May 2015 The AADvance Safety Controller Chapter 2 Processor Base Unit A processor base unit holds up to three processor modules HOAUZ ICS TRIPLEX TECHNOLOGY Base Unit Clamp Arm External Ethernet Serial Data and Power Connections The processor base unit external connections are e Farthing Stud e Ethernet Ports E1 1 to E3 2 e Serial Ports S1 1 to S3 2 e Redundant 24 Vdc powers supply PWR 1 and PWR 2 Rockwell Automation Publication ICSTT RM448I EN P May 2015 49 Chapter 2 The AADvance Safety Controller e Program Enable security key KEY e The FLT connector currently not used Figure 6 External Connectors on the Processor Base Unit The power connections supply all three modules with redundant power each processor module each have two Serial ports and two Ethernet port connector
91. execution such that each module can be debugged separately Any I O device can be represented as a single module or a group of redundant modules Different data types are accommodated You can work directly on a pre defined I O configuration expand and change the configuration and the workbench fully supports directly represented I O variables as described in the IEC 61131 3 standard An engineer can validate a full application off line without the target hardware platform The powerful simulator within the development environment can do structural and functional tests of each module and of the full application Rockwell Automation Publication ICSTT RM448I EN P May 2015 Application Resource Development Chapter 3 Application Resource Program Security Aids to Software Development The AADvance controller includes a Program Enable key that protects the application from access that has not been approved for change The key must be fitted to the KEY connector on the T9100 processor base unit before you can download and make changes to an application resource The program enable key is supplied with the processor base unit and is fitted as shown Other security features are available such as password protection at the Workbench and the use of firewall settings The development environment automatically verifies the syntax of the source code entered in each of its supported languages It performs checks at each stage of dev
92. f the T9100 processor base unit e Secure the socket assembly by inserting the two M3 socket cap screws e Tighten the screws with a 2 5 mm Allen key e Install the cable to the socket assembly and tighten the retaining screws by hand 2 Insert the free end of the expansion cable into a right hand socket of a T9300 I O base unit e Insert a cable plug assembly into the right hand socket of the processor or I O base unit e Secure the plug assembly by inserting the two M3 socket cap Screws e Tighten the screws with a 2 5 mm Allen key e Install the cable to the plug assembly and tighten the retaining screws by hand Rockwell Automation Publication ICSTT RM448I EN P May 2015 129 Chapter 5 Install the AADvance System Connect Between a T9300 I O Base Unit and a T9300 I O Base Unit Extending from Extending from Left Hand side Right Hand side le ao a T jm ia Z 8 Item Description 1 M3 Socket Cap Screw 2 Cable Plug Assembly 3 Cable Socket Assembly 4 M3 Nut 1 Connect the expansion cable between a T9100 processor base unit or a T9300 I O Base unit to a T9300 I O base unit e Insert a cable plug assembly into the right hand socket of the processor or I O base unit e Secure the plug assembly by inserting the two M3 socket cap screws e Tighten the screws with a 2 5 mm Allen key e Install the cable to the plug assembly and tighten the retaining screws by hand 2 Connect t
93. following Note Termination 1200 68nF Termination Free connector supplied 9100 Processor Base part 1 Select an applicable cable We recommend 2 pair overall shielded cable 2 Remove the serial port connector from the 9100 processor base unit 3 Make the connections shown in the illustration Terminate the twisted pair with a 120 Q resistor in series with a 68 nF capacitor at the two ends 4 Connect the signal ground not illustrated from the 0 V terminal to the slave device Rockwell Automation Publication ICSTT RM448I EN P May 2015 105 Chapter 5 Install the AADvance System IMPORTANT Do not connect the signal ground to the AC safety ground 5 Insert the connector into the 9100 processor base unit Connect Multiple Slave Devices Half Duplex You can use a half duplex serial connection to connect multiple Modbus slave devices to the AADvance controller To make the physical connection do the following Slave 1 Termination i Termination Note Termination 1200 68nF Free connector supplied 9100 Processor Base part 1 Select an applicable cable We recommend 2 pair overall shielded cable 2 Remove the serial port connector from the 9100 processor base unit 3 Make the connections shown in the illustration Terminate the twisted pair at the two ends with a 120 Q resistor in series with a 68 nF capacitor 106 Rockwell Automation Publication
94. ge appears e Check that any associated power indicator is lit Rockwell Automation Publication ICSTT RM448I EN P May 2015 137 Chapter 6 System Start Up e As each circuit breaker is tested leave the breaker in the on position so that any unwanted connection between different power circuits can be detected 5 Trip and re instate each circuit breaker in turn and verify the correct circuits are isolated and restored Similarly disengage and replace each fuse and verify the associated circuits 6 Atthe same time verify correct operation of any power indicators supplied with the system Start Up Process Once the procedures for power distribution tests have been successfully completed the controller is ready for installation of its modules and its second power up The installation process should be completed in the following order l Switch off power to the controller both field power and controller power sources Make a record of the module and base unit serial numbers for future reference Reinstate the power Install the modules in the following sequence Install the program enable key to the connector labeled KEY on the processor base unit Install the first Processor module e Refer to the Processor Module start up process Install the second or the third processor module if required e Refer to the Processor Module start up process Install the I O modules e Refer to the I O Module start up pro
95. hapter 2 Main Components Physical Features remove a module and install a new one without interrupting the system operation In simplex configurations removing a module will interrupt the system operation However certain restrictions apply on module replacement timing for Safety Related systems see the AADvance Safety Manual 553630 for guidance Field connection wiring is attached at the connectors on the termination assemblies Ethernet and Serial data connections are made at the T9100 Processor Base Unit There are no physical links needed to be set up on any modules or base units Standard modules are used for all the different configurations IMPORTANT Processor modules must be replaced with a module containing the same firmware revision you cannot use processor modules with different firmware revisions on the same controller TUV Approved Operating System The AADvance system runs an IEC 61508 approved operating system and the overall system is certified to IEC 61508 Part 1 7 1998 2000 SIL 3 An AADvance controller is built from durable processor and I O modules and assemblies designed to IEC 61508 standards for safety systems and runs the AADvance Workstation software Field devices connect direct to a controller and external communication links over Ethernet and serial links use a secure protocol A new and innovative style characteristic of the AADvance controller 1s the design of the hardware All the modules a
96. he requirements of EN 60079 0 2012 A11 2013 EN 60079 15 2010 IEC 60079 0 Ed 6 and IEC 60079 15 Ed 4 Enclosure is to be marked with the following Warning Do not open when energized After installation of subject devices into the enclosure access to termination compartments shall be dimensioned so that conductors can be readily connected Grounding conductor should have a minimum cross sectional area of 3 31 mm e Subject devices are for use in an area of not more than pollution degree 2 in accordance with IEC 60664 1 e Subject devices are to use conductors with a minimum conductor temperature rating of 85 C e Subject devices are to be installed in the vertical orientation only AVERTISSEMENT Conditions sp ciales pour une utilisation s re e Mod les 9110 la plage de temp rature ambiante est de 25 C 60 C e Pour tous les autres mod les la plage de temp rature est de 25 C 70 C e Les dispositifs concern s doivent tre install s dans une enceinte certifi e ATEX CEIEx IP54 accessible l aide d un outil et qui a t valu e conforme aux exigences des normes EN 60079 0 2012 A11 2013 EN 60079 15 2010 IEC 60079 0 Ed 6 and IEC 60079 15 ed 4 Le marquage suivant doit tre appos sur l enceinte Avertissement Ne pas ouvrir sous tension Apr s l installation des dispositifs concern s dans l enceinte l acc s aux compartiments de raccordement sera dimensionn de fa
97. he 24 V dc power connectors the earth stud is shown between the two power leads Rockwell Automation Publication ICSTT RM448I EN P May 2015 99 Chapter 5 Install the AADvance System Connect the 24 V dc System The dual redundant 24 Vdc system power taken from the chosen power source 1s connected to the controller at two plugs labeled PWR 1 and Power to an AADvance PWR 2 on the processor base unit Controller The processor base unit has a link between the 24 Vdc connections to the center terminal of each connector PWR 1 and PWR 2 This link may be useful to connect the 24 Vdc supply to further devices OV 24V de OV 24V de Rockwell Automation Publication ICSTT RM448I EN P May 2015 100 Install the AADvance System Chapter 5 Procedure to Connect Serial Communications Cabling For each power supply connection do the following Connect the negative line from the power supply typically labeled 0 V to the left hand terminal Connect the positive line from the power supply typically labeled 24 V to the right hand terminal Apply a minimum tightening torque of 0 5 Nm 0 37 ft Ib to the terminal screws IMPORTANT Make sure that PWR 1 and PWR 2 are supplied from independent 24 Vdc sources The serial ports S1 1 and S1 2 S2 1 and S2 2 S3 1 and S3 2 support the following signal modes depending on use RS485fd A four wire full duplex connection that features different busses f
98. he free end of the expansion cable to the left hand plug of an I O base unit using a cable socket assembly e Insert a cable socket assembly into the left hand connector of the T9300 processor base unit e Secure the socket assembly by inserting the two M3 socket cap screws e Tighten the screws with a 2 5 mm Allen key 130 Rockwell Automation Publication ICSTT RM448I EN P May 2015 Install the AADvance System Chapter 5 e Install the cable to the socket assembly and tighten the retaining screws by hand Fault Reporting Reference Each module has a set of front panel status indicators The function and meaning of these indicators related to each module is as follows Information Status Indicators on the 94xx Series Input and Output Module _ AADvance Table 10 Status Indicators on the 94xx Series Input and Output Module Indicator Status Description Healthy OFF No power GREEN No module faults present RED The module has one or more faults e The Healthy indicator can turn RED immediately after power is applied to the module before then turning GREEN e If Healthy is GREEN and the Ready and Run are RED then the module is said to be in its shutdown state refer to the Troubleshooting Manual Chapter 3 for more information on the shutdown state Ready No power or module is unlocked Locked and prepared to report channel values Locked but not prepared to report channel values Run No power or module is unlocked Module is
99. he slot on the head of the module clamp screw is vertical and then push the module home until the module connectors are fully mated with the I O base unit and termination assembly connectors 3 The locking screw requires a quarter turn clockwise to lock Use a broad 9mm flat blade screwdriver to lock the clamp screw The locking screw acts as a power interlock device and must be in the locked position when power is applied otherwise the module will not be configured Rockwell Automation Publication ICSTT RM448I EN P May 2015 127 Chapter 5 Install the AADvance System Install T9310 Expansion Use T9310 expansion cables to connect additional groups of T9300 I O Cables base units 1 The ferrites supplied with the expansion cable are snap on components Fit the ferrites 50 mm 2 in from each end and secure with cable ties either side of the ferrites tem Description 1 SCSI 3 Cable 2 Ferrite 3 Cable Tie Connect Expansion Cable between T9100 Base Unit and T9300 I O Base unit 1 0 Bus2 Extending from Extending frorn Left Hand side Right Hand side Item Description M3 Socket Cap Screw Cable Plug Assembly Cable Socket Assembly M3 Mut E ww Pi 1 Connect the expansion cable to a T9100 processor base unit for an I O Bus 2 connection Rockwell Automation Publication ICSTT RM448I EN P May 2015 128 Install the AADvance System Chapter 5 e Insert a cable socket assembly into the left hand connector o
