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AADvance Controller
Solutions Handbook
Issue: 09
DOCUMENT: 553631
(ICSTT-RM447J_EN_P)
Solutions Handbook (AADvance Controller)
ii Document: 553631
(ICSTT-RM447J_EN_P) Issue: 09:
Notice
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 associated with 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.
Reproduction of this manual in whole or in part, without written permission of
Rockwell Automation is prohibited.
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 refer to your own (or supplied) system safety manual, installation instructions
and operator/maintenance manuals.
Documentation Feedback
Your comments will help us to serve your documentation needs better. If you
discover any errors or have any suggestions on how to improve this publication send
your comments to our product support group: icstsupport@ra.rockwell.com
This symbol calls attention to items which "must" be considered and implemented
when designing and building an AADvance controller for use in a Safety
Instrumented Function (SIF). It appears extensively in the AADvance Safety Manual.
Note: Notes are used extensively to provide important information about the
product.
WARNING MAINTENANCE
Maintenance must be carried out only by qualified personnel.
Failure to follow these instructions may result in personal injury.
iv Document: 553631
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Issue Record
Issue Date Comments
01 Dec 2008 First Issue
02 Feb 2009
03 Feb 2010
04 Mar 2010 Updates after peer review
05 June 2010 updates for release 1.1.1
06 Oct 2010 updates to meet UL requirements
07 Nov 2010 updates for ATEX and UL Certification and release 1.2
08 July 2012 Release 1.3 version
09 Aug 2013 Changes to TUV certification topic, add On-line update
feature and module specification data.
Document: 553631 v
(ICSTT-RM447J_EN_P) Issue: 09:
Solutions Handbook (AADvance Controller)
Forward
This technical manual describes the features, performance and functionality of the
AADvance controller and systems. It sets out some guidelines on how to specify a
system to meet your application requirements.
Note: The AADvance controller is a logic solver. It uses processor modules and I/O
modules. An AADvance system is formed by one or more controllers, their power
sources, communications networks and workstations.
vi Document: 553631
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Solutions Handbook (AADvance Controller)
Contents
Chapter 1 The AADvance System ........................................................................... 1-1
The AADvance Controller .............................................................................................................................. 1-1
Performance and Electrical Specifications .............................................................................................. 1-3
Scan Times ..................................................................................................................................................... 1-4
Environmental Specifications ..................................................................................................................... 1-5
Controller TUV Certification ................................................................................................................... 1-7
Certification for use in Hazardous Environments................................................................................ 1-7
File No: E341697.......................................................................................................................................... 1-7
File No: E251761.......................................................................................................................................... 1-8
KCC-EMC Registration ........................................................................................................................... 1-12
Main Components ........................................................................................................................................... 1-13
Hardware Components............................................................................................................................ 1-13
AADvance Workstation Software and Application Development Environment ....................... 1-14
Controller Functionality ................................................................................................................................. 1-16
SNTP ............................................................................................................................................................. 1-16
CIP over EtherNet/IP ................................................................................................................................ 1-16
HART ............................................................................................................................................................ 1-17
SNCP Safety Networks ............................................................................................................................ 1-18
Peer-to-Peer................................................................................................................................................ 1-20
Serial Communication Interface ............................................................................................................. 1-22
Time Synchronization (SNTP) ................................................................................................................ 1-22
Modbus Master ........................................................................................................................................... 1-23
The OPC Portal Server ............................................................................................................................ 1-24
Controller IP Address Setting................................................................................................................. 1-25
Recovery Mode .......................................................................................................................................... 1-25
DiffServ Configuration .............................................................................................................................. 1-25
Ethernet Forwarding ................................................................................................................................. 1-26
Transparent Communication Interface (TCI) ..................................................................................... 1-27
Compiler Verification Tool ..................................................................................................................... 1-27
Technical Features ........................................................................................................................................... 1-28
TUV Approved Operating System......................................................................................................... 1-28
Internal Diagnostics ................................................................................................................................... 1-28
Controller Internal Bus Structure ......................................................................................................... 1-28
System Modification and On-line Updates........................................................................................... 1-29
ControlFLASH Firmware Upgrades ...................................................................................................... 1-31
Physical Features .............................................................................................................................................. 1-32
Product Dimensions .................................................................................................................................. 1-32
Compact Module Design.......................................................................................................................... 1-33
Module Polarization Keying ..................................................................................................................... 1-34
Module Locking Mechanism .................................................................................................................... 1-35
Termination Assemblies ........................................................................................................................... 1-35
Ethernet, Serial Data and Power Connections ................................................................................... 1-37
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Solutions Handbook (AADvance Controller)
Estimate Module Supply Power Dissipation and Field Loop Power Dissipation ................................ 6-7
Chapter 7 Module Overview and Specifications ..................................................... 7-1
T9110 Processor Module ................................................................................................................................ 7-2
Processor Module Specification ............................................................................................................... 7-4
T9100 Processor Base Unit............................................................................................................................. 7-5
T9100 Base Unit Specification .................................................................................................................. 7-7
T9300 I/O Base Unit (3 way) .......................................................................................................................... 7-8
T9300 Base Unit Specification .................................................................................................................. 7-9
T9310 Expansion Cable Assembly ............................................................................................................... 7-10
T9310 Extension Cable Specification .................................................................................................... 7-11
T9401/2 Digital Input Module, 24V dc, 8/16 channel .............................................................................. 7-12
T9401/2 Digital Input Module Specification ......................................................................................... 7-13
T9801/2/3 Termination Assemblies for Digital Inputs ............................................................................ 7-14
T9801/2/3 Digital Input Termination Assembly Specification ......................................................... 7-15
T9431/2 Analogue Input Module, 8/16 Channel....................................................................................... 7-16
T9431/2 Analogue Input Module Specification ................................................................................... 7-17
T9831/2/3 Termination Assemblies for Analogue Inputs....................................................................... 7-18
T9831/2/3 Analogue Input Termination Assembly Specification .................................................... 7-19
T9451 Digital Output Module, 24V dc, 8 channel ................................................................................... 7-20
T9451 Digital Output Module Specification ........................................................................................ 7-21
T9851/2 Termination Assemblies for Digital Outputs ........................................................................... 7-22
T9851/2 Digital Output Termination Assembly Specifications ....................................................... 7-23
T9481/2 Analogue Output Module ............................................................................................................. 7-24
T9481/2 Analogue Output Module Specification ............................................................................... 7-25
T9881/2 Termination Assembly for Analogue Output Module............................................................ 7-26
T9881/2 Analogue Output Termination Assembly Specification ................................................... 7-27
Chapter 8 Application (Resource) Development ................................................... 8-1
Programming Language Support ..................................................................................................................... 8-1
Program Management Facilities ...................................................................................................................... 8-1
Support for Variable Types ............................................................................................................................. 8-2
I/O Connection (Addressing of Physical I/O) ............................................................................................. 8-2
Off-line Simulation and Testing ...................................................................................................................... 8-2
Application (Resource) Program Security ................................................................................................... 8-2
Aids to Software Development ...................................................................................................................... 8-3
AADvance Workbench Licensing Options ................................................................................................. 8-3
DIN Rails Fitting ................................................................................................................................................. 8-4
Chapter 9 System Build ............................................................................................ 9-1
Free Space Around the Controller ............................................................................................................... 9-1
Base Units, DIN Rail installations and Expansion Cables ......................................................................... 9-3
Assemblies of Base Units ................................................................................................................................. 9-3
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Power Supply Requirements ........................................................................................................................... 9-4
Adding Cable Management .............................................................................................................................. 9-4
Chapter 10 Parts List ................................................................................................ 10-1
Chapter 11 Glossary of Terms ................................................................................. 11-1
Chapter 12 Additional Resources ............................................................................ 12-1
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Chapter 1
The AADvance System
An AADvance system consists of an AADvance controller, an external operator's
workstation, field connections, power sources and external network connections. The
flexibility of the design allows a system to be built to suit your own requirements from
a standard range of modules and assemblies.
