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ABB Advant Controller 450, User Manual

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Advant

®

 Controller 450 User’s Guide

Section 5.5.4 Fault Classification and Scheme of Measures

3BSE 002 415R701 Rev A 

5-37

5.5.4 Fault Classification and Scheme of Measures

To guide in the advanced fault finding a rough fault classification is made outgoing from the 
indications provided by the available diagnostics functions.

Advanced fault finding is not the object of this User’s Guide. However some trial might be 
successful. Hints are referred. A classification is valuable too when ordering support from ABB.

Faults are classified in the following four groups A......D:

A.

Faults in the power supply system.

If there is no power supply redundancy, a serious supply failure will result in a controller 
shut down. 
These types of failures are distinguished from other failures, which also results in shut 
down, by the lack of indications like voltage regulator LED 5 V and power distribution 
unit LED LIVE (24 V). See further information in 

Section 5.5.9.5, Check of Power 

Supply

.

B.

Faults which do not stop the system. 

If the RUN LED indicator on processor module front is turned ON but not the HLT LED, 
the system is probably still functional. 
Look for red LEDs in the cabinet and try to define the limited part of the controller which 
fail. Then see a suitable “Check...” instruction in this 

Chapter 5, Maintenance

.

C.

Faults which stop the system. 

The red HLT indicator on the processor module front is turned ON to indicate that the 
system has stopped. 
It is probably meaningful to try a system restart. Especially if a software error is verified 
by halt code or system message. See 

Section 5.5.16, System Restart, INIT

.

Hardware faults also result in system halt (HLT). 

Section 5.5.9.9, Fault Finding by 

Reducing the System

 gives adequate information.

D. 

Faults which give no indications by the built-in diagnostics.

Ask for support from ABB.

5.5.5 Test Equipment 

The character display on the processor module front showing error codes and the indicating 
LEDs on the specific hardware modules are normally sufficient aids when finding faults. 
The following equipment simplifies the work and should be available:

Basic Fault Finding

•

Digital multimeter for calibration and test purposes.

•

Test leads with 4 mm banana contacts and 2 mm reducer sockets.

•

Ordinary hand tools.

•

Necessary parts of the documentation listed in 

Section 1.4, Related Documentation

.

•

Specific documentation enclosed at delivery, drawings, and so on.

•

Spare units and fuses. (The type and catalogue numbers for all units included in the
Advant Controller 450 delivery are given in the apparatus list.)

Summary of Contents for Advant Controller 450

Page 1: ...Advant OCS with Master software GYDQW RQWUROOHU User s Guide 3BSE 002 415R701 Rev A ...

Page 2: ... a registered trademark of MOTOROLA Inc MODBUS is a registered trademark of Gould Electronics PROFIBUS DP is a trademark of the international organization PROFIBUS INTERNATIONAL PI Echelon LON LonTalk LONWORKS and Neuron are registered trademarks of Echelon Corporation Siemens and all Siemens products mentioned in this publication are trademarks of Siemens AG UDPCE is a trademark of ABB Industri A...

Page 3: ...3 4 System Clock External Clock Synchronization 1 35 1 7 3 5 Configuration 1 35 1 7 3 6 Execution 1 35 1 7 3 7 Start up 1 36 1 7 4 Free Programmable Module 1 36 1 7 5 Power Supply 1 36 1 7 6 Process Interface 1 45 1 7 6 1 S100 I O 1 54 1 7 6 2 S400 I O 1 68 1 7 6 3 S800 I O 1 70 1 7 7 Communication 1 80 1 7 7 1 Provided Link Types 1 80 1 7 7 2 Applied Communication 1 90 1 7 8 Process Control 1 92 ...

Page 4: ...r Supply and Fusing 2 9 2 1 8 Process Connection 2 11 2 1 8 1 Connection Principles Fusing and Voltage Distribution 2 11 2 1 9 Hazardous Applications 2 13 2 1 10 High Voltage Switch gear Applications 2 13 2 1 11 Lightning Stroke Protection 2 13 2 1 12 Weight and Mounting Dimensions 2 13 2 1 13 Transportation and Storing 2 15 2 2 Setup 2 15 2 2 1 Safety Regulations 2 16 2 2 1 1 Personnel and Proces...

Page 5: ...n 2 43 2 2 15 Checklists 2 43 2 2 15 1 Grounding Philosophy Earthing Line System 2 43 2 2 15 2 Process Cabling Shielding Grounding Maximum Length 2 44 2 2 15 3 Supply 2 45 2 2 15 4 Lightning Protection 2 45 2 2 15 5 Subrack Connection Unit Circuit Board 2 46 2 2 15 6 Cabinets Internal Cables 2 47 2 2 15 7 External Cables 2 47 2 2 15 8 Communication Communication Cables 2 48 2 2 15 9 Miscellaneous ...

Page 6: ...tion 2 71 2 5 3 6 Tuning of Feedback Control Loops 2 72 2 5 3 7 Use of PC Programming During Operation when Commissioning 2 72 2 5 3 8 Listing of Executing Unit Status 2 73 2 5 3 9 Check of Process Input Output System 2 73 2 5 3 10 Listing of PC Program and Data Base 2 77 2 5 4 Final Control 2 79 2 6 Implementation of Functions in Systems Already Operating 2 79 2 6 1 Servicing Tool 2 80 2 6 2 Safe...

Page 7: ... 3 1 10 Heat Dissipation 3 32 3 1 10 1 Cabinet Ventilation 3 32 3 1 10 2 Heat Dissipation Permitted in Cabinets 3 32 3 1 10 3 Cabinets in Groups 3 33 3 1 10 4 Calculation of Heat Generated in a Cabinet 3 33 3 1 11 Maintenance and Repair 3 34 3 1 12 Expansion Possibilities and Spare Considerations 3 34 3 1 13 Memory Calculation 3 35 3 1 14 CPU optimization Load Calculation 3 39 3 2 Technical Data I...