100. ical Component List 3 Pages Model 9852 Critical Component List 3 Pages Model 9881 Critical Component List 2 Pages Model 9882 Critical Component List 2 Pages Model 9892 Critical Component List 3 Pages T9000 DIB Product Information 17 Special conditions for safe use e Models 9110 and 9111 The ambient temperature range is 25 C to 60 C Drawing No 275070 276370 553632 130669_UL 130649_UL 130659_UL 130629_UL 130689 9401_9402 _U L 130779_UL 130689 9431_9432 _U L 130849 9481_9482 _U L 130859 9482 _UL 130729_UL 130739 _UL 130819_9801_UL 130809_9802_UL 130789_9083_UL 130819_9831_UL 130809_9832_UL 130789 9833_UL 130829_9851_UL 130799_9852_UL 130879_9881_UL 130869_9882_UL 131219_9892_UL 554155 e All other Models The ambient temperature range is 25 C to 70 C e Subject devices are to be installed in an ATEX Certified IP54 tool accessible enclosure that has been evaluated to the requirements of EN 60079 0 2012 A11 2013 and EN 60079 15 2010 Enclosure is to be marked with the following Warning Do not open when energized After installation of subject devices into the enclosure access to termination compartments shall be dimensioned so that conductors can be readily connected Grounding conductor should have a minimum cross sectional area of 3 31 mm Rev Level C A 09A Be Eaa D Dem O Win Dm Date 2012 05 17 2011 12 14 2014 05 2011 08 24 2011 08 24 201
101. ical Rating Values Voltage Range Maximum Current Vdc mA Module Back plane Electrical Ratings Input Output Electrical Ratings 9100 18 32 10 4A 400 mA per slot 9300 9 6A 400 mA per slot 9110 380 9401 260 Input 18 32 Vdc 24 mA 9402 260 Input 0 32 Vdc 6 5 mA 9431 Input 0 32 Vdc 6 5 mA 9432 Input 18 32 Vdc 24 mA 9481 Output 18 32 Vdc 0 20 mA 9482 Output 18 32 Vdc 0 20 mA 9451 Output 18 32 Vdc 0 5 Pilot duty 16 VA 1 5 A Inrush 58 Rockwell Automation Publication ICSTT RM448I EN P May 2015 The AADvance Safety Controller Chapter 2 Technical Features Expansion Cable This is used to add extra rows of I O base units and modules Controller Internal Bus Structure Internal communication between the processor modules and I O modules is supported by command and response busses that are routed across the processor and I O base units The processor modules acts like a communications master sending commands to its I O modules and processing their returned responses The two command busses I O Bus 1 and I O Bus 2 take the commands from the processor to the I O modules on a multi drop basis An inter processor link IPL supplies the communication links between dual or triple processor modules Each I O module has a dedicated response line which returns to the processor The unique response line for each I O module supplies an unambiguous identification of the source of the I
102. icular application will require the provision of barrier strips with galvanic isolation for example to provide consistency with an existing installation In these cases there may be a separate intrinsic safety ground as well The minimum workstation requirements for the application development software are as follows e lt A PC running e Operating system 32 or 64 bit e Microsoft Windows XP Service Pack 3 CAUTION Do not use XP Professional x64 Edition e Windows Vista e Windows 7 e Microsoft Windows Server 2003 e Microsoft Windows Server 2008 IMPORTANT For Workbench 1 3 Network Licensing Windows 64 bit version will only work with the USB license key and will not recognize a Workbench software license key Rockwell Automation Publication ICSTT RM448I EN P May 2015 Before You Begin Chapter 4 Design Considerations for Maintenance Activities Hardware e 1 6 GHz CPU e 1 GB RAM 32 bit or 2 GB RAM 64 bit add 512 MB if running in a virtual machine e DirectX 9 capable video card running at 1024 x 768 resolution display e 5 400 RPM hard disk e 3 GB available hard disk space e DVD drive or network connection to read software distribution files NOTE If the application is Workbench 1 3 and adopts the USB dongle licensing option the workstation PC will require one free USB port e Network port 10 100 Base T Ethernet for communications with the controller It is recommended that the PC has a
103. ies items which must be thought about and put in place when designing and assembling an AADvance controller for use in a Safety Instrumented Function SIF It appears extensively in the AADvance Safety Manual Identifies information that is critical for successful application and understanding of the product Provides key information about the product or service Tips give helpful information about using or setting up the equipment WARNINGS AND CAUTIONS WARNING EXPLOSION RISK Do not connect or disconnect equipment while the circuit is live or unless the area is known to be free of ignitable concentrations or equivalent AVERTISSEMENT RISQUE D EXPLOSION Ne pas connecter ou d connecter l quipement alors qu il est sous tension sauf si l environnement est exempt de concentrations inflammables ou quivalente MAINTENANCE Maintenance must be carried out only by qualified personnel Failure to follow these instructions may result in personal injury CAUTION RADIO FREQUENCY INTERFERENCE Most electronic equipment is influenced by Radio Frequency Interference 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 CAUTION The module PCBs contains static sensitive components Static handling precautions must be observed DO NOT touch expos
104. ing clips and lever to hold them in position Install Base Units and Termination Assemblies Enclosure DIN Rail Assembly Method Figure 13 Fit I O Base Unit onto DIN Rails Processor base unit Retaining Clip VO base unit SS Connector Protection WN x Cover Retaining Lever Hi Pc Protection Covers Retaining Clip Retaining Lever a IMPORTANT Fit the rubber connector protection cover to exposed connectors that are not joined to another base unit For a system build that uses DIN rails do the following 1 Install the DIN rails e The AADvance controller will be mounted onto one or more pairs of parallel DIN rails For each pair of rails mount the lower rail with its center line 101 0mm below the center line of the upper rail M5 thread rolling screws are suitable 2 Mount the T9100 processor base unit e Place the T9100 processor base unit onto the DIN rails and position it towards the left leaving space for the T9300 I O base units to the right 92 Rockwell Automation Publication ICSTT RM448I EN P May 2015 Install the AADvance System Chapter 5 e Secure the processor base unit onto the DIN rails by sliding the retaining lever below the base unit to the left 3 Mount each T9300 I O base unit e Place a T9300 I O base unit onto the DIN rails to the right of the T9100 processor base unit e Slide the I O base unit to the left until the joining connectors are fully mated e Insert the retaini
105. ink is healthy and the slave can communicate with the master No process data is transferred or modified portable equipment Enclosed equipment that is moved while in operation or which can easily be moved from one location to a different location while connected to the power supply Examples are programming and debugging tools and test equipment See hand held equipment processor base unit A backplane assembly holding all of the processor modules in an AADvance controller Part number 9100 See also processor module processor module The application execution engine of the AADvance controller housed in a self contained and standardized physical enclosure 180 producer A controller producing a tag to one or more consumers The controller produces a tag when a consumer asks for one program enable key A security device that permitting access to the application in an AADvance controller Part number 9906 Supplied with the processor base unit See also key connector project A collection of configurations and the definition of the linking between them See configuration proof test A test performed at a predetermined frequency which functionally tests all of the components making up a Safety Instrumented Function designed specifically to show any undetected failures so that these can be repaired to make sure that the Safety Instrumented Function continues to satisfy its designed perform
106. ion Before You Begin Chapter 4 Estimate AADvance Use the following table to make an estimate of the weight of your controller Controller Weight Table 9 AADvance Controller Module Weight Item Number _ Weight Allowance Subtotal Used g oz x 460 g 16 oz x 430 g 15 oz x 280 g 10 oz x 340 g 12 oz x 280 g 10 oz x 340 g 12 oz x 340 g 12 oz x 290 g 10 5 oz x 133 g 5 oz x 133 g 5 oz x 260 g 10 oz x 360 g 13 oz x 670 g 24 oz x 175 g 6 oz Processor Base Unit Processor Module Digital input module 24 Vdc 8 channel Digital input module 24 Vdc 16 channel Analogue input module 8 channel Analogue input module 16 channel Digital output module 24 Vdc 8 channel Analogue output module 8 channel I O base unit 3 way Simplex Termination assembly Dual Termination Assembly Triple Termination Assembly Expansion cable assembly and 2 m cable Termination Assemblies average weight Total estimated controller weight Estimating Center of Gravity If it is necessary to calculate the location of the center of gravity of an AADvance controller destined for a maritime or other shock mounted application it is reasonable to assume the center of gravity of each assembly of modules and their base unit is at the geometric center of the assembly Design Considerations for All applications of the controller will require at least two separate ground earth systems Electrical Groun
107. irect connection is required from the controller to the workstation PC for example during setting up use a crossover cable This will depend on the characteristics of the network interface in the PC Rockwell Automation Publication ICSTT RM448I EN P May 2015 89 Chapter 4 Before You Begin Wiring for 100BASE TX Ethernet Crossover Cable The fixed connectors on the controller are RJ45 sockets Use CatSe enhanced cables with RJ45 modular plugs for the network cabling Connect the network cables to the sockets on the T9100 processor base unit e For each network connection insert the RJ45 modular plug on the cable into the appropriate socket e Make sure the length of the cable does not exceed 100m 328 ft Refer to the illustration for an example LC 90 Rockwell Automation Publication ICSTT RM448I EN P May 2015 Chapter 5 Install the AADvance System The system installation defines the steps that will ensure the system is correctly installed and ready for the on site factory tests before the system is brought on line This chapter describes how to install the AADvance system hardware into the chosen enclosure In addition to the installation guidelines given in this chapter you must also use installation and commissioning procedures that obey the rules and standards of the country of installation These standards can include for example IEC 61511 NFPA72 and ISA 84 00 01 depending on the location Un
108. lves and pumps AITA Analogue input termination assembly alarms and events AE An OPC data type providing time stamped alarm and event notifications Rockwell Automation Publication ICSTT RM448I EN P May 2015 Chapter 10 9000 Series Glossary allotted process safety time The part of the total process safety time allotted to a sub function of a process application software Software written specially for a user application typically using logic sequences limits and expressions to read inputs make decisions and control outputs for a specified system architecture Organizational structure of a computing system describing the functional relationship between board level device level and system level components asynchronous A data communications term describing a serial transmission protocol A start signal is sent before each byte or character and a stop signal is sent after each byte or character An example is ASCII over RS 232 C See also RS 232 C RS 422 RS 485 availability The probability that a system can do its specified functions when required for use Normally expressed as a percentage 173 Chapter 10 9000 Series Glossary backplane clip A sprung plastic device to holding together two adjacent AADvance base units Part number 9904 Used in pairs base unit One of two designs making the supporting parts of an AADvance controller See 1 0 base unit and processor base u
109. mation Publication ICSTT RM448I EN P May 2015 System Start Up Chapter 6 4 Browse to the device in the RSLinx window Select the 19110 device to update and click OK NM Autobrowse 2 efresh 132 Browsing node 192 168 1 211 found Workstation EUGBICSACHOLGAT aa Linx Gateways Ethernet AADvance Ethernet 192 168 1 192 168 1 211 Unrecognized Device ICS44dvance ICSA4dvance 5 AB_ETH 1 Ethernet Cancel 5 Select the firmware revision for the latest Release _ ControlFLASH 19110 QUAI BZN s BURA Firmware Revision Catalog Number T9110 Serial Number 50404153 Current Revision 1 2 0 Select the new revision for this update Revision Restrictions F Show all revisions Current Folder c program files controlflash Fa lt Back Cancel Help Rockwell Automation Publication ICSTT RMA4BI EN P May 2015 155 Chapter 6 System Start Up 6 Check the summary details click Finish ControlFLASH T9110 OD Tins D PE NY B ATIIA TI BY Summary DANGER The target module is about to be update with new firmware During the update the module will be unable to perform its normal contral 1 function Please make sure that all processes Contr ol affected by this equipment have been suspended p and that all safety critical functions are not e affected To abort this firmware update press Cancel now To begin the update now press Finish Catalog