This chapter describes the main components that can be used to build an AADvance
controller.
In This Chapter
The AADvance Controller ............................................................................... 1-1
Main Components ............................................................................................ 1-13
Controller Functionality .................................................................................. 1-16
Technical Features ............................................................................................ 1-28
Physical Features ............................................................................................... 1-32
The significant benefits of the AADvance controller are its performance and flexibility.
Being designed to IEC 61508 it meets both SIL2 and SIL3 application requirements
from the basic range of modules and mixed SIL rated applications can be covered by
this range of modules.
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 choose between fail safe and fault tolerant
solutions. This scalability is user configurable, therefore, there is no change to the
complexity of operations or programming if you choose to add redundant capacity to
create a fault tolerant solution.
A controller is built from a range of compact plug-in modules that are straightforward
to assemble into a system. They can be mounted onto DIN rails in a cabinet (see
photograph) or directly mounted onto a wall in a control room. They do not require
forced air cooling or special environmental control equipment. However, certain
consideration to the cabinet type must be applied when used in hazardous
environments.
Attribute Value
Functional Characteristics
Safety accuracy limit 200μA for Analogue Inputs and 1.0V dc for Digital
Inputs.
Electrical Characteristics
Scan Times
The following scan times were taken from a test system consisting of production
modules.
Module Scan Time
T9401 Digital input module, 24V dc, 8 channel
Single 1.23ms
Dual 1.73ms
Triple 2.08ms
T9431 Analogue input module 24V dc, 8 channel
Single 1.26ms
Dual 1.91ms
Triple 2.33ms
T9451 Digital output module, 24V dc, 8 channel
Single 1.43ms
Dual 2.44ms
AADvance Workbench Sleep Period 57.2ms
Scan overhead per module 0.09ms
The tests did not measure the effect of logic complexity and communications loading.
The scan time is:
6 (Number of module groups x scan time shown above) + Sleep Period + (Total
modules x scan overhead)
The scan time will vary by up to +/- 5ms (not including the effect of logic and
communications).
Note: The AADvance application scan time is limited to a minimum of 64ms to allow
all processes to run. Small applications will report a scan time of approximately 57 -
61ms. Large applications may have longer scan times but each scan time will be
consistent to within approximately 5ms.
Environmental Specifications
The following environmental specification defines the minimum recommended
environmental conditions for an AADvance controller installation. Additional
conditions apply to installations in a Hazardous environment.
Attribute Value
Operating Temperature Range:
For use in Hazardous Environments (UL
Certification):
Processor Modules –25 °C to 60 °C (–13 °F to 140 °F)
I/O Modules and Assemblies –25 °C to 70 °C (–13 °F to 158 °F)
For use in Non-Hazardous Environments
(TUV Certification)
All Modules and Assemblies –25 °C to 70 °C (–13 °F to 158 °F)
Storage and Transport Temperature –40 °C to 70 °C (–40 °F to 158 °F)
Module Surface Temperature (during normal 43° C (109 °F) ± 2 °C
operation)
Humidity
Operating 10% to 95% RH, non-condensing
Storage and Transport 10% to 95% RH, non-condensing
Vibration
Note:
Casing: Standard AADvance modules also have a plastic casing and are rated IP20:
Protected against solid objects over 12mm (1/2in.) for example "fingers". There is no
specific protection against liquids.
TÜV Certification
TÜV is the safety certifying authority for an AADvance controller. The AADvance
system is certified to the following standard:
IEC 61508, Part 1-7:1998-2000 EN 50178:1997
IEC 61511-1:2004 EN 50156-1:2004
EN 61131-2:2007 EN 54-2:1997, A1:2006 (†)
EN 61326-3-1:2008 NFPA 72:2007
EN 61000-6-2:2005 NFPA 85:2007
EN 61000-6-4:2007 NFPA 86:2007
(†) The analogue output modules are not certified to EN 54-2.
You can download a copy of the TUV certificate from www.tuvasi.com.
The Euro Controller version of the AADvance product is also tested to Q1 Extended
Design levels of ISO 13628-6: 2006 Sub Sea Production Control System.
Products Covered
The products investigated and approved:
Programmable Logic Controllers Models: 9110 Processor Module; 9401/2 Digital
Output 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 and 9852 Digital Output Termination Assembly, Dual; 9881
Analogue Output Termination Assembly, Simplex; 9882 Analogue Output Termination
Assembly, Dual.
Products Covered
The products investigated and approved:
Programmable Logic Controllers Models: 9110 Processor Module; 9401/2 Digital
Output Module; 9431/2 Analogue Input module; 9451 Digital output module; 9482
Analogue Output Module.
Certificate
The AADvance controller modules have been evaluated to the requirements of EN
60079-0: 2009 and EN 60079-15: 2010 under Certificate Number: DEMKO 11 ATEX
1129711X .
[ certificate to be supplied]
Module label
KCC-EMC Registration
Hardware Components
Each controller is built from a standard range of modules and assemblies; it consists of
processor modules, a processor base unit, digital and analogue I/O modules, I/O base
units and termination assemblies all of which are assembled as follows:
A processor module is installed into a processor base unit that can hold up to 3
processor modules.
3-way I/O base units are connected to the processor base unit and to each other.
Each I/O base unit holds up to three I/O modules and termination assemblies. A
controller can have up to 8 I/O base units on each of two I/O busses, giving a total
capacity for up to 48 I/O modules.
I/O modules are connected to field devices through external connectors on the
termination assemblies.
The processor module and base units are designed for use as either single, dual or
triple redundant processor module arrangements. The base processor base unit
provides external connections for Serial and Ethernet networks and the dual
redundant system power inputs.
The I/O base unit plugs directly into the processor base unit and carries the redundant
system power for the modules, the processor commands across a command bus and
I/O data across individual data response busses.
I/O base units also directly plug into each other and are secured and held in place by a
clamping arm and retaining clips; hence, a controller becomes a complete mechanically
and electrically interconnected assembly without the need for additional wiring or
cabling. The I/O modules are also designed for use in single or dual or triple redundant
configurations.
Termination assemblies are matched to a specific type of I/O module and have terminal
blocks that provide 8 or 16 connections for the wiring to the field elements. The
termination assemblies for dual and triple arrangements have channel to channel
isolation. Termination assemblies for simplex input modules and termination
assemblies for simplex and dual output modules are single ended (non-isolated) with a
common return.
An expansion cable can be used to connect the processor base unit or an I/O base unit
to another I/O base unit. This is useful for to breaking long runs of interconnected
base units and provides some flexibility in the physical layout of a controller
installation, particularly if the controller is installed in a cabinet.
Workstation Software
The AADvance workstation uses software that enables you to design the complete
control strategy as one, then to target parts of the strategy at each controller.
Interaction between the resources is automatic, significantly reducing the complexity of
configuration in a multi-resource solution.
The workstation software, known as the Workbench is compliant with IEC61131
industrial standard and has the following powerful features:
the regulation of the flow of control decisions for an interacting distributed control
system
providing for the consistency of data
providing a means for synchronous operation between devices
eliminating the need to have separate synchronous schemes
easing the development and maintenance of robust systems
The Workbench lets you create local and distributed control applications using the
five languages of IEC 61131-3. Engineers can choose one language or a combination of
languages that best suits their knowledge and programming style and the nature of the
application.