Page 8: ...ion Building Menus 3 76 Chapter 4 Runtime Operation 4 1 Product Operation 4 1 4 1 1 Working Modes 4 1 4 1 2 Ordering Working Modes 4 2 4 1 3 Start Modes 4 2 4 1 4 Primary and Backup Processor Module 4 3 4 1 5 Relations between Start Modes and Working Modes 4 4 4 1 5 1 First Power up 4 5 4 1 5 2 Power up and Initialization of Controller which Contains Application 4 6 4 1 6 Relations between Enginee...

Page 9: ...ecution Units 4 28 4 1 12 Initialization of Process Communication 4 29 4 1 13 Diagnostics 4 30 4 2 Operating Overview 4 30 4 3 Runtime Tutorial 4 30 4 4 Operating Instructions 4 30 4 5 Runtime Operation Menus 4 30 Chapter 5 Maintenance 5 1 Preventive Maintenance 5 1 5 1 1 Safety Regulations 5 1 5 1 1 1 Personnel and Process Safety 5 1 5 2 Preventive Maintenance 5 2 5 2 1 Safety Regulations 5 2 5 2...

Page 10: ... 9 7 Check of Processor Module 5 49 5 5 9 8 I O 5 50 5 5 9 9 Fault Finding by Reducing the System 5 51 5 5 10 User Repair 5 53 5 5 10 1 Board and Subrack Mounted Unit Exchange 5 53 5 5 10 2 Replacement of Redundant Processor Module 5 66 5 5 10 3 Replacement of Redundant S100 I O Bus Extenders 5 66 5 5 10 4 Replacement of Power Supply Unit 5 68 5 5 10 5 Replacement of 5 V Regulator 5 69 5 5 10 6 Re...

Page 11: ...erface A 10 A 5 PM511V Processor Module A 12 A 6 RB5xx Dummy Modules A 14 A 7 RC527 Fan Unit A 15 A 8 RF533 Controller Subrack 12 SU A 17 A 9 RF540 RF541 Modem Subrack A 20 A 10 SA1xx Power Supply Units A 22 A 11 SB510 Backup Power Supply 110 230 V a c d c A 25 A 12 SB511 Backup Power Supply 24 48 V d c A 28 A 13 SB522 Battery Unit A 30 A 14 SC5x0 Submodule Carriers A 32 A 15 SD150 d c d c Convert...

Page 12: ...ion Forms F 1 Appendix G Memory Calculation G 1 Form for Memory Calculation G 1 Appendix H Halt Codes H 1 Example of Halt Code Printout H 1 H 2 List of Halt Codes and Corrective Actions H 1 Appendix I System Messages I 1 Message Coding I 1 I 2 Message Types I 2 I 3 List of System Messages and Corrective Actions I 3 Appendix J Hexadecimal to Decimal Representation J 1 Conversion Guide J 1 ILLUSTRAT...

Page 13: ... HART Implementation 1 52 Figure 1 21 Principle of HART implementation using S800 I O 1 53 Figure 1 22 Digital Input Signal Block Diagram 1 56 Figure 1 23 Digital Output Signal Block Diagram 1 58 Figure 1 24 Analog Input Signal Block Diagram 1 62 Figure 1 25 Analog Input Output Signal with Redundancy Block Diagram 1 62 Figure 1 26 Analog Output Signal Block Diagram 1 65 Figure 1 27 Pulse Counter I...

Page 14: ...tandard Central Cabinet Configuration maximum 2 5 Figure 2 2 Distributed Location of S100 I O Cabinets Example of Cabinet Configuration 2 6 Figure 2 3 S100 I O with Object Oriented Connection Units Example of Cabinet Configuration 2 7 Figure 2 4 Grounding of Electronic Equipment 2 8 Figure 2 5 Connections with Multi core Cable and Coupling Boxes 2 12 Figure 2 6 Minimum Distance to the Walls and th...

Page 15: ...ly Terminal Settings 3 3 Figure 3 5 Examples of Distribution Board Fusing d c 3 9 Figure 3 6 Reduction Factors for Cabinets Installed in Groups 3 33 Figure 3 7 Advant Controller 450 Priority System 3 40 Figure 3 8 CPU Load Calculation Methods 3 42 Figure 3 9 Load from Cyclic Functions Overview 3 45 Figure 3 10 Load Caused by Subscription 3 50 Figure 3 11 Load Caused by Sending Data Set MasterBus 3...

Page 16: ...rning Label regarding ESD 5 3 Figure 5 2 System Status Display Advant Controller 400 applied to Advant Controller 450 5 9 Figure 5 3 System Status Display S100 I O 1 5 22 Figure 5 4 System Status Display S100 I O 2 5 23 Figure 5 5 System Status Display S100 I O Redundant Board 5 24 Figure 5 6 System Status Display Fieldbus 5 25 Figure 5 7 System Status Display Fieldbus 5 26 Figure 5 8 System Statu...

Page 17: ...ection Units Connection and Terminal Numbering D 8 Figure D 13 Location of Connection Units on a Mounting Bar D 8 Figure D 14 Typical Internal Connection D 9 Figure D 15 Terminal Block Numbering D 9 Figure D 16 Location of Mains Units D 9 Figure D 17 Example of general Disposition of a Double Cabinet D 10 Figure H 1 Example of LSYSHI Printout H 1 TABLES Table 1 1 Related Documentation Configuratio...

Page 18: ...43 Table 2 6 Process Cabling Shielding Grounding max Length 2 44 Table 2 7 Supply 2 45 Table 2 8 Lightning Protection 2 45 Table 2 9 Subrack Connection Unit