110. mation Publication ICSTT RM448I EN P May 2015 sate state A condition which permitting the execution of a process demand Usually entered after the detection of a fault condition ensuring that the effect of the fault is to enable rather than disable a process demand safety accuracy The accuracy of an analogue signal in which the signal is guaranteed to have no dangerous faults If the signal drifts outside this range it is declared faulty safety critical state A faulted condition preventing the execution of a process demand sensor A device or a combination of devices that measures a process condition Examples are transmitters transducers process switches and position switches sequential function chart An IEC 61131 language dividing the process cycle into a number of specified steps separated by transitions See limited variability language SFF Safe Failure Fraction Given by the total rate of safe failures plus the rate of detected dangerous failures divided by the total rate of safe failures plus the rate of detected and undetected dangerous failures SIF Safety Instrumented Function A type of process control performing specified functions to get or maintain a safe state of a process when unacceptable or dangerous process conditions are detected 181 Chapter 10 9000 Series Glossary SIL Safety Integrity Level One of four possible levels specified in IEC 61508 and IEC 61511 f
111. mblies and to the processor across I O bus connections EC 61000 A series of international standards providing techniques for testing and measuring electromagnetic compatibility EC 61131 An international standard defining programming languages electrical parameters and environmental conditions for programmable logic controllers Part 3 which is entitled Programming Languages defines more than one limited variability language EC 61499 An international standard defining an open architecture for distributed control and automation EC 61508 An international standard for functional safety encompassing electrical electronic and programmable electronic systems hardware and software aspects 178 EC 61511 An international standard for functional safety and safety instrumented systems for the process industry encompassing electrical electronic and programmable electronic systems hardware and software aspects indicator A device whose state can change to provide data input AADvance Workbench variable In the context of an AADvance Workbench variable a quantity passed to the Workbench from a controller instruction list An IEC 61131 language almost the same as the simple textual language of PLCs See limited variability language integer A variable type specified by the IEC 61131 standard IXL ISaGRAF eXchange Layer The protocol for communications between ISaGRAF based compone
112. motes the safety of persons and property consistency of control response and to make maintenance easy bus A group of conductors for related data Typically allocated to address data and control functions ina microprocessor based system bus arbitration A mechanism for deciding which device has control of a bus Rockwell Automation Publication ICSTT RM448I EN P May 2015 9000 Series Glossary Chapter 10 CIP Common Industrial Protocol communications protocol created by Rockwell Automation for the Logix controller family and supported by the AADvance controller AADvance controllers use the protocol to send data to and from Logix controllers using a consumer producer model It can also be used to communicate data between AADvance controllers clearance The shortest distance in air between two conductive parts coding peg A polarizing key fitted to the 9100 processor base unit and to each termination assembly ensuring that only a module having the correct type can be fitted in a slot Part number 9903 coil In IEC 61131 3 a graphical component of a Ladder Diagram program representing the assignment of an output variable In Modbus language a discrete output value Compiler Verification Tool CVT A software utility that validating a compiled application to look for errors introduced by the Workbench or the compiler Frequently abbreviated to CVT configuration A grouping of the application sof
113. mplex dual or triple configurations Individual output modules have been designed to meet the requirements for SIL 3 in a simplex or dual configurations Safe SIL 3 rated Black Channel external communication over Ethernet Safety Configurations An AADvance system supports the following safety configurations Fail safe I O modules fail safe in the most basic simplex system SIL 2 SIL 2 architectures for fail safe low demand applications All SIL 2 architectures can be used for energize or de energize to trip applications SIL 3 SIL 2 low demand architectures SIL 2 fail safe architectures SIL 2 fault tolerant input architectures SIL 2 triplicated input architectures SIL 2 fault tolerant output architectures SIL 2 fault tolerant input output architectures SIL 3 architectures 18 SIL 3 de energize to trip applications SIL 3 energize to action applications when fitted with dual digital output modules Rockwell Automation Publication ICSTT RM448I EN P May 2015 The AADvance Safety Controller Chapter 2 e SIL 3 simplex or dual output module architectures e SIL 3 fail safe I O fault tolerant processor architecture e SIL 3 fault tolerant architecture e SIL 3 fault tolerant simplex dual and triple input architectures e SIL 3 dual or triple processor architectures e SIL 3 high demand applications where the required safe state is greater than 4 mA when fitted with dual analogue output modules A saf
114. n above Where Sync time is a function of the total number of modules defined according to the following table 0 10 modules 20 ms 11 20 modules 22 ms 21 30 modules 24 ms 31 40 modules 27 ms 41 48 modules 32 ms Though the average scan time will be within ms of the scan time calculated above the calculation does not take into account the effects of application logic and network communication and individual scans can vary by up to 4 ms around the average scan time Throughput time is the time from input change to output action For asynchronous inputs the throughput times can be derived from the Scan time calculated above according to the following formulae e Minimum throughput time Scan period 7 ms e Maximum throughput time 2 x Scan time 13 ms Rockwell Automation Publication ICSTT RM448I EN P May 2015 21 Chapter 2 The AADvance Safety Controller System Installation Environment 22 An example configuration scan time System configuration includes T9432 Analogue input simplex modules x 30 and T9451 Digital output simplex modules x 18 Total I O modules 48 Sync time 32 ms Scan time 39 3 ms 32 ms 48 x 0 04 ms 30 x 1 170 ms 18 x 1 174 ms gt 129 5 ms Minimum throughput time 129 5 ms 7 ms gt 136 5 ms Maximum throughput time 2 x 129 5 ms 13 ms 272 0 ms The installation environment can be a source of common cause failure so it is necessary that the in
115. n sub section is wired in accordance with the drawings and that the subsections are isolated from each other Do the following I 2 Power Distribution and First NOTE Power Up Make sure all power sources are isolated Switch off all circuit breakers and open distribution fuses Remove all modules from the controller Check that the circuit breakers and fuses of the correct capacity and rating are installed in the correct locations Check that all subsections are isolated from each other Before you begin this task you must have checked the power distribution integrity The power distribution and first power up verifies that the power distribution circuits function as designed and as detailed in the drawings It shows the correct voltages are appearing and only in the correct places It also provides an opportunity to verify correct operation of any power indicators outside the controller itself Do the following 1 Make sure all modules are removed 2 Trip all circuit breakers and disengage all power distribution fuses and field fuses 3 Apply power to the incoming power terminals 4 Itis good practice to switch on power supplies to field devices before supplies to the controller Devise a formal sequence in which to switch on individual circuits e In sequence check each circuit breaker or fuse for zero volts on the destination side and then close the circuit breaker or fuse and verify that the appropriate volta
116. nd assemblies connect together easily without the need for inter module wiring CAUTION The controller contains static sensitive components When the controller is installed attach a label that is clearly visible to tell operators to follow anti static precautions when they touch or move modules Failure to follow these instructions can result in damage to the equipment Rockwell Automation Publication ICSTT RM448I EN P May 2015 41 Chapter 2 The AADvance Safety Controller Environmental Specification An AADvance system can be installed in a non hazardous or a hazardous environment In a non hazardous environment a system does not have to be installed in an enclosure however the area where it is installed must maintain a Pollution Degree 2 environment IEC 60664 1 The following environmental specification defines the minimum environmental conditions for an AADvance controller installation Additional conditions apply to systems installed in a Hazardous environment Table 3 Environmental Specification Attribute Value Operating Temperature Range For use in Hazardous Environments Processor Modules 25 C to 60 C 13 F to 140 F I O Modules and Termination 25 C to 70 C 13 F to 158 F Assemblies For use in Non hazardous 25 C to 70 C 13 F to 158 F Environments Processor Modules 1 0 modules and Termination Assemblies Storage and Transport Temperature 40 C to 70 C 40 F t
117. ne 9801 Digital Input Termination Assembly Simplex 9802 Digital Input Termination Assembly Dual 9803 Digital Input Rockwell Automation Publication ICSTT RM448I EN P May 2015 23 Chapter 2 The AADvance Safety Controller Installation Requirements for Hazardous Environment 24 Termination Assembly TMR 9831 Analogue input Termination Assembly Simplex 9832 Analogue Input Termination Assembly Dual 9833 Analogue Input Termination Assembly TMR 9851 Digital Output Termination Assembly Simplex and 9852 Digital Output Termination Assembly Dual 9892 Digital Output Termination Assembly Dual 9881 Analogue Output Termination Assembly Simplex 9882 Analogue Output Termination Assembly Dual Non Hazardous Installation Requirements Environmental In a non hazardous environment a system can be installed in an enclosure or on a support wall however the enclosure or the area where it is installed must not be more than a Pollution Degree 2 or similar environment in accordance with IEC 60664 1 2007 The surrounding air temperature ratings are e For the 9110 Processor module 60 C e For all other I O modules base units and termination assemblies 70 C Pollution Degree Definition For the purpose of evaluating creepage distances and clearances the following four degrees of pollution in the micro environment are established e Pollution Degree 1 No pollution or only dry pollution occurs The pollution has no influ
118. ng at a constant 25 C and low humidity high humidity temperature and frequent power cycles are all factors that will shorten the batteries operational life The battery has a design life of 10 years when the processor module is continually powered for processor modules that are un powered the design life is up to 6 months CAUTION The battery may explode if mistreated Do not attempt to recharge disassemble or dispose of in a fire ATTENTION La pile peut exploser si elle est maltrait e Ne tentez pas de la recharger d sassembler ou de la br ler WARNING Batteries must only be changed in an area known to be non hazardous AVERTISSEMENT Les piles ne doivent tre remplac es que dans une zone r put e non dangereuse Rockwell Automation Publication ICSTT RMA4BI EN P May 2015 123 Chapter 5 Install the AADvance System Procedure To replace a faulty battery do the following 1 Use a small cross head screwdriver to release and remove the battery cover Fault Reset 2 Remove the battery by pulling on the blue ribbon 3 Insert a new battery orientate it the positive terminal to the right Trap the ribbon behind the new battery so it can be removed in the future and then push the battery into the holder 4 Put the cover back and secure it with the cross head screw 5 Push the Fault Reset button on the processor module The processor Healthy LED will go green applies if the module is par