It is also a secure development environment that requires a hardware (USB Dongle) or
software license to run on a PC. There is also a Program Enable key (not applicable
to a Euro Controller) that must be plugged into the processor base unit to allow the
user to modify and download the application resource or access the
AADvanceDiscover utility to check the status of the controller IP address. The
Program Enable key when it is removed protects the application from unauthorized
access.
The development environment includes:
tools for program development
program documentation
function block library management
application archiving
database configuration
import/export utilities
on-line monitoring
off-line simulation and controlled on-line changes.
If the Workbench is used for safety related applications then you must follow
the guidelines given in the AAdavnce Safety Manual (Doc No: 553630).
Operating System
The 9110 Processor Module must have an operating system with the following
specification:
Windows XP with Service Pack 3
Windows Vista, Windows 7 & Server 2003 in both 32-bit and 64-bit versions
Note: Work Bench Licensing –Windows 64-bit version will only work with the
USB Licensing option (dongle option).
Network port (10/100 Base T Ethernet)
Access to a CD-ROM drive, for software installation
Note: If the application adopts the USB (dongle) licensing option for the
Workbench software, the processor module will also require one free USB port.
AADvanceDiscover Utility
The AADvanceDiscover utility is installed when you install the
<DevelopmentSoftwareTools>, and appears on the Start menu of the computer. it
displays a list of the <ProductName> controllers on the broadcast network, and
reports a status for each one.
Controller Functionality
SNTP
The AADvance controller supports the Simple Network Time Protocol (SNTP)
service that can circulate an accurate time around the network. As an SNTP client the
controller will accept the current time from external Network Time Protocol
(NTP) and SNTP network time servers.
SNTP clients settings tell the controller the IP address of the external server; the
version of SNTP offered by the server; and the operating mode for the time
synchronization signal that the processors will use for their real time clock.
An AADvance controller can also fulfill the role of one or more SNTP servers (one for
each processor) to provide a network time signal throughout the network. To enable
server time on an interface it is necessary to specify the direct broadcast address for
that interface. This works for broadcast or unicast modes. This method of configuring
is derived from the NTP configuration command language.
Note: The AADvance Controller will support the following number of connections
and variables:
HART
The AADvance controller supports utilizing dedicated HART modems on each
analogue input and output channel allowing HART field device status, diagnostics and
process data to be integrated into the application logic, thus increasing the level of SIF
diagnostics significantly.
The AADvance analogue input/output modules use HART commands #03 to collect
data from the field device as defined by Revision 5 of the HART specification. The
application can be configured to use HART information to monitor and respond to
device conditions. It may also be used to provide diagnostic information such as
comparison and error reporting.
An additional feature of the AADvance controller is that it also combines with the
AADvance DTM to enable asset management software (ASM) to communicate with
HART devices.
Note: The AADvance system does not alter the messages passed between the asset
management software and the field device and acts as a transport mechanism only.
Peer-to-Peer
AADvance provides the capability for a SIL 3 certified Peer-to-Peer data connections,
allowing safety data to be transferred between AADvance and Trusted Controllers.
The Trusted Peer-to-Peer network protocol enables you to share safety data between
AADvance systems or AADvance and Trusted TM systems across an Ethernet network.
Data can be transferred between individual systems or from one to several systems at
the same time using multicast network connections. Peer-to-Peer communication is
configured by defining a peer network controller and I/O devices within the application
program.
Note: AADvance currently supports multicast network connections on the left most
port only.
Table 3:
Note: To set up SNTP you need to connect your controller to a suitable network
using one of the Ethernet ports. The network must be connected to an external NTP
server or have NTP loaded on to it.
Note: The AADvance controller does not support the Modbus ASCII protocol.
You can set up an individual list of messages (commands) for each slave device.
Modbus read commands cause data to read from the slave device to the Modbus
master, while Modbus write commands cause data to be copied from the Modbus
master to the slave device. You can also define a sequence of broadcast write
commands, which a Modbus master can send to multiple Modbus RTU slaves without
requiring an acknowledgement. The AADvance controller can control and monitor
individual Modbus master objects and their slave links.
The Modbus master functionality has a safety integrity level of zero (SIL0) and should
only be used for non-safety applications.
The Modbus RTU slave devices are connected to one or more of the serial ports on
the controller; a typical arrangement will use a multi-drop (RS-485) arrangement. The
engineering workstation and the Modbus TCP devices are shown connected to the
Ethernet ports on separate networks; alternatively these can be combined onto one
network.
Recovery Mode
Recovery Mode is a shutdown mode and uses a base level firmware. It is entered
automatically when a critical firmware failure occurs or it can be entered manually by
pressing the processor Fault Reset button immediately after the module has booted
up. The Recovery Mode is also used when you want to download a new firmware
upgrade.
As an alternative firmware version it allows the following maintenance activities:
Update the firmware using the ControlFLASH utility
Program the processor IP Address with the AADvance Discover utility
Extract diagnostic information
Note: When in Recovery Mode the I/O communications are disabled and the
Application code is not running. The inputs and outputs will revert to their fail-safe
settings.
DiffServ Configuration
This option allows you to specify the priority of IP traffic and is particularly useful for
ensuring that high priority services are either not affected or less affected during
periods of network congestion.
When you set up this option you apply a priority value to a service and therefore
differentiate it from less important services. You can do this by setting a suitable
configuration of routers, or switches able to inspect IP headers and prioritize by the
Type of Service (ToS) header option. Network devices will then apply their rules to
prioritize IP traffic; AADvance simply maintains the priority when responding to
incoming messages and sets a priority according to the configuration for messages it
initiates.
Ethernet Forwarding
When enabled, the "Ethernet Forwarding" feature will forward all Ethernet packets
destined for a host (3rd Party Device) connected to one of the AADvance’s Ethernet
ports along with any broadcast and multicast Ethernet traffic. Incoming messages on
the other port will be forwarded directly to the second. The forwarded messages will
be unaltered by the AADvance controller.
This feature can be enabled using the AADvance Discover utility. Packets intended for
the AADvance itself (i.e. the destination MAC address of the packet matches the
processor’s receiving port MAC address) as well as broadcasts and multicasts are still
sent to the AADvance application as normal.
Note: The Ethernet network carrying Safety Data on a Safety application is considered
to be a black channel, therefore, it is unaffected by this function. However, by
implementing Ethernet Forwarding you may be forwarding non-safety data onto a
safety network and could effectively bridge a safety and non-safety segregated network
through the AADvance.
Important Note: To use the TCI function you must stop the resource. This will
have a serious effect on a Safety Related application.
Technical Features
Internal Diagnostics
The AADvance controller contains comprehensive internal diagnostic systems to
identify faults that develop during operation and raise appropriate alarm and status
indications. The diagnostic systems run automatically and check for system faults
associated with the controller, and field faults associated with field I/O circuits.
Serious problems are reported immediately, but faults on non-essential items are
filtered to avoid spurious alarms. The diagnostic systems monitor such non-essential
items only periodically, and need a number of occurrences of a potential 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 the whole
controller.
The application software uses its variable structures to report a problem; these
variables proved status reports and are configured using the AADvance Workbench.
A Fault Reset button on each processor module serves to clear a fault indication.
However, the diagnostic systems will report a serious problem again so quickly there
will be no visible change in the status indications. Pressing the Fault Reset button when
no fault is indicated has no effect.
NOTE: If you are still using an earlier product release the I/O module configuration
cannot be changed with an on-line update.