119. ng clips at the top and bottom of the base units e Secure the I O base unit onto the DIN rails by sliding the retaining lever below the base unit to the left Then insert the backplane clips into the top and the bottom slots 4 Mount end stops onto DIN rails e Install two end stops onto the upper DIN rail one at each end of the assembly Rockwell Automation Publication ICSTT RM448I EN P May 2015 93 Chapter 5 Install the AADvance System Fitting Termination Assemblies Figure 14 How to Fit Termination Assemblies O base unit Termination assembly Tabs 1 To fit termination assemblies do the following e Insert the retaining clip on the back of the termination assembly into the slot on the I O base unit Press the termination assembly onto the base unit and then slide the assembly upwards as far as it will go e Make sure the retaining tab clips over the printed circuit board to secure the termination assembly in position 2 Check coding pegs e Observe the legend on the 9100 processor base unit and repeated on some termination assemblies which defines the six 94 Rockwell Automation Publication ICSTT RM448I EN P May 2015 Install the AADvance System Chapter 5 possible positions for a coding peg The positions are numbered from 1 to 6 e Examine a coding peg fitted and identify the index recess on the hexagonal flange e Refer to the following table and verify each coding peg is fitt
120. nit binding A relationship between two variables in different AADvance controllers One variable is a producer and the other is a consumer The system updates the value in the consumer to match the data in the producer See SNCP protocol black channel A path for communications data which does not maintain the integrity of the data transferred over it Measures to find and compensate for errors introduced by the black channel are implemented by software or hardware or both in the safety critical sender and receiver blanking cover A plastic moulding to hide an empty slot in an AADvance controller base unit Boolean A type of variable that can only accept only the values true and false 174 BPCS Basic process control system A system responding to input signals and generating output signals causing a process and its related equipment to operate in a desired way having no safety instrumented functions with a safety integrity level of 1 or higher See IEC 61511 and ANSI ISA 84 00 01 2004 Part 1 IEC 61511 1 Mod for a formal definition Equivalent to the Process Control System PCS specified by IEC 61508 breakdown voltage The maximum voltage AC or DC that can be continuously applied between isolated circuits without failure of the insulation BS EN 54 A standard for fire detection and fire alarm systems BS EN 60204 A standard for the electrical equipment of machines which pro
121. nstall the AADvance System 116 e Apply a minimum tightening torque of 0 5 Nm 0 37 ft Ib to the terminal screws Recommended Field Circuit for Digital Outputs This circuit is applicable for simplex and dual configurations of digital output modules The two 10 A fuses shown are included on the termination assembly within the controller The 5 A fuses satisfy UL508 requirements for digital output field supplies see illustration below Figure 18 Digital Output Field Circuit Field Power 24V de Source 424V de Fe memme es l Power Distribution Ch 1 Ch 8 jas _ l Field I m ati i Element Termination Assembly DES l SE m m m m For inductive loads a back EMF protection diode must be fitted at the load A fuse rated minimum 32 Vdc maximum 5 A for an input of 0 28 3 V and a maximum fuse current rating of 100 V for an input of 28 3 42 4 V must be installed in series with the field power terminals on modules T9451 to comply with the UL 508 certification Rockwell Automation Publication ICSTT RM448I EN P May 2015 Install the AADvance System Chapter 5 Recommended Fuse Types The 10A fuses are fitted into the termination assembly and are e T9902 SMF Omni Block Surface Mount Fuse Block 154 010 with a 10 A 125 V Fast Acting Fuse Littelfuse The field power input 5 A fuses are e No 396 TES 5 A time lag fuse UL 248 14 125 V T Leadfree manufactu
122. ntegrated system If the controller is applied to a safety related application then the safety requirements are also tested Devising tests for Functional The tests performed during functional acceptance testing must include the following Acceptance e Performance tests including timing reliability and availability integrity and safety requirements and constraints e Interface testing Write down the test cases and define the pass criteria for every test Make sure that the test cases allow for the associated systems and their interfaces which the system needs to communicate with If a requirement cannot be physically demonstrated devise a written analysis to show how the system achieves the requirement The AADvance controller has been tested to the limits given in its module specifications If appropriate do the following e Environmental tests including electromagnetic compatibility life and stress testing e Testing in degraded modes and fault modes e Exception testing Test Environment for It is recommended that the testing is done in a factory environment before installing and commissioning at the plant Functional Acceptance Rockwell Automation Publication ICSTT RM448I EN P May 2015 165 Chapter 7 Functional Acceptance Testing Ma naging Functional Define the person or authority which will be responsible for doing each test and also the person or authority such as the customer or their Acceptance Te
123. nto a slot behind a removable cover on the front panel of the processor module The battery position is shown in the illustration CAUTION The battery may explode if mistreated Do not recharge disassemble or dispose of in a fire Battery Specification A Polycarbon monofluoride Lithium Coin Battery with a nominal voltage of 3V Nominal capacity mAh 190 Continuous standard load mA 0 03 Operating temperature range 30 C to 80 C manufactured by Panasonic 52 Rockwell Automation Publication ICSTT RM448I EN P May 2015 The AADvance Safety Controller Chapter 2 Processor Maintenance Socket Behind the removal cover on the processor front panel is a maintenance socket SK1 This socket is for maintenance use only WARNING SK1 is for maintenance only When AADvance is installed in a hazardous location power must be disconnected or the area known to be free of ignitable concentrations of flammable gases or vapours when using this socket AVERTISSMENT Port SK1 pour les modules T9110 et T9111 Pour la maintenance uniquement lorsqu install en environnement dangereux L alimentation doit tre coup e ou la zone exempte de concentrations de gaz ou de vapeurs inflammables lorsqu il est utilis Rockwell Automation Publication ICSTT RMA4BI EN P May 2015 53 Chapter 2 The AADvance Safety Controller 54 1 0 Base Unit An I O base unit holds up to three I O modules L C
124. nts K key connector The receptacle on the AADvance controller for the program enable key A 9 way D type socket on the 9100 processor base unit Rockwell Automation Publication ICSTT RM448I EN P May 2015 9000 Series Glossary Chapter 10 ladder diagram An IEC 61131 language composed of contact symbols representing logical equations and actions The main function is to control outputs based on input conditions See limited variability language LAN Local area network computer network covering a small physical area characterized by a small geographic range having no need for leased telecommunication lines live insertion The removal and then reinsertion of an electronic module into a system while the system remains powered The assumption is that removal of the module and reinsertion will cause no electrical harm to the system Also known as hot swap low demand mode Where the Safety Instrumented Function only performs its designed task on demand and the frequency of demands is no more than one time each year M manual call point A component of a fire detection and fire alarm system enabling a person to trigger an alarm Modbus An industry standard communications protocol developed by Modicon Used to communicate with external devices such as distributed control systems or operator interfaces Rockwell Automation Publication ICSTT RM448I EN P May 2015 Modbus object A repres
125. o 158 F Range Module Surface Temperature during 43 C 109 F 2 C usual operation Humidity Operating 10 to 95 RH non condensing Storage and Transport 10 to 95 RH non condensing Vibration Functional Stress 5 Hz to 9 Hz Continuous 1 7 mm amplitude Occasional 3 5 mm amplitude Withstand 10 Hz to 150 Hz Acceleration 0 1gin 3 axes Endurance 10 Hz to 150 Hz Acceleration 0 5 g in 3 axes Shock 15 g peak 11 ms duration sine Altitude Operating O to 2 000 m 0 to 6 600 ft 42 Rockwell Automation Publication ICSTT RM448I EN P May 2015 The AADvance Safety Controller Chapter 2 Storage and Transport 0 to 3 000 m 0 to 10 000 ft This equipment must not be transported in unpressurized aircraft flown above 10 000 ft Electromagnetic Interference Tested to the following standards EN 61326 1 2006 Class A EN 61326 3 1 2008 EN 54 4 1997 A1 EN 61131 2 2007 EN 62061 2005 Hazardous Location Capability Suitable for Class Div 2 Groups A B Cand D There is no specific protection against liquids Rockwell Automation Publication ICSTT RM448I EN P May 2015 43 Chapter 2 The AADvance Safety Controller 44 Product Dimensions A typical controller arrangement is shown with processor modules installed on the processor base unit and an I O base unit mated with the processor base unit I O modules are installed on the base unit and a termination assembly plugged into the I O base unit mm Processor
126. odels The ambient temperature range is 25 C to 70 C 00 IC F0060 Issue 7 0 This certificate may only be reproduced in its entirety and without any change schedule included Page 2 of 5 Rockwell Automation Publication ICSTT RM448I EN P May 2015 The AADvance Safety Controller Chapter 2 13 Schedule 14 TYPE EXAMINATION CERTIFICATE No DEMKO 11 ATEX 1129711 X Rev 2 Report 4786336921 Electrical data Backplane Ratings j Mode Voltage Vde Current mA Input Output Ratings 18 32 10 4A 400mA per slot we 8 4 Esa LAN 18 32 10 4A 400mA per slot E NF ee ee O N 18 32 9 6A 400mA per slot ECA se ase 18 32 380 A iis WE Wil W 18 32 380 Fits wits bit 18 32 260 18 32 18 32 18 32 260 18 32 260 18 32 16VA 1 5A Inrush 0 32 0 32 18 32 18 32 18 32 0 32 18 32 18 32 18 32 18 32 18 32 Pp N NIN N 22 219 oO ojo Routine tests None 16 Descriptive Documents Project Report No 4786336921 Hazardous Location Testing Drawings Description Drawing No Rev Level Date Model 9100 Schematic 8 Pages 130662 O 2009 12 17 Model 9101 Schematic 6 Pages 131022_1715A2A D7 2011 05 31 Model 9300 Schematic 2 Pages 130622 E 2008 06 07 Model 9110 and 9111 Schematic Board No 151421 25 130642 N1 201 1 09 13 Pages Model 9110 and 9111 Schematic Board No 151431 9 130652 P5 201 1 05 31 Pages Models 9401 9402 9431 and 9432 Schematic Board 130682 AE3 2012 05 18 Nos 151441 and 1519
127. of variable types for the controller TCP Transmission control protocol A set of rules used by applications requiring guaranteed delivery of a stream of bytes from a program found on one computer to a different program typically found on a different computer An example for an AADvance controller is Modbus communications over Ethernet One of the core protocols of the Internet Protocol suite termination assembly A printed circuit board connecting field wiring to an input or output module The circuit includes fuses for field circuits The board carries screw terminals to connect the field wiring to the controller and the whole assembly clips onto the 9300 I O base unit TMR Triple modular redundant A fault tolerant arrangement in which three systems complete a process and their result is processed by a voting system to provide one output T V certification Independent third party certification against a range of international standards including IEC 61508 U U Rack unit A unit of measure used to give the height of equipment intended for mounting in a standard rack Equivalent to 44 45 mm 1 inches Rockwell Automation Publication ICSTT RM448I EN P May 2015 9000 Series Glossary Chapter 10 V validation In quality assurance approval that the product does what the user requires verification In quality assurance approval that the product conforms to the specifications voting system A
128. oit tre install dans une enceinte normalis e IP 54 si l environnement est class en degr de pollution 2 conform ment a la norme CEI 60664 1 2007 Pollution Degree Definition For the purpose of evaluating creepage distances and clearances the following four degrees of pollution in the micro environment are established e Pollution Degree 1 No pollution or only dry pollution occurs The pollution has no influence e Pollution Degree 2 Only non conductive pollution occurs except that occasionally a temporary conductivity caused by condensation is to be expected e Pollution Degree 3 Conductive pollution occurs or dry non conductive pollution occurs which becomes conductive due to condensation which is to be expected e Pollution Degree 4 Continuous conductivity occurs due to conductive dust rain or other wet conditions Enclosure Requirements for a Hazardous Environment Class Division 2 Groups A B Cand D The enclosure must comply with the following UL requirements Rockwell Automation Publication ICSTT RM448I EN P May 2015 71 Chapter 4 Before You Begin Special Conditions for Safe Use e Models 9110 The ambient temperature range is 25 C to 60 C 13 F to 140 F e All other Models the ambient temperature range is 25 C to 70 C 13 F to 158 F e Subject devices are to be installed in an ATEX IECEx Certified IP54 tool accessible enclosure that has been evaluated to t
129. on 140 Rockwell Automation Publication ICSTT RM448I EN P May 2015 System Start Up Chapter 6 Step Task Serial 2 Will stay OFF as the Module boots up 10 to 20 seconds then is depends on data connection Ethernet 1 Will stay OFF as the Module boots up 10 to 20 seconds then is depends on data connection Ethernet 2 Will stay OFF as the Module boots up 10 to 20 seconds then is depends on data connection When the Run indicator goes AMBER push the Fault Reset button and the processor will show the following indications 2 Healthy GREEN Ready GREEN will flash for a short time as the module educates Run AMBER to GREEN AMBER as the module educates System Healthy GREEN Force Off to GREEN Aux Depends on application Serial 1 Depends on data Connection Serial 2 Depends on data Connection Ethernet 1 Depends on data Connection Ethernet 2 Depends on data Connection 3 To insert a 3rd processor module repeat step 1 and insert in slot C Rockwell Automation Publication ICSTT RM448I EN P May 2015 141 Chapter 6 System Start Up 1 0 Module Sta rt up Process The start up sequence is different when a module is installed into an on 142 Step Step line system that is running compared to installing the module into a system that is off line and has processor modules but no I O modules installed Table 13 Single Module or First Module of a group Installation Procedure Task This procedure applies to a singl
130. on faciliter le raccordement des conducteurs Le conducteur de mise la terre devra avoir une section minimale de 3 31 mm e Les dispositifs concern s sont utilisables dans un environnement pr sentant un degr de pollution 2 au maximum conform ment la norme CEI 60664 1 e Les dipositifs concern s doivent utiliser des conducteurs avec une temp rature nominale minimum de 85 C e Les dispositifs concern s doivent tre install s verticalement uniquement 72 Rockwell Automation Publication ICSTT RM448I EN P May 2015 Before You Begin Chapter 4 WARNING EXPLOSION HAZARD Do not connect or disconnect equipment while the circuit is live or unless the area is known to be free of ignitable concentrations or equivalent AVERTISSEMENT RISQUE D EXPLOSION Ne pas connecter ou d connecter l quipement alors qu il est sous tension sauf si l environnement est exempt de concentrations inflammables ou quivalente WARNING Substitution of any component may impair suitability for Class Division 2 or equivalent AVERTISSEMENT La substitution de composants peut rendre impropre a l utilisation en Classe Division 2 ou quivalente CAUTION For AADvance modules 9110 9801 9803 9831 9833 9851 9852 9892 9881 and 9882 a disconnect suitable for the location where they are installed shall be provided to allow for removal of power from the fuses before replacement ATTENTION Pour les mo
131. or specifying the performance requirements of the safety functions allocated to a safety related system SIL4 has the highest level of safety integrity SIL1 has the lowest For an installation to get a specified SIL rating all of the parts of the installation together with the AADvance controller must fulfill these requirements SNCP Safety Network Control Protocol A set of rules that allowing different AADvance controllers in a system to share data SNCP is a SIL 3 certified protocol which provides a safety layer for an Ethernet network SNTP Simple Network Time Protocol A set of rules for synchronizing the real time clocks of AADvance controllers and other devices over Ethernet networks structured text A high level IEC 61131 3 language with syntax equivalent to that of Pascal Useful for making complex procedures that cannot be expressed easily with graphical languages synchronous A data communications term describing a serial transmission protocol A pre arranged number of bits is expected to be sent across a line each second To synchronize the sending and receiving machines a clocking signal is sent by the transmitting computer There are no start or stop bits TA See termination assembly 182 target An attribute of a configuration which describes characteristics of the AADvance controller on which the configuration will run Includes characteristics such as the memory model and the sizes
132. or transmit and receive This selection must also be used when the controller is acting as a Modbus master using the optional four wire definition specified in Section 3 3 3 of the Modbus over serial standard RS485fdmux A four wire full duplex connection with tri state outputs on the transmit connections This must be used when the controller is acting as a Modbus slave on a four wire bus RS48Shdmux A two wire half duplex connection applicable for master slave or slave use This is shown in the Modbus over serial standard Each processor uses the two serial ports above it on the baseplate Data is not mirrored between ports Therefore a single processor system has two ports available a dual processor system has four ports and a triple processor system has six ports available to it Connect the serial communications cabling to the six plugs labeled S1 1 through S3 2 on the T9100 processor base unit For each serial communications connection connect the cabling according to the following illustration Apply a minimum tightening torque of 0 22 Nm 0 16 ft Ib to the terminal screws Make sure the length of the cable does not exceed 1 200 m 3 900 ft Rockwell Automation Publication ICSTT RM448I EN P May 2015 101 Chapter 5 Install the AADvance System Terminal Function Description 4 wire Function Description 2 wire TRX_A Receive data A inverting Transmit receive data A inverting TRX_B Receive data B
133. output electrical specifications The controller is designed to operate in its specified environment without forced air cooling However forced air cooling may be needed in individual circumstances when the controller shares its enclosure with other heat producing equipment and the internal temperature could exceed the recommended operating temperature range Module Orientation Rockwell only recommend that modules are oriented vertically if modules are mounted in any other orientation then specific temperature tests must be done to ensure reliable and predictable operation Maximum Air Temperature The maximum air temperature rating in an enclosure where AADvance modules are installed to ensure predictable operation is 70 C 158 F Estimate Heat Dissipation The heat in the enclosure is generated from several sources such as the power supplies the AADvance modules and some of the field loop power Use the following calculation and the data given in the tables to estimate the overall heat dissipation e Power supply consumption Watts x 100 efficacy the sum of the system power consumed by the modules part of the field power that is in the enclosure Table 7 Module Supply Power Heat Dissipation The following module power dissipation values are worst case values over the range of operating voltages and currents Rockwell Automation Publication ICSTT RM448I EN P May 2015 83 Chapter 4 Before You Begin
134. packing and Pre The components are packed to make sure they arrive undamaged and P g ready for assembly Nevertheless you should inspect all modules before assembly Checks beginning the assembly work On receipt carefully inspect all the shipping cartons for damage e fany cartons are damaged note the damage on the carrier s shipping document before signing it Save any damaged cartons for inspection by the carrier e If any part of the delivered components has been damaged during shipping notify the carrier and Rockwell Automation immediately Damaged goods must be returned Rockwell Automation for repair or replacement see Warranty and Returns instructions with delivery documentation CAUTION Handling Modules Stored at Extreme Temperatures It is recommended that modules removed from storage should be allowed to normalize their temperature before installation This is particularly important when modules have been stored at very low temperatures where condensation can occur Remove the modules and place them in an upright position and wipe away any condensation that might appear on the modules Failure to follow these recommendations could lead to damage to modules or incorrect operation when installed into a running system Rockwell Automation Publication ICSTT RM448I EN P May 2015 91 Chapter 5 Install the AADvance System The following illustration shows how to it the backplanes on to Din rails and use the retain
135. perational Documents as amended STANDARDS The electrical apparatus and any acceptable variations to it specified in the schedule of this certificate and the identified documents was found to comply with the following standards IEC 60079 0 2011 Explosive atmospheres Part 0 General requirements Edition 6 0 IEC 60079 15 2010 Explosive atmospheres Part 15 Equipment protection by type of protection n Edition 4 This Certificate does not indicate compliance with electrical safety and performance requirements other than those expressly included inthe Standards listed above TEST amp ASSESSMENT REPORTS A sample s of the equipment listed has successfully met the examination and test requirements as recorded in Test Report US UL ExT R12 0041 00 US UL ExTR12 0041 01 US UL ExTR12 0041 02 Quality Assessment Report DK ULD QAR 10 0001 02 Rockwell Automation Publication ICSTT RM448I EN P May 2015 33 Chapter 2 34 The AADvance Safety Controller IECEXx Certificate of Conformity Certificate No IECEx UL 12 0032X Date of Issue 2014 05 28 Issue No 2 Page 3 of 4 Schedule EQUIPMENT Equipment and systems covered by this certificate are as follows These devices are low power open type programmable logic controllers that are intended for installation in an ultimate enclosure The 9000 Programmable Logic Controller Series consist of the following modules Please see Annex for additional details CONDI
136. quipment G Rockwell Automation Publication ICSTT RM448I EN P May 2015 group A collection of two or three input modules or two output modules arranged together to supply enhanced availability for their input or output channels hand held equipment Equipment which is intended to be held in one hand while being operated with the other hand See portable equipment HART Highway Addressable Remote Transducer An open protocol for process control instrumentation It combines digital signals with analogue signals to give control and status data for field devices For more details about HART devices refer to the HART Application Guide created by the HART Communication Foundation and the full HART specifications You can download documents from www hartcomm org high demand mode Where the Safety Instrumented Function in the safety system only performs its designed task on a demand and the frequency of demands is more than one time each year hot swap See live insertion 177 Chapter 10 9000 Series Glossary 1 0 base unit A backplane assembly holding one two or three I O modules and their related termination assembly or assemblies in an AADvance controller Part number 9300 See 1 0 module and termination assembly 1 0 module An AADvance module continuing interfaces for inputs from field sensors and generating output for field elements Connects to the field through Termination Asse
137. r perform an on line update 3 Check the current date and time settings e Enter Debug mode e Request IXL Restricted Access e Force the RTC Read Boolean and all the time fields in the RTC Control Rack Variables to TRUE IMPORTANT Do not force the RTC Write Boolean at this point 126 Rockwell Automation Publication ICSTT RM448I EN P May 2015 Install the AADvance System Chapter 5 e The RTC Status Variables will show the current date and time in the processor Procedure to Set the Date and Time 1 Unlock the RTC Read variable so it turns FALSE 2 Select each RTC Program Rack variable and enter the date and time values 3 Toggle the RTC Write variable TRUE then FALSE to write the new date and time setting to the processor 4 Lock and force the RTC Read variable to TRUE 5 The RTC Status rack now displays the new date and time of the processor 6 Unlock all the RTC Control variables Install 1 0 Modules DOS NOmnE e Before inserting a new I O module examine it for damage e The identification labels on the sides of the I O module will be hidden when the module is installed Therefore before installation write down the location of the module and the details shown on the label Installation 1 Examine the coding pegs on the termination assembly and make sure that they complement the sockets on the rear of the new I O module 2 Place the I O module on to the dowel pins on the T9300 I O base unit Make sure t