Expansion Cable
When new I/O modules need to be added and there is not enough space in the
existing row of modules, you can use an Expansion Cable to install a new row of
modules. A typical arrangement using an expansion cable is shown below.
Note: I/O module upgrades using ControlFLASH are not currently supported in this
release.
Physical Features
An innovative feature of the AADvance controller is the design of the hardware.
Everything fits together easily without any need for inter-module wiring.
Product Dimensions
Attribute Value
Base unit dimensions (H × W × D), approx. 233 × 126 × 18mm (see text)
(9-¼ in × 5 × ¾ in)
Module dimensions (H × W × D), approx. 166 × 42 × 118mm
(6-½ in × 1-⅝ in × 4-⅝ in)
Module Dimensions
All modules have the same dimensions.
Base units are moulded from a similar material. Each base unit can be mounted onto
standard DIN rails or directly onto a panel or wall. The moldings incorporate slots and
clamps for DIN rail mountings, and holes for screw fixing.
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 (in some cases fuses) and connectors for the
plug-in I/O modules. Termination assemblies are matched to their relevant I/O
modules by the coding pegs and sockets and come in three types: simplex, dual or
triple. Therefore, they can accommodate one two or three I/O modules. Each
assembly provides connections for up to 16 channels but can accommodate 8 or 16
channel modules.
Termination assembly design gives the controller greater flexibility for building
redundant and fault tolerant systems. I/O module(s) plugged into its matched
termination assembly can provide simplex, dual or triple modular redundant
configurations.
The version illustrated is a simplex termination assembly for a digital input module.
The field wiring connectors are located to the left, the fuses have a cover (shown
open) and the module sockets are to the right.
Part No: Digital Input Fuses T9901: No 396/TE5 50mA time lag fuse; UL 248-14, 125
V,T Leadfree; manufactured by Littlefuse.
Part No: Digital Output Fuses T9902: SMF Omni-Block, Surface Mount Fuse Block
154 010, with a 10A, 125V Fast Acting Fuse, Littlefuse.
Serial Communications
The serial ports (S1-1 & S1-2, S2-1 & S2-2, S3-1 & S3-2) support the following
signal modes depending upon use:
RS485fd: A four-wire full duplex connection that features separate busses for
transmit and receive. This selection should also be used when the controller is
acting as a Modbus master using the optional four-wire definition described 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 should be used when the controller is acting as a
Modbus slave on a four-wire bus.
RS485hdmux: A two-wire half duplex connection appropriate for or master slave
or slave use. This is shown in the Modbus-over-serial standard.
Note: Processor modules must be replaced with a module containing the same
firmware revision, you cannot use processor modules with different firmware
revisions.
In This Chapter
SIL2 Architectures .............................................................................................. 2-1
SIL3 Architectures .............................................................................................. 2-6
Planned Certified Configurations .................................................................. 2-11
SIL2 Architectures
SIL2 architectures are recommended for fail-safe low demand applications. All SIL2
architectures can be used for energize or de-energize to trip applications. In any
configuration when a faulty processor or input module is replaced then the previous
fault tolerance level is restored. For example in a fault tolerant input arrangement and
one module is faulty then the system will degrade to 1oo1D, by replacing the faulty
module the configuration is restored to 1oo2D.
Definitions:
Low Demand Mode - in this mode the frequency of demands on the safety-related
system is no greater than twice the proof test interval. Where the proof test interval
refers to how often the safety system is completely tested and ensures it is fully
operational. For the AADvance System the default manual test interval is the value
used to calculate the PFH and PFD values.
High Demand Mode - sometimes called continuous mode, is where the frequency of
demands for operation made on a safety-related system is greater than twice the
manual test interval.
For High Demand applications you must use a minimum of a dual processor
configuration.
SIL3 Architectures
SIL3 architectures have at least two processor modules and are suitable for use with:
SIL3 de-energize to trip applications
SIL3 energize to action applications when fitted with dual output modules
Faulted input modules in a SIL3 arrangement may be replaced without a time limit;
faulted output modules must be replaced within the MTTR assumed in the PFD
calculations.
In all SIL3 architectures, when the processor modules have degraded to 1oo1D on the
first detected fault, the system must be restored to at least 1oo2D by replacing the
faulty processor module within the MTTR assumed in the PFD calculations or all SIL3
safety instrumented function and high demand safety instrumented functions must be
shut down.
If required you can configure triple processor modules as a variation of this SIL3
architecture. Using this arrangement the processor modules operate in 2oo3D under
no fault conditions and 1oo2D on the detection of the first fault in any module. They
degrade to 1oo1D on the detection of faults in any two modules, and will fail-safe
when there are faults on all three modules.
For de-energize to action operation one 9451 digital output module is sufficient for
SIL3 requirements. However, for energize to action operation, dual digital output
modules are required.
The single output module operates in 1oo1D under no fault conditions and fail-safe
when there is a fault on the module. For energize to action operation, the output
modules operate in 1oo2D under no fault conditions, degrade to 1oo1D on the
detection of the first fault in either module and fail-safe when there are faults on both
modules.
Table 11: Modules for TMR Input and Processor, Fault Tolerant Output
Note: All configurations that use dual or triplicate processor modules are suitable for
SIL3 architectures with de-energize to trip outputs. Dual outputs are also required for
SIL3 energize to action outputs.
Modules Conditions
Processor Base Safety-related and can be used for safety critical applications in Fault
tolerant/High demand SIL2 applications with 2 modules fitted or
T9100
SIL3 applications with 2 or 3 modules fitted.
I/O Base Safety-related and can be used for safety critical applications in SIL3.
T9300 (3-way)
Note: Revisions of modules are subject to change. A list of the released versions is
held by TÜV or can be obtained from Rockwell Automation.
In This Chapterr
Fundamental Architectures .............................................................................. 3-1
Simplex I/O Architecture.................................................................................. 3-1
Dual Architecture for Fault Tolerant Applications..................................... 3-5
Triple Modular Redundant Architecture ...................................................... 3-7
Fundamental Architectures
The standard AADvance modules can be arranged to provide three fundamental
architectures based on simplex, dual and triple modular redundant processors
modules. To these can be added I/O modules for redundant and/or fault tolerant
configurations based on the following arrangements:
Input modules in simplex, dual and triple modular redundant formations
Output modules in simplex and dual arrangements
An AADvance system can mix different I/O architectures within one controller — for
example simplex and dual input modules with dual processor modules. The modular
construction of the controller enables you to create numerous other arrangements
that can be tailored for a particular application.
Once a system has been built and commissioned it can be expanded using any of the
architectures described in this chapter. However, this expansion can be carried out
with an on-line update.
NOTE: To keep these examples simple the illustrations show only T9401 digital input
modules being used; however, T9431 analogue input modules or a mixture of the two
can be used instead.
This example supports 8 field inputs and 8 outputs. There is space for two more
processor modules and one more I/O module. To further expand the I/O capacity you
would need to add I/O base units then the required number of I/O modules and
termination assemblies.
Note: The T9852 dual termination assembly can be used with both 8 channel and 16
channel input modules.
IMPORTANT: All configurations that use dual or triplicate processor modules are
suitable for SIL3 architectures with de-energize to action outputs. Dual output
modules are required for SIL3 energize to action outputs.
You can add further groups of three input modules and pairs of output modules to
provide additional I/O capacity. For example, a triple modular redundant controller
using 8-channel modules for 16 inputs and 16 outputs could be arranged like this. For
16 channel TMR input you should use the T9402 16 channel digital input modules in
the same arrangement.