138. rangement e Expand a simplex or group arrangement e Downgrade a group arrangement e Move a module to a different slot e Change an application variable You only have to plug an additional I O base unit into the side socket on an installed I O base unit The command busses on the I O base units do not need different terminations on the open ends of transmission lines and the data response busses and power sources are supplied across all I O base units Termination assemblies are pushed into the I O base unit for the additional I O modules To put the new modules on line and make the changes to the system fully operational the hardware configuration in the AADvance Workbench software must be updated by an on line update IMPORTANT For Release 1 3 you can change the 1 0 module configuration with an on line update However if you are using an earlier product release the 1 0 configuration cannot be changed with an on line update Rockwell Automation Publication ICSTT RM448I EN P May 2015 61 Chapter 2 The AADvance Safety Controller 62 IMPORTANT An on line update could affect the operation of the controller such that the application is stopped or the 1 0 data flow is interrupted The AADvance Safety Manual outlines the precautions you need to follow when doing on line updates on a Safety System When there is not sufficient space for extra I O base units on a row you can use the Expansion Cable to connect a new row of I O b
139. rce agpeemert noes D you accept the teem below cick T USER LICENSE AGREEMENT Rev 12 2009 RTANT READ THIS AGREEMENT CAREFULLY Thos End User License p and onbre co electroesc documertahon Documertatson Any AE Eris Er zdis Ba ba Phea O1 De Not Agee 4 Click Browse to select the location of the installation or Next to select the default location CoatreiFLASH 9 00 015 Select Installation Folder The malake val malal Cortal LASH to ur bolloeang bolder Too metal n thes bolder cki We To natal to differed bolder enter below a chch Tar Eois C Progam Fier Cora LASH Rockwell Automation Publication ICSTT RM448I EN P May 2015 145 Chapter 6 System Start Up 5 Click Next to start the installation i ControlFLASH 9 00 015 Confirm Installation Enable FactoryT alk Security The installer is ready to install ControlFLASH on your computer Click Next to start the installation e ControlFLASH installs i ControlFLASH 9 00 015 Installing ControlFLASH 9 00 015 ControlFLASH is being installed Please wait Cancel 146 Rockwell Automation Publication ICSTT RM448I EN P May 2015 System Start Up Chapter 6 6 To launch ControlFLASH select the Yes I want to launch ControlFLASH option then click Close i ControlFLASH 9 00 015 Installation Complete ControlFLASH has been successfully installed You can view the README file and launch controlFLASH
140. red by Littelfuse NOTE 1 Instead of fitting two 5 A fuses you can use Class 2 power supplies for the 24 Vdc field voltage Class 2 is specified by the NEC as supplying less than 100 watts at 24 V 2 The field power must be wired using 12 AWG wire 3 The field power must be supplied with an isolating source 4 The minimum current required for line monitoring is 20 mA for a dual pair Digital Output Slew Tolerance It is possible during sustained periods of abnormal input current slewing that channels can be declared faulted as a consequence of diagnostics otherwise designed to ensure the channels are operating within their designed safety accuracy To avoid spurious declaration of channel faults it is necessary to ensure that the field supply voltage and output signal condition satisfies the maximum slew rate criteria defined in the Solutions Handbook Accordingly it may be necessary to condition the field supply voltage or output signal such as by filtering or by appropriate choice of process safety time Connections to T9851 T9852 Digital Output TA 8 Channel Simplex Dual The field element wiring and field power connections are as shown Rockwell Automation Publication ICSTT RM448I EN P May 2015 117 Chapter 5 Install the AADvance System Figure 19 Digital Output Termination Assembly Wiring V2 e Apply a minimum tightening torque of 0 5 Nm 0 37 ft Ib to the terminal screws 118 Rockwell Automation
141. redundant system m out of n requiring at least m of the n channels to be in agreement before the system can take action Rockwell Automation Publication ICSTT RM448I EN P May 2015 W withstand voltage The maximum voltage level that can be applied between circuits or components without causing a failure of the insulation word A 16 bit unsigned value from 0 to 65535 One of the IEC 61131 types See also integer 183 Chapter 10 9000 Series Glossary Page intentionally left blank 184 Rockwell Automation Publication ICSTT RM448I EN P May 2015 Chapter 11 Additional Resources For more information about the AADvance system refer to the related Rockwell Automation technical manuals shown in this document map Solutions Handbook 553031 Safety Manual 553030 System Build Manual 553632 Configuration Guide 5536033 or 555063 Trouble shooting and Maintenance Manual 553034 PHD and PFD Data Manual 553847 OPC Portal Server User Manual 553701 Actual configuration guide applicable is dependent upon version of AADvance Workbench used Rockwell Automation Publication ICSTT RM448I EN P May 2015 185 Chapter 11 Additional Resources Publication Purpose and Scope Safety Manual This technical manual defines how to safely apply AADvance controllers for a Safety Instrumented Function It sets out standards which are mandatory and makes recommendations to make
142. restoration of power the retained data is loaded back into the variables assigned as retained variables for use by the application scan e Diagnostic logs The processors diagnostic logs are stored in the portion of RAM backed by the battery Set the Real Time Clock Manually If the system has only one controller and does not have a different time server you have to set the processor real time clock manually using RTC variables The following procedure assists in setting the clock Set up the following variables in the Dictionary RTC Control Rack Variables all BOOLEAN Outputs RTC Control RTC Read RTC Control RTC Write RTC Control Year Rockwell Automation Publication ICSTT RM448I EN P May 2015 125 Chapter 5 Install the AADvance System RTC Control Month RTC Control Day of Month RTC Control Hours RTC Control Minutes RTC Control Seconds RTC Control Milliseconds RTC Status Variables All Word Inputs RTC Status RTC Status RTC Status RTC Status RTC Status RTC Status RTC Status Year Month Day of Month Hours Minutes Seconds Milliseconds RTC Program Rack Variables RTC Program Year RTC Program Month RTC Program Day of Month RTC Program Hours RTC Program Minutes RTC Program Seconds RTC Program Milliseconds Procedure to Check the Current Date and Time 1 Wire the processor variables Refer to the topic Wire Processor Variables 2 Build and download the program o
143. rm its normal control i function Please make sure that all processes Contr ol affected by this equipment have been suspended T i and that all safety critical functions are not _ affected To abort this firmware update press Cancel now To begin the update now press Finish Catalog Number 19110 Serial Number 504D4153 Current Revision 1 2 0 New Revision 1 22 0 lt Back Finish Cancel Help The continue message is displayed ControlFLASH 9 Are you sure you want to begin L updating the target device J 7 Click Yes to continue with the update 150 Rockwell Automation Publication ICSTT RM448I EN P May 2015 System Start Up Chapter 6 e A progress bar is displayed ControlFLASH 9 00 015 Progress Catalog Number 19110 Serial Number 504D4153 Current Revision 1 2 0 New Revision 1 22 0 Transmitting block 164 of 4617 E e When the progress bar reaches the end it may take several minutes for the next screen to appear NOTE It has not locked up Wait until the next message box appears You may get a Comms error message as AADvance processors do not automatically reboot as ControlFLASH expects them to but the firmware download should have completed correctly Rockwell Automation Publication ICSTT RM448I EN P May 2015 151 Chapter 6 System Start Up ControlFLASH run T9110 LS ControlFLASH 9 00 015 AB_ASA DLL Failed to communicate to the target devi
144. rmination Assembly Shield i if used IE Terminal Blacks 0w Analogue Input Slew Tolerance It is possible during sustained periods of abnormal input current slewing that channels can be declared faulted as a consequence of diagnostics otherwise designed to ensure the channels are operating within their designed safety accuracy To avoid spurious declaration of channel faults it is necessary to ensure that the input signal condition satisfies the maximum slew rate criteria defined in the Solutions Handbook Accordingly it may be necessary to condition the input signal such as by filtering sensor slew rate configuration or by appropriate choice of process safety time 114 Rockwell Automation Publication ICSTT RM448I EN P May 2015 Install the AADvance System Chapter 5 Connections to T9831 Non isolated Analogue Input TA 16 Channel Simplex CH9 CH10 CH11 CH12 CH13q FCHI4 FCHI5 CH16 PE GRR M ES ON OT LLL otoo eee QZ 12 18 12 2 D O O 2 RE e Apply a minimum tightening torque of 0 5 Nm 0 37 ft Ib to the terminal screws Connections to T9832 T9833 Isolated Analogue Input TA 16 Channel TMR CHI CH2 CH3 CH4 CH5 CH6 CH7 CH8 CH9 CH10 CH11 CHI2 CH13 CH14 CH15 CHI6 CH1 9 CH2 CH34 CHa PCH5S f CH f CH7 9 CHE f CH9 PCHIO EH11 4 PCH12 f CH13H CH14 9CH154 9CH16 Rockwell Automation Publication ICSTT RM448I EN P May 2015 115 Chapter 5 I
145. rocessor base unit by using the 93100 expansion cable I O Bus 2 The expansion cable also connects the right hand side of I O base units to the left hand side of other I O base units to install extra rows of I O base units Base units are secured in place by top and bottom clips that are inserted into the slots on each base unit Rockwell Automation Publication ICSTT RM448I EN P May 2015 77 Chapter 4 Before You Begin Figure 11 Connecting Base Units with Expansion Cables Processor A Processor B Processor C IO Bus 2 10 Bus 1 9300 Expansion Cable 9300 Expansion Cable The expansion bus accessed from the right hand edge of the 9100 processor base unit is designated I O Bus 1 while the bus accessed from the left hand edge is designated I O Bus 2 The module positions slots in the I O base units are numbered from 01 to 24 the left most position being slot 01 Any individual module position within the controller can thus be uniquely identified by the combination of its bus and slot numbers for example 1 01 The electrical characteristics of the I O bus interface limit the maximum possible length of either of the two I O buses the combination of I O base units and expansion cables to 8 meters 26 24 ft NOTE The 9310 Expansion Cable is 2 m 6 56 ft Adding Field Cable Management The field power and other system wiring will be connected to terminals along the top of the base units It is recommended
146. rogress bar 6 Click Yes I want to launch ControlFLASH then click Close Upgrade Processor OS FPGA ATTENTION Do not attempt to upgrade firmware ona LSP and BUSP Firmware running system ControlFLASH will not warn you that a system is running and you will lose control of the application when the system reboots This procedure describes how to upgrade the processor module firmware using ControlFLASH TIP ControlFLASH can upgrade three processor modules at the same time when installed into a 9100 base unit 1 Run the ControlFLASH software by either Rockwell Automation Publication ICSTT RM448I EN P May 2015 153 Chapter 6 System Start Up e Launching from the installation e Double clicking the desktop icon e Launching from the Start button i ControlFLASH Untitled R ControlFLASH 9 00 015 Welcome to ControlFLASH Welcome to ControlFLASH the firmware update tool ControlFLASH needs the following information from you before it can s begin updating a device Contr ol W 1 The Catalog Number of the target device 7 2 The Network Configuration parameters optional 3 The Network Path to the target device 4 The Firmware Revision for this update View Log Bact Next gt Cancel Help 2 Click Next 3 Select T9110 from the list OD TiO 4 PEN s BAIA Catalog Number Enter the catalog number of the target device TEE Control TTISAENTR cm o 154 Rockwell Auto
147. s IMPORTANT A login is required to access the link If you do not have an account then you can create one using the Sign Up link at the top right of the web page DOCUMENT NUMBER The UK document number 553632 Copyright Rockwell Automation 2015 DOCUMENTATION FEEDBACK Your comments help us to write better user documentation If you discover an error or have a suggestion on how to make this publication better send your comment to our technical support group at http rockwellautomation custhelp com Rockwell Automation Publication ICSTT RM448I EN P May 2015 SYMBOLS In this manual we will use these notices to tell you about safety considerations IMPORTANT NOTE TIP Rockwell Automation Publication ICSTT RM448I EN P May 2015 SHOCK HAZARD Identifies an electrical shock hazard If a warning label is fitted it can be on or inside the equipment WARNING Identifies information about practices or circumstances that can cause an explosion in a hazardous environment which can cause injury or death property damage or economic loss ATTENTION Identifies information about practices or circumstances that can cause injury or death CAUTION Identifies information about practices or circumstances that can cause property damage or economic loss BURN HAZARD Identifies where a surface can reach dangerous temperatures If a warning label is fitted it can be on or inside the equipment This symbol identif
148. s The KEY connector supports all three processor modules and prevents access to the application unless the Program Enable key is inserted Serial Communications Ports The serial ports S1 1 and S1 2 S2 1 and S2 2 S3 1 and S3 2 support the following signal modes depending on use e RS485fd A four wire full duplex connection that features different busses for transmit and receive This selection must also be used when the controller 1s acting as a Modbus master using the optional four wire definition specified in Section 3 3 3 of the Modbus over serial standard e RS485fdmux A four wire full duplex connection with tri state outputs on the transmit connections This must be used when the controller is acting as a Modbus slave on a four wire bus e RS485hdmux A two wire half duplex connection applicable for master slave or slave use This is shown in the Modbus over serial standard 50 Rockwell Automation Publication ICSTT RM448I EN P May 2015 The AADvance Safety Controller Chapter 2 Processor Back up Battery The 9110 processor module has a back up battery that powers its internal Real Time Clock RTC and a part of the volatile memory RAM The battery only supplies power when the processor module is no longer powered from the system power supplies The specific functions that the battery maintains on complete loss of power are e Real Time Clock The battery supplies power to the RTC chip itself e Retained Variabl
149. s Pan 3 ed Doo0 O00 00000000R T9892 Digital Output Termination Assembly The T9892 Terminal Assembly module operates in conjunction with the T9451 Digital Output Module and provides 8 dual configuration output channels It shares the same pin out as the standard AADvance T9852 Digital Output Terminal Assembly and has the same coding peg configuration The difference is that the T9892 has a separate connector for the field power input voltage connections the left most terminal block shown below It also has additional fusing to give extra protection against field faults 56 Rockwell Automation Publication ICSTT RM448I EN P May 2015 The AADvance Safety Controller Chapter 2 Figure 9 T9892 Dual Termination Assembly 7 ae a pa a E je S B Backplane Electrical Ratings To comply with UL CSA standards use the following voltage and current ratings for the Processor and I O Backplanes when designing your power distribution IMPORTANT These are the maximum allowed electrical ratings given by UL for the backplane load installed with the relevant TAs and modules They are not operating values so don t use them to calculate the controller power consumption or heat dissipation values Refer to the separate topics on estimating Heat Dissipation and Power Consumption Rockwell Automation Publication ICSTT RM448I EN P May 2015 57 Chapter 2 The AADvance Safety Controller Table 5 Maximum Electr
150. s and tests specified in IEC 61131 EN 61010 1 and EN 60950 and must be big enough for the system requirements Power Arrangements for Field Devices Output modules use an external source of power for field devices This may be the power source used for the controller or a separate power source e For digital and analogue outputs a field power supply of 24 Vdc within a range of 18 32 Vdc is required Recommended field circuits are given for each type of I O module later in the section Connecting Field Wiring IMPORTANT Itis highly recommended that the negative side of the field supply be connected to earth ground This will avoid possible fail danger conditions that can be caused by some earth fault monitors used with floating power supplies Power Distribution Protection The power distribution circuit for each field input and for each output module must be protected externally to the controller Rockwell Automation recommend that power distribution must meet national and local panel wiring protection standards Digital Output Field Power Special fusing arrangements are required for Digital Output field supplies for UL ATEX and IECEx approved installations see topic on field loops for Digital Output Modules Rockwell Automation Publication ICSTT RM448I EN P May 2015 81 Chapter 4 Before You Begin Estimating Power Consumption To estimate the power supply requirements power supply sizing you need to know the
151. same time Rockwell Automation Publication ICSTT RM448I EN P May 2015 143 Chapter 6 System Start Up NOTE Detailed information and procedures on firmware revision are given in the AADvance Configuration Guide Doc No 553633 and AADvance Configuration Guide Doc No 555063 for Workbench 2 0 Tools and Resources You will need the ControlIFLASH firmware upgrade kit e Quick Start and RSLinx Classic Lite software or better e ControlFLASH programming tool along with its required support drivers and on line HELP e Firmware for the processor modules being upgraded Stage 1 Install This procedure will install Recovery Mode and Secondary Boot ControlFLASH for Recovery ar Mode and Secondary Boot 1 Run the 350720 102 ControlFLASH msi file Firmware i ControlFLASH 9 00 015 Welcome to the ControlFLASH 9 00 015 Setup Wizard Factory Talk By The installer will guide you through the steps required to install ControlFL4SH on your computer WARNING This computer program is protected by copyright law and international treaties Unauthorized duplication or distribution of this program or any portion of it may result in severe civil or criminal penalties and will be prosecuted to the maximum extent possible under the law 2 Click Next 144 Rockwell Automation Publication ICSTT RM448I EN P May 2015 System Start Up Chapter 6 3 Read and agree to the license and click Next Peace tate moment to mead the kce
152. sion sauf si l environnement est exempt de concentrations inflammables ou quivalente Design Provisions The design of the controller installation should make the following provisions e Clear access to remove and install modules termination assemblies base units and security dongle Program Enable key Repair of controller modules will be by module replacement A way for plant operations personnel Clear access to examine remove and to inspect the status LEDs on each install fuses located on the module The status LEDs report termination assemblies faults y AADvance Healthy Ready Run System Healthy Force Aux Serial 1 serial 2 Ethernet 1 Ethernet 2 Rockwell Automation Publication ICSTT RM448I EN P May 2015 Before You Begin Chapter 4 Clear access to terminals and Clear access to the Security Dongle connectors for field power and Program Enable Key network wiring and access to the wiring itself In addition it may be appropriate to make the following provisions e A lock on the door of the enclosure to deter unauthorized access and possible unofficial modifications e Lighting e Utility sockets Connecting the AADvance The T9100 processor base unit has six auto sensing 10 100BASE TX Ethernet ports which allow it to connect to a local area network through Controller to the Network standard Rj45 Ethernet cable These are two ports for each processor module If a d
153. stallation assessment covers the environmental specification for the AADvance system and includes the following e the prevailing climatic conditions e type of area e g is it a hazardous or non hazardous area e location of power sources e earthing and EMC conditions In some customer installations parts of the system can be installed in differing locations in these cases the assessment must include each location Power Sources and Heat Dissipation Calculations It is highly recommended that module supply power and field loop power consumption calculations are done to find out the heat dissipation before designing a suitable enclosure and making a decision about the installation environment see topic System Design for Heat Dissipation Safety Related System Installation Process For a Safety Related System the installation process must also be in line with the following You must use the installation guidelines given in this manual and any installation and commissioning procedures that comply with applicable international or local codes and standards Rockwell Automation Publication ICSTT RM448I EN P May 2015 The AADvance Safety Controller Chapter 2 Environment Standards Installation Requirements for Non Hazardous Environment CAUTION AADvance modules are suitable for use in Class Division 2 Groups A B C and D Hazardous locations or Non hazardous locations only or equivalent ATTENTION Pour l
154. sting representative who will witness each test Testing must be done on a known version of the controller Record the type serial number and physical location of each module so that the system can be dismantled shipped and built with the modules in the same locations Review and finalize the technical manuals which have been prepared for the maintenance and operation of the system 166 Rockwell Automation Publication ICSTT RM448I EN P May 2015 Chapter 8 Dismantling the AADvance System About Dismantling a System Pismantling Dismantling is the opposite of the system assembly procedure Disposal It is necessary to make a plan for the collection treatment recovery and environmentally sound disposal of the equipment at the end of its life Contact Rockwell Automation to discuss the applicable way to do this Re use Before disposing of serviceable items contact Rockwell Automation and find out if it is possible to return unwanted items for possible future reconditioning Rockwell Automation Publication ICSTT RM448I EN P May 2015 167 Chapter 8 Dismantling the AADvance System Page intentionally left blank 168 Rockwell Automation Publication ICSTT RM448I EN P May 2015 Chapter 9 Parts List Base Units Part No Part Description T9100 Processor base unit T9300 I O base unit 3 way Modules Part No Part Description T9110 Processor module T9401 Digital input module 24 Vdc 8 channel isolate
155. stribution files NOTE If the application is Workbench 1 3 and adopts the USB dongle licensing option the workstation PC will require one free USB port e Network port 10 100 Base T Ethernet for communications with the controller It is recommended that the PC has a 2 2 GHz or higher CPU 1 024 MB or more RAM a 1 280 x 1 024 display and a 7 200 RPM or higher hard disk It is also recommended that the hard disk has at least 10 GB free space This provides sufficient space to hold the distribution zip file the Rockwell Automation Publication ICSTT RM448I EN P May 2015 39 Chapter 2 The AADvance Safety Controller 40 unzipped source files and the installed program files and also enough space for Windows to operate reasonably quickly You can get back a lot of this space by deleting the source files after finishing the installation Importing and Exporting Data The AADvance Workbench can import and export existing data in standard file formats such as Microsoft Excel AADvance Workbench Licensing The AADvance Workbench is licensed software There are three types of license full single controller and demo e The single controller license is applicable for applications which use only one controller The software features which add a second or subsequent controller to the project are disabled and you cannot Open an existing project which uses more than one controller e The full license supplies all of the featur
156. supply voltage and output signal condition satisfies the maximum slew rate criteria defined in the Solutions Handbook Accordingly it may be necessary to condition the field supply voltage or output signal such as by filtering or by appropriate choice of process safety time 120 Rockwell Automation Publication ICSTT RM448I EN P May 2015 Install the AADvance System Chapter 5 Install Modules Install a 9110 Processor Module Connections to T9881 T9882 Analogue Output TA 8 Channel Simplex Dual This diagram shows the T9882 The T9881 has the same terminal arrangement CH1 CH3 CH5 CH7 CH2 CH4 CH6 CH8 CH1 CH3 CH5 CH7 Apply a minimum tightening torque of 0 5 Nm 0 37 ft Ib to the terminal screws The modules of the AADvance controller mount onto the base units The processor module s mount onto the T9100 processor base unit while the various I O modules mount onto the T9300 I O base unit and associated termination assemblies The product range includes two sizes of blanking covers to conceal unused module positions The shorter cover is for a spare position on the processor base unit while the taller cover is for a spare position on an I O base unit Do the following e Before inserting a new processor module examine it for damage e The identification labels on the sides of the module will be hidden after the module is installed Therefore