In This Chapter
Example Controllers .......................................................................................... 4-1
Mixed I/O Architectures ................................................................................... 4-3
Mixed Safety Integrity Levels ........................................................................... 4-4
Distributed Architectures................................................................................. 4-5
Typical Network Applications ......................................................................... 4-6
Example Controllers
The following example shows a process protected by one distributed AADvance
system. It uses an 8000 Series Trusted controller to handle bulk I/O, and four
AADvance controllers for other parts of the plant.
Controllers 1 and 2 represent two similar controllers applied to identical, duplicated
areas of plant. The duplication of plant (represented by the two compressors K1 and
K2) in this system allows controllers 1 and 2 to be fail safe designs.
The parts of the plant managed by Controllers 3 and 5 are assumed (for the sake of
this illustration) to need safety instrumented systems certified to a mixture of SIL2 and
SIL3. Controller 3 exploits the flexibility of the AADvance system to provide mixed
SILs within one controller.
Controller 4 manages the fire and gas system throughout the plant. The example uses
an 8000 Series Trusted controller here in a role which uses a large quantity of field
devices. The 8000 Series Trusted controller is completely integrated into the system
and shares the applications with the AADvance controllers.
The engineering workstation may connect to the safety network (as illustrated), to the
information network or to both networks.
As drawn, the OPC portal server collects data from the controllers and displays it on
the HMIs and, conversely, delivers commands from the HMIs to the controllers. The
information network carries real time data (Modbus TCP) from the BPCS to the
controllers.
In This Chapter
I/O Channel Capacity ........................................................................................ 5-1
Adding I/O Channel Capacity .......................................................................... 5-5
Bus Connectors and Expansion Cable........................................................... 5-5
Redundancy and Fault Tolerance .................................................................... 5-6
Expansion using Distributed Controllers ...................................................... 5-6
Input Channels
12 groups of three 8-channel input modules occupy 12 base units and yield 12 x 8
= 96 input channels.
Output Channels
6 pairs of output modules occupy the remaining 4 base units and yield 6 x 8 = 48
output channels.
In This Chapter
Information to Specify a New Controller..................................................... 6-1
Define a New System ........................................................................................ 6-2
Choosing Termination Assemblies ................................................................. 6-5
Specify I/O Base Units ....................................................................................... 6-5
Estimate AADvance Controller Weight ....................................................... 6-6
Estimate Module Supply Power Dissipation and Field Loop Power
Dissipation ............................................................................................................ 6-7
You need one termination assembly for each group of associated modules. For
example:
Four T9401 digital input modules used in two, dual redundant configurations need
two T9802 termination assemblies — one for each pair of modules
Four T9401 digital input modules used for simplex inputs need four T9801
termination assemblies — one for each module
Note: All figures given are worst-case estimates based upon maximum operating field
current and voltages.
Total:
Total:
In This Chapter
T9110 Processor Module ................................................................................. 7-2
T9100 Processor Base Unit ............................................................................. 7-5
T9300 I/O Base Unit (3 way) ........................................................................... 7-8
T9310 Expansion Cable Assembly ................................................................ 7-10
T9401/2 Digital Input Module, 24V dc, 8/16 channel ............................... 7-12
T9801/2/3 Termination Assemblies for Digital Inputs ............................. 7-14
T9431/2 Analogue Input Module, 8/16 Channel ....................................... 7-16
T9831/2/3 Termination Assemblies for Analogue Inputs ....................... 7-18
T9451 Digital Output Module, 24V dc, 8 channel .................................... 7-20
T9851/2 Termination Assemblies for Digital Outputs ............................ 7-22
T9481/2 Analogue Output Module .............................................................. 7-24
T9881/2 Termination Assembly for Analogue Output Module ............ 7-26
Attribute Value
Functional Characteristics
Degradation 1oo1D, 1oo2D and 2oo3D
Processor clock 400MHz
Memory
Boot flash 512kB
SRAM 512kB
Bulk flash 64MB
SDRAM 32MB
Sequence of events (for internal variables)
Event resolution 1ms
Time-stamp accuracy Application Scan
Performance Characteristics
Safety Integrity Level (SIL) 1 processor: non-safety applications up to SIL1
and SIL2 safety applications
2 Processors: up to SIL3 safety applications
3 Processors: up to SIL3 fault tolerant and
TMR safety applications.
I/O Modules supported 48
Electrical Characteristics
Module supply voltage:
Voltage Redundant + 24V dc nominal; 18V dc to 32V
dc range
Module supply power dissipation 8W (27.3 BTu/h)
Typical Surface Temperature of an 43°C ± 5°C
Operating Module
Mechanical Specification
Dimensions (height × width × depth) 166mm × 42mm × 118mm
(6-½ in. × 1-5/8 in. × 4-5/8 in.)
Weight 430g (15 oz.)
Casing Plastic, non-flammable
The processor base unit provides the electrical connections between the T9110
processor modules, and the rest of the controller modules and has the following
connections:
Command and response bus connections for up to 48 I/O modules
Inter-processor links
Two Ethernet 100 BaseT connectors per processor
Two serial data connections per processor
Dual +24v System power
Ground stud
Program enable key
The processor base unit holds the IP address of each processor module separately in a
BUSP (U1 shown in above illustration) which is installed during manufacture. This
means that you can remove a defective processor module and install a new one
without needing to set up the IP address of the new module.
Attribute Value
Electrical Specification
Supply voltage requirements Redundant + 24V dc nominal; 18V dc to 32V
dc range
Number of processor modules supported 1, 2 or 3
Number of I/O base units supported 16: 8 per I/O bus
E1-1, E1-2; E2-1, E2-2; E3-1, E3-2 Connectors for Ethernet Ports 1 & 2 for
Processor A, B and C
S1-1, S1-2; S2-1,S2-2; S3-1, S3-2 Connectors for Serial Ports 1 & 2 for
Processor A, B and C
PWR-1, PWR-2 Connectors for Redundant +24V dc Power
Supplies
FLT Not used
KEY Connector for the Program Enable Key
Mechanical Specification
Dimensions (height × width × depth) 235mm x 126mm
(9 1/4 in x 5 in)
Weight 460g (16 oz.)
Attribute Value
Electrical Specification
Supply voltage requirements Redundant + 24V dc nominal; 18V dc to 32V
dc range (from Processor Base unit)
Physical Specification
Number of I/O modules supported 1, 2 or 3
Command busses One
Response busses 24
Buses per system 2
Base units per bus 8
I/O Modules per bus 24 individual modules (not counting grouping)
(e.g. 12 dual or 8 triple module groups)
Mechanical Specification
Dimensions (height × width × depth) 235mm x 126mm
(9 1/4 in x 5 in)
Weight 133g (5 oz.)
Attribute Value
Electrical Specification
Carries the following Signals: Command Bus
I/O Response Bus x 24
Backplane 0V Return
Redundant System +24V DC_1 & 2 power
supplies
Mechanical Specification
Length 2m (78.74 ins)
Weight
SCS1-3 Cable Assembly 57gm, 2 oz
Cable Plug Assembly 50gm, 2oz
Cable Socket 50gm, 2oz
Attribute Value
Functional Characteristics
Input Channels T9401: 8
T9402: 16
Performance Characteristics
Safety integrity level IEC 61508 SIL3 *
Safety level degradation 1oo1D, 1oo2D,2oo3D
Safety accuracy limit 1V
Self test interval < 1 hour; system dependent
Sample update interval (no filter) 6ms
Sequence of events
Event resolution 1ms
Time-stamp accuracy 10ms
Electrical Characteristics
Module Supply Voltage:
Voltage Redundant + 24V dc nominal; 18V to 32V dc
range
Module supply power dissipation T9401: 3.3W (11.3 BTU/hr)
T9402: 4.0W (13.6 BTU/hr)
Input data voltage range 0V to 32V dc
Channel load see TA specification
Input voltage measurement accuracy ± 0.5V
Input voltage resolution 5mV 13-bit
Field loop power dissipation (see T9801/2/3 Termination Assembly)
Channel Isolation-maximum withstand ± 1.5KV dc for 1 minute
Mechanical Specification
Dimensions 166mm x 42mm x 118mm
(6½ in. × 1 21/32 in. × 4 21/32 in.)
Weight T9401: 280g (10 oz.)
T9402: 340g (12 oz.)
Casing Plastic, non-flammable
* SIL3 is the maximum achievable for a single channel. Selected CPU, input and output voting
configurations may increase or decrease the actual SIL achieved.
The termination assembly protects each channel input by a fuse. Fuses can be replaced
without removing a module or the termination assembly.
Attribute Value
Functional Characteristics
Field Connections 16
Input modules supported
T9801 One T9401/2
T9802 Two T9401/2
T9803 Three T9401/2
Electrical Characteristics
Input channel fuses 50mA, 125V, Type T
Attribute Value
Functional Characteristics
Input channels: T9431: 8
T9432: 16
Degradation 1oo1D, 1oo2D and 2oo3D
Performance Characteristics
Safety integrity level IEC 61508 SIL3 *
Safety level degradation 1oo1D, 1oo2D and 2oo3D
Safety accuracy limit 200μA
Self test interval < 1 hour system dependent
Sample update interval (no filter) 6ms
Value of least significant bit 0.98μA
Error at 25°C ± 2ºC
After 1 year at 40°C 0.21% + 10μA
After 2 years at 40°C 0.22% + 10μA
After 5 years at 40ºC 0.23% + 10μA
Temperature drift (0.01% + 0.3μA)°C
Electrical Characteristics
Module supply voltage:
Voltage Redundant +24V dc nominal
Module supply power dissipation T9431: 3.3W (11.3 BTU/hr)
T9432: 4.0W (13.6 BTU/hr)
Input Current
Nominal 4 to 20mA dc
Maximum range 0 to 24mA dc
Input channel load see TA Specification
Resolution 0.98μA, 15-bit
Measurement calibrated accuracy at 25°C ± 0.05mA
Field loop power dissipation see 9831/2/3 TA Specification
Channel isolation - maximum ± 1.5kV dc for 1 minute
withstanding
Mechanical Specification
Dimensions (height × width × depth) 166mm × 42mm × 118mm
(6-½ in. × 1-21/32 in. × 4-21/32 in.)
* SIL3 is the maximum achievable for a single channel. Selected CPU, input and output voting
configurations may increase or decrease the actual SIL achieved. Refer to the Safety Manual
for further details.
The termination assembly protects each sensor input signal by a 50mA fuse. Fuses can
be replaced without removing an I/O module or termination assembly.
Attribute Value
Functional Characteristics
Field connections 16
Number of input modules supported
T9831 One
T9832 Two
T9833 Three
Electrical Characteristics
Input channel fuses 50mA per channel
Channel load 135: ± 2:
Channel isolation:
T9831 None
T9832/T9833 ± 1.5kV dc Maximum withstanding for 1 minute
Maximum field loop power dissipation 0.08W per field loop (0.27BTU/hr)
Mechanical Specification
Dimensions (height × width)
T9831 132mm × 42mm (5-¼ in. × 1-21/32 in.)
T9832 132mm × 84mm (5-¼ in. × 3-5/16 in.)
T9833 132mm × 126mm (5-¼ in. × 5 in.)
Weight
T9831 133g (5oz)
T9832 260g (10oz)
T9833 360g (13oz)
When a controller uses a pair of digital output modules in a dual configuration, the two
fail-safe output switches on each channel are combined in a parallel arrangement so
that they automatically form a fault-tolerant output configuration.
Attribute Value
Functional Characteristics
Output channels 8
Performance Characteristics
Safety integrity level IEC 61508 SIL3 *
Safety level degradation 1oo1D, 1oo2D
Self-test interval <30 mins (30s per module)
Electrical Characteristics
Module supply voltage:
Voltage Redundant +24V dc nominal;
18V dc to 32V dc range
Module supply power dissipation 3.0W (10.2BTU/hr)
Output Voltage:
Maximum voltage without damage –1V to +60V dc
Operating field supply voltage 18 - 32V dc
Output current: 1A continuous per channel
Minimum current required for line monitoring 10mA per module (20mA for dual
pair)
Maximum voltage drop 1V dc
Maximum current at de-rated temperature 8A all channels @ 60°C
De-rated current at maximum temperature 6A all channels @ 70°C
Output off resistance (effective leakage) 50K:
Voltage monitoring accuracy ± 0.5V
Current monitoring accuracy ± 10mA
Output overload protection
Surge 2A for up to 50ms
Continuous 1.5A
Maximum field loop power dissipation 0.57W per field loop (1.94BTU/hr)
Mechanical Specification
Dimensions (height × width × depth) 166mm × 42mm × 118mm
(6-½ in. × 1-21/32 in. × 4-21/32 in.)
Weight 340g (12 oz.)
Casing Plastic, non flammable
* SIL3 is the maximum achievable for a single channel. Selected CPU, input and output voting
configurations may increase or decrease the actual SIL achieved. Refer to the Safety Manual
for further details.
The termination assembly routes the output channels for final elements from the
digital output module to terminal blocks for field connections. The terminal blocks also
accept two 24V dc power sources for field power. The termination assembly
incorporates two replaceable 10A fuses, one for each power source. These fuses can
protect the output module against some field faults.
Attribute Value
Functional Characteristics
Field connections 8
Modules supported T9851 : One
T9852 : two
Electrical Characteristics
Dual field supply voltage +24Vdc
Field supply fuses 10A for each field supply
Mechanical Specification
Dimensions (height x width)
T9851 132mm × 42mm (5-¼ in. × 1-21/32 in.)
T9852 132mm × 84mm (5-¼ in. × 3-5/16 in.)
Weight
T9851 133g (5oz)
T9852 260g (10oz)
Attribute Value
Functional Characteristics
Output channels T9481: 3
T9482: 8
Performance Characteristics
Safety integrity level awaiting approval
Safety level degradation 1oo1D, 1oo2D
Safety accuracy 200PA
Self-test interval < 1 hour, system dependent
Value of Least significant bit (control) 0.98PA
Value of least significant bit (monitor) 3.9PA
Error at 25°C ± 2°C
After 1 year at 40°C 0.30% + 10PA
Aftter 2 years at 40°C 0.35% + 10PA
After 3 years at 40°C 0.44% + 10PA
Temperature drift (0.01% + 0.1PA) per °C
Electrical Characteristics
Module supply voltage:
Voltage Redundant +24V dc nominal;
18 V dc to 32V dc range
Module supply power dissipation 3.6W (12.3BTU/hr)
Output voltage:
Maximum voltage without damage ± 60V dc
Operating field supply voltage 18 - 32V dc
Output current
Nominal 4 - 20mA
Maximum range 0.1mA - 24mA
Calibrated accuracy at 25°C 10PA
Output current control resolution 0.98μA, 15-bit
Output current control accuracy at 25°C ± 10μA
Output current monitoring resolution 3.9μA, 13-bit
Compliance voltage 3V to 32V dc
Load impedance
Attribute Value
Functional Characteristics
Field connections 8
Modules supported T9881: One
T9882: Two
Electrical Characteristics
Channel isolation ± 1.5kV dc maximum withstand for 1 minute
Mechanical Specification
Dimensions (height x width)
T9881 132mm × 42mm (5-¼ in. × 1-21/32 in.)