157. t of a running system 124 Rockwell Automation Publication ICSTT RM448I EN P May 2015 Install the AADvance System Chapter 5 If the battery is replaced when more than one processor module is installed then the processor clock will be updated automatically through synchronization If you have previously set up SNTP when you set up your processor module then the clock will be reset to the current time automatically If you have not set up SNTP it is recommended that you do so as this will not only reset the processor clock but will also keep the time accurately during operation Refer to the AADvance Configuration Guide for the SNTP set up instructions The following applies e Ifthe battery is replaced when only one processor module is installed and the processor module is not powered up and SNTP has not been set up you must set the clock to the current time as soon as practicable e The battery does not do any function while the processor module is powered and the application is running The Processor s Real Time Clock provides Date and Time data for SOE functions and also for the Processor diagnostic log entries The specific functions that the battery maintains on complete loss of power are the following e Real Time Clock The battery provides power to the RTC chip itself e Retained Variables Data for retained variables is stored at the end of each application scan in a portion of RAM backed by the battery On
158. tain these items of documentation e I O wiring database with checklist e Complete set of drawings e Bill of materials 2 Ensure that each item of documentation is the latest issue e Mark each item as Test Copy 3 Create a system activity log book and ensure the log book accompanies the system into test e Allocate an entry number for each test and record each test against its number in the log book e If during functional tests the system does not behave as expected record the problem in the log book Allocate a new entry and fault number for each problem System Physical Design Assess the physical design of the system to determine whether it 1s ready to be tested Do the following Check e Verify there is physical segregation of any mains supply circuits from the 24 Vdc controller circuits Rockwell Automation Publication ICSTT RM448I EN P May 2015 135 Chapter 6 System Start Up e Review the arrangements of terminals and the provision of cable entries for field wiring e Evaluate the ease of access for maintenance activities Procedure to Verify Build Assess the build state of the system against the test documentation Do the following State e Compare the arrangement of the system with the General Arrangement drawings to make sure the system has been manufactured and assembled correctly e Verify that every item shown in the bill of materials on the General Arrangement drawings 1s either in place or is a
159. ted is 47 mW at 26 4 V e R2 3K9 Q 1 1W maximum power dissipated is 182 mW at 26 4 V Suggested threshold values for the ESD line monitoring circuits are as follows Threshold ID Value mV Maximum Allowed 32000 SHORT CIRCUIT Threshold 8 19000 Threshold 7 18500 ON nominal 16V Threshold 6 11000 Threshold 5 10500 INDETERMINATE Threshold 4 6500 Rockwell Automation Publication ICSTT RM448I EN P May 2015 109 Chapter 5 Install the AADvance System Threshold 3 6000 OFF nominal 8V Threshold 2 3500 Threshold 1 3000 OPEN CIRCUIT Assumptions e Loop supply voltage 24 V 10 e Maximum Field Cable Line Resistance lt 100 total this means lt 50 50 Q for the two cables e Minimum Isolation is 0 75M Q between the field loop conductors e These values will let the input find more accurately different voltage levels that represent OPEN CCT OFF ON SHORT CCT and will also identify Over Voltage and an input which is not ON or OFF The values make sure that a line fault will be declared before it becomes possible for a false declaration of ON and OFF states because of a combination of resistor value drift and loop voltage variation Field Loop Circuit for Line Monitored Digital Input for Fire and Gas Systems F amp G 24V dc Controller aos Termination Assembly 4K990 R2 ur Shield if used Enr Blocks e The F amp G circuit will also permit two devices to be in alarm without
160. the operating temperature of the modules Modules operating at the extremes of the temperature band for a continuous period can have a reduced reliability 76 Rockwell Automation Publication ICSTT RM448I EN P May 2015 Before You Begin Chapter 4 ATTENTION DISSIPATION THERMIQUE ET EMPLACEMENT DE L ENCEINTE La temp rature ambiante nominale maximum dans une enceinte o un processeur AADvance et des modules d E S standard sont install s pour assurer une fiabilit pr visible est de 70 2C 158 F pour modules d E S et de 60 C 140 F pour processeur La consommation lectrique du systeme et du terrain par les modules et les ensembles de raccordement est dissip e sous forme de chaleur Vous devez tenir compte de l effet de la dissipation thermique lors de conception et de disposition de votre enceinte par exemple des enceintes continuellement expos es la lumi re solaire auront une temp rature interne plus l v e qui pourrait accro tre la temp rature de fonctionnement des modules La fiabilit des modules fonctionnant aux limites extr mes de la plage de temp rature pendant une p riode prolong e peut tre r duite Base Units Rows and Expansion Cables AADvance 9300 I O base units connect to the right hand side of the 9100 processor base unit I O Bus 1 and to the right hand side of other 9300 I O base units by a direct plug and socket connection The I O base units connect to the left hand side of the p
161. tware and settings for a specified AADvance controller The grouping must have a target but for an AADvance controller it can have only one resource Rockwell Automation Publication ICSTT RM448I EN P May 2015 consumer The consuming controller requests the tag from the producing controller contact A graphical component of a Ladder Diagram program representing the status of an input variable continuous mode Where the Safety Instrumented Function in the safety system is continually maintaining the process in a safe condition controller A logic solver The combination of application execution engine and I O hardware controller system One or more controllers their power sources communications networks and workstations coverage The percentage of faults that are detected by automated diagnostics See also SFF creepage distance The shortest distance along the surface of an insulating material between two conductive parts cross reference Information calculated by the AADvance Workbench relating to the dictionary of variables and where those variables are used in a project 175 Chapter 10 9000 Series Glossary D data access DA An OPC data type providing real time data from AADvance controllers to OPC clients de energize to action An output circuit for a safety instrumented function where the field device is usually energized Removal of power de activates the device di
162. vailable to be installed e Check that any special features configurations or options called for on the drawings are present and correct e Check nameplates and identification labels against the drawings Identify any non conformance found between the system and the drawings If appropriate correct the drawing Record each non conformance in the log book Procedure to Conduct the Carry out a mechanical inspection to verify that an acceptable standard of workmanship has been achieved in the assembly and wiring and that the Mechanical Inspection test arrangements are correct Do the following e Visually inspect the controller and verify that base units modules and terminals are free of damage e Review the termination of system cabling against the drawings Procedure to Check Ground SHOCK HAZARD Connect the AC safety busbar to the building earth ground Bonding before doing electrical testing or applying power to the system Failure to follow these instructions can cause injury to persons Check that the ground continuity does not exceed 0 2 Q e Check that the isolation between grounds is 10M Q 136 Rockwell Automation Publication ICSTT RM448I EN P May 2015 System Start Up Chapter 6 Procedure to Check Power IMPORTANT Before you begin this task you must have checked the Distribution Integrity ground bonding Check the integrity of the power distribution system to verify that each power distributio
163. ve Electrical Equipment for use in Class I and II Division 2 and Class III Division 1 and 2 Hazardous Locations e UL508 Industrial Control Equipment Seventeenth edition with revisions through and including April 15 2010 e NRAG7 E251761 Programmable Controllers for Use in Hazardous Locations Certified for Canada Class I Division 2 Groups A B C and D The products have been investigated using requirements contained in the following standards e CSA C22 2 No 213 M1987 Nonincendive Control Equipment for Use in Class I Division 2 Hazardous Locations e CSA C22 2 No 142 M1987 Process Control equipment Edition 1 Revision date 1990 09 01 Products Covered The products investigated and approved Programmable Logic Controllers Models 9110 Processor Module 9401 2 Digital Input Module 9431 2 Analogue Input Module 9451 Digital output Module 9482 Analogue Output Module Listed Accessories for use with PLCs 9100 Processor Backplane 9300 I O Backplane 9801 Digital Input Termination Assembly Simplex 9802 Digital Input Termination Assembly Dual 9803 Digital Input Termination Assembly TMR 9831 Analogue input Termination Assembly Simplex 9832 Analogue Input Termination Assembly Dual 9833 Analogue Input Termination Assembly TMR 9851 Digital Output Termination Assembly Simplex Rockwell Automation Publication ICSTT RM448I EN P May 2015 The AADvance Safety Controller Chapter 2 1 2 3 i
164. ve a higher internal temperature that could affect the operating temperature of the modules Modules operating at the extremes of the temperature band for a continuous period can have a reduced reliability ATTENTION DISSIPATION THERMIQUE ET EMPLACEMENT DE L ENCEINTE La temp rature ambiante nominale maximum dans une enceinte o un processeur AADvance et des modules d E S standard sont install s pour assurer une fiabilit pr visible est de 70 2C 158 F pour modules d E S et de 60 C 140 F pour un processeur modules La consommation lectrique du syst me et du terrain par les modules et les ensembles de raccordement est dissip e sous forme de chaleur Vous devez tenir compte de l effet de la dissipation thermique lors de conception et de disposition de votre enceinte par exemple des enceintes continuellement expos es la lumi re solaire auront une temp rature interne plus l v e qui pourrait accro tre la temp rature de fonctionnement des modules La fiabilit des modules fonctionnant aux limites extr mes de la plage de temp rature pendant une p riode prolong e peut tre r duite Rockwell Automation Publication ICSTT RM448I EN P May 2015 Before You Begin Chapter 4 Enclosure Requirements for a Non hazardous Environment An AADvance system must be installed in an IP54 enclosure for use in a Pollution Degree 2 environment or similar in accordance with IEC 60664 1 2007 Un syst me AADvance d
165. work Configuration parameters optional 3 The Network Path to the target device 4 The Firmware Revision for this update View Log Bact Next gt Cancel Help 2 Click Next 3 Select T9110 from the list OD Tina 4 PEN s BURA Catalog Number Enter the catalog number of the target device TEE Control 1715 AENTR caen __ 4 Browse to the device in the RSLinx window 148 Rockwell Automation Publication ICSTT RM448I EN P May 2015 System Start Up Chapter 6 Select the 19110 device to update and click OK Browsing node 192 168 1 211 found ae Linx Gateways Ethernet gs AADvance Ethernet 192 168 1 192 168 1 211 Unrecognized Device ICS4Advance ICS dvance 25 AB_ETH 1 Ethernet 5 Select the firmware revision for the latest Release rs ControlFLASH 19110 OD Tis a ZR s EAIA ER Firmware Revision Catalog Number T9110 SerialNumber 50404153 Current Revision 1 2 0 Control Select the new revision for this update pp j 1 22 0 P Show all revisions Current Folder c program files controlflash Fa lt Back Cancel Help 6 Check the summary details click Finish Rockwell Automation Publication ICSTT RMA4BI EN P May 2015 149 Chapter 6 System Start Up OD Tins BZ RY s EAIA BY Summary DANGER The target module is about to be update with new firmware During the update the module will be unable to perfo
166. y each functional module program organization unit and its operations and the interactions between modules to form the complete application This modular construction can help future use of code units Engineers can debug their own modules independently from each other Programs can be tried and tested on the computer before downloading to the controller hardware For each controller you can declare variables using all types identified in IEC 61131 3 including Boolean 16 bit integer signed and unsigned and 32 bit real Controller specific types include structures to hold Rockwell Automation Publication ICSTT RM448I EN P May 2015 65 Chapter 3 Application Resource Development 1 0 Connection Addressing of Physical 1 0 Off line Simulation and Testing 66 multiple variables for each I O channel type Variables are easily imported from external databases if required Variables are found in a data dictionary The development environment supplies a hierarchical tree of variables and a grid like representation of their definitions To show the links between the hardware independent logical variables of the AADvance application program and the physical I O channel available on the controller the AADvance Workbench has a powerful I O connection editor I O channel links are easily identified between the logical programming and the I O wiring configuration The I O configuration can be tested separately from the application

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