T9882 132mm × 84mm (5-¼ in. × 3-5/16 in.)
Weight
T9881 133g (5oz)
T9882 260g (10oz)
In This Chapter
Programming Language Support...................................................................... 8-1
Program Management Facilities ....................................................................... 8-1
Support for Variable Types .............................................................................. 8-2
I/O Connection (Addressing of Physical I/O) .............................................. 8-2
Off-line Simulation and Testing ....................................................................... 8-2
Application (Resource) Program Security .................................................... 8-2
Aids to Software Development....................................................................... 8-3
AADvance Workbench Licensing Options .................................................. 8-3
DIN Rails Fitting .................................................................................................. 8-4
In This Chapter
Free Space Around the Controller ................................................................ 9-1
Base Units, DIN Rail installations and Expansion Cables .......................... 9-3
Assemblies of Base Units .................................................................................. 9-3
Power Supply Requirements ............................................................................ 9-4
Adding Cable Management ............................................................................... 9-4
The expansion bus accessed from the right hand edge of the 9100 processor base unit
is designated bus 1, while the bus accessed from the left hand edge is designated bus 2.
The module positions (slots) within 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 expansion cable assemblies are two metres long. The maximum possible length of
an entire bus (the combination of I/O base units and expansion cables) is 8 metres.
This is limited by the electrical characteristics of the interface.
An over current fault in the controller must not result in the whole system losing
power. Consequently, the power sources must be able to deliver the peak current
needed to open any over current protection devices (such as fuses) without
themselves failing.
The power supply protection of the controller is within the modules, the power
distribution arrangement must provide a circuit breaker on the input side of each
power source.
The power sources should come from a commercially available industrial un-
interruptible power supply (UPS) system. A suitable UPS should have capacity sufficient
to meet the entire system load (including field devices as well as the controller) and a
suitable contingency allowance for any projected future expansion.
Modules
Part No. Part Description
T9110 Processor module
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
T9844 Frequency Input Module TA, Simplex, Active (not yet released)
T9845 Frequency Input Module TA, Dual, Active (not yet released)
T9846 Frequency Input Module TA, TMR, Active (not yet released)
T9847 Frequency Input Module TA, Simplex, Passive (not yet released)
T9848 Frequency Input Module TA, Dual, Passive (not yet released)
T9849 Frequency Input Module TA, TMR, Passive (not yet released)
Expansion Cable Assembly
Expansion cable assembly, comprising expansion cable and two adaptors
Part No. Part Description
T9310-02 Backplane expansion cable, 2 metre
Blanking Covers
Part No. Part Description
T9191 Blanking cover (tall) for I/O positions with no TA fitted
T9193 Blanking cover (short) for I/O positions with TA or a Processor
Software
Part No. Part Description
T9082U IEC 61131 Workbench, USB key, single user, single controller
T9082D IEC 61131 Workbench, hard disk key, single user, single controller
Demonstration Unit
Part No. Part Description
T9141 AADvance Demonstration Unit (Including HMI)
Micellaneous Items
Part No. Part Description
T9020 Euro BUSP Kit
Notes:
T9901: No 396/TE5 50mA time lag fuse; UL 248-14, 125 V,T Leadfree; manufactured
by Littlefuse.
T9902: SMF Omni-Block, Surface Mount Fuse Block 154 010, with a 10A, 125V Fast
Acting Fuse, Littlefuse.
T9905: Poly-carbonmonofluride Lithium Coin Battery, BR3032, 20mm dia; Nominal
voltage 3V; Nominal capacity (mAh) 190; Continuous standard load (mA) 0.03;
Operating temperature 30°C to 80°C, supplied by Panasonic
Glossary of Terms
A asynchronous
accuracy A data communications term describing a
serial transmission protocol. A start signal is
The degree of conformity of a measure to a
sent before each byte or character and a
standard or a true value. See also
stop signal is sent after each byte or
'resolution'.
character. An example is ASCII over RS-
achievable safe state 232-C. See also 'RS-232-C, RS-422, RS-485'.
A safe state that is achievable. availability
Note: Sometimes, a safe state cannot be
The probability that a system will be able to
achieved. An example is a non-recoverable
carry out its designated function when
fault such as a voting element with a shorted
required for use — normally expressed as a
switch and no means to bypass the effect of
percentage.
the short.
actuator
B
backplane clip
A device which causes an electrical,
mechanical or pneumatic action to occur A sprung, plastic device to hold together
when required within a plant component. two adjacent AADvance base units. Part
Examples are valves and pumps. number 9904. Used in pairs.
AITA base unit
Analogue input termination assembly. One of two designs which form the
supporting parts of an AADvance controller.
alarms and events (AE)
See 'I/O base unit' and 'processor base unit'.
An OPC data type that provides time
bindings
stamped alarm and event notifications.
Bindings describe a "relationship" between
allotted process safety time
variables in different AADvance controllers.
The portion of the total process safety time Once a variable is "bound" to another
allotted to a sub function of that process. variable, a unique and strong relationships is
created between the two variables and the
application software SIL 3 Certified SNCP protocol is used to
Software specific to the user application, ensure that the consuming variable is
typically using logic sequences, limits and updated with the data from the producing
expressions to read inputs, make decisions variable.
and control outputs to suit the
black channel
requirements of the system for functional
safety. A communication path whose layer (i.e.
cabling, connections, media converters,
architecture routers/switches and associated
Organizational structure of a computing firmware/software, etc.) has no requirement
system which describes the functional to maintain the integrity of safety critical
relationship between board level, device data transferred over it. Measures to detect
level and system level components. and compensate for any errors introduced
into the black channel must be implemented
by the safety critical sender and receiver (by
software and/or hardware means) to make
sure the data retains its integrity.
blanking cover C
A plastic moulding to hide an unused slot in CIP
an AADvance base unit.
Common Industrial Protocol. A
boolean communications protocol, formally known
as 'CIP over Ethernet/IP', created by
A type of variable that can accept only the
Rockwell Automation for the Logix
values 'true' and 'false'.
controller family, and which is also
BPCS supported by the AADvance controller.
AADvance controllers use the protocol to
Basic process control system. A system
exchange data with Logix controllers. The
which responds to input signals and
data exchange uses a consumer/producer
generates output signals causing a process
model.
and associated equipment to operate in a
desired manner, but which does not clearance
perform any safety instrumented functions
The shortest distance in air between two
with a claimed safety integrity level of 1 or
conductive parts.
higher.
Refer to IEC 61511 or to ANSI/ISA— coding peg
84.00.01—2004 Part 1 (IEC 61511-1 Mod)
A polarization key, fitted to the 9100
for a formal definition.
processor base unit and to each termination
Equivalent to the Process Control System
assembly, which ensures only a module of
(PCS) defined by IEC 61508.
the correct type may be fitted in a particular
breakdown voltage slot. Part number 9903.
The maximum voltage (AC or DC) that can coil
be continuously applied between isolated
In IEC 61131-3, a graphical component of a
circuits without a breakdown occurring.
Ladder Diagram program, which represents
BS EN 54 the assignment of an output variable. In
Modbus language, a discrete output value.
A standard for fire detection and fire alarm
systems. Compiler Verification Tool (CVT)
BS EN 60204 The Compiler Verification Tool (CVT) is an
automatic software utility that validates the
A standard for the electrical equipment of
output of the application compilation
machines, which promotes the safety of
process. This process, in conjunction with
persons and property, consistency of
the validated execution code produced by
control response and ease of maintenance.
the AADvance Workbench, ensures a high
bus degree of confidence that there are no
errors introduced by the Workbench or the
A group of conductors which carry related
compiler during the compilation of the
data. Typically allocated to address, data and
application.
control functions in a microprocessor-based
system. configuration
bus arbitration A grouping of all the application software
and settings for a particular AADvance
A mechanism for deciding which device has
controller. The grouping must have a
control of a bus.
'target', but for an AADvance controller it
can have only one 'resource'.
consumer dictionary
The consuming controller requests the tag The set of internal input and output
from the producing controller. variables and defined words used in a
program.
contact
discrepancy
A graphical component of a Ladder Diagram
program, which represents the status of an A condition that exists if one or more of the
input variable. elements disagree.
continuous mode DITA
See high demand mode. Digital input termination assembly.
controller DOTA
A logic solver; the combination of Digital output termination assembly.
application execution engine and I/O
hardware.
E
controller system element
A set of input conditioning, application
One or more controllers, their power
processing and output conditioning.
sources, communications networks and
workstations. energise to action
coverage A safety instrumented function circuit where
the outputs and devices are de-energized
The percentage of faults that will be
under normal operation. Application of
detected by automated diagnostics. See also
power activates the field device.
'SFF'.
creepage distance EUC
Equipment Under Control. The machinery,
The shortest distance along the surface of
apparatus or plant used for manufacturing,
an insulating material between two
process, transportation, medical or other
conductive parts.
activities.
cross reference
expansion cable assembly
Information calculated by the AADvance
A flexible interconnection carrying bus
Workbench relating to the dictionary of
signals and power supplies between
variables and where those variables are used
AADvance base units, available in a variety
in a project.
of lengths. Used in conjunction with a cable
D socket assembly (at the left hand side of a
base unit) and a cable plug assembly (at the
data access (DA)
right hand side of a base unit).
An OPC data type that provides real-time
data from AADvance controllers to OPC
F
clients. fail operational state
de-energize to action A state in which the fault has been masked.
See 'fault tolerant'.
A safety instrumented function circuit where
the devices are energized under normal fail safe
operation. Removal of power de-activates
The capability to go to a pre-determined
the field devices.
safe state in the event of a specific
malfunction.
M OPC
manual call point A series of standards specifications which
support open connectivity in industrial
A component of a fire detection and fire
automation.
alarm system which is used for the manual
initiation of an alarm. output (Workbench variable)
Modbus In the context of an AADvance Workbench
variable, this term describes a quantity
An industry standard communications
passed from the Workbench to a controller.
protocol developed by Modicon. Used to
communicate with external devices such as P
distributed control systems or operator
peer to peer
interfaces.
A Peer to Peer network consists of one or
Modbus object
more Ethernet networks connecting
A representation of the configuration together a series of AADvance and/or
settings for a Modbus master or for its Trusted controllers to enable application
associated slave links, within the AADvance data to be passed between them.
Workbench. The settings include
pinging
communication settings and messages.
In Modbus communications, sending the
module locking screw
diagnostic Query Data command over a link
The AADvance latch mechanism seen on and by receiving a reply ensuring that the
the front panel of each module and link is healthy and the controller is able to
operated by a broad, flat-blade screwdriver. communicate with the master. No process
Uses a cam action to lock to the processor data is transferred or modified. In the case
base unit or I/O base unit. of slave devices that will not support pinging
then the Standby command will default to
N Inactive state, but no error will be returned.
NFPA 85 portable equipment
The Boiler and Combustion Systems
Enclosed equipment that is moved while in
Hazards Code. Applies to certain boilers,
operation or which can easily be moved
stokers, fuel systems, and steam generators.
from one place to another while connected
The purpose of this code is to contribute to
to the supply. Examples are programming
operating safety and to prevent uncontrolled
and debugging tools and test equipment.
fires, explosions and implosions.
process safety time (PST)
NFPA 86
For equipment under control this
A standard for Ovens and Furnaces.
represents the period of time a dangerous
Provides the requirements for the
condition can exist without the protection
prevention of fire and explosion hazards in
of a safety instrumented system before a
associated with heat processing of materials
hazardous event occurs.
in ovens, furnaces and related equipment.
processor base unit
O
A backplane assembly which holds all of the
on-line processor modules in an AADvance
The state of a controller that is executing controller. Part number 9100. See also
the application software. 'processor module'.
SFF synchronous
Safe Failure Fraction. Given by (the sum of A data communications term describing a
the rate of safe failures plus the rate of serial transmission protocol. A pre-arranged
detected dangerous failures) divided by (the number of bits are expected to be sent
sum of the rate of safe failures plus the rate across a line per second. To synchronise the
of detected and undetected dangerous sending and receiving machines, a clocking
failures). signal is sent by the transmitting computer.
There are no start or stop bits.
SIF
Safety Instrumented Function. A form of
T
process control that performs specified TA
functions to achieve or maintain a safe state
See 'termination assembly'.
of a process when unacceptable or
dangerous process conditions are detected. target
SIL An attribute of a 'configuration' which
describes characteristics of the AADvance
Safety Integrity Level. One of four possible
controller on which the configuration will
discrete levels, defined in IEC 61508 and IEC
run. Includes characteristics such as the
61511, for specifying the safety integrity
memory model and the sizes of variable
requirements of the safety functions to be
types for the controller.
allocated to a safety-related system. SIL4 has
the highest level of safety integrity; SIL1 has TCP
the lowest.
The whole of an installation (of which the Transmission control protocol. One of the
AADvance system forms a part) must meet core protocols of the Internet Protocol
these requirements in order to achieve an suite. It provides reliable, ordered delivery
overall SIL rating. of a stream of bytes from a program on one
computer to another program on another
SNCP computer. Common applications include the
World Wide Web, e-mail and file transfer
SNCP (Safety Network Control Protocol) is
and, for an AADvance controller, Modbus
the Safety Protocol that allows elements of
communications over Ethernet.
an AADvance System to exchange data.
SNCP is a SIL 3 certified protocol which termination assembly
provides a safety layer for the Ethernet
network making it a "Black Channel". A printed circuit board which connects field
wiring to an input or output module. The
SNTP circuit includes fuses for field circuits. The
board carries screw terminals to connect
Simple Network Time Protocol. Used for
field wiring to the controller, and the whole
synchronizing the clocks of computer
assembly clips onto the 9300 I/O base unit.
systems over packet-switched, variable-
latency data networks. TMR
structured text Triple modular redundant. A fault tolerant
arrangement in which three systems carry
A high level IEC 61131-3 language with
out a process and their result is processed
syntax similar to Pascal. Used mainly to
by a voting system to produce a single
implement complex procedures that cannot
output.
be expressed easily with graphical languages.
TÜV certification
Independent third party certification against
a defined range of international standards
including IEC 61508.
U
U
Rack unit. A unit of measure used to
describe the height of equipment intended
for mounting in a standard rack. Equivalent
to 44.45mm (1-¾ inches).
V
validation
In quality assurance, confirmation that the
product does what the user requires.
verification
In quality assurance, confirmation that the
product conforms to the specifications.
voting system
A redundant system (m out of n) which
requires at least m of the n channels to be in
agreement before the system can take
action.
W
withstand voltage
553847 PFH avg and This document contains the PFHavg and PFDavg Data for the
PFDavg Data AADvance Controller. It includes examples on how to calculate
the final figures for different controller configurations. The data
supports the recommendations in the AADvance Safety Manual
Doc No: 553630.
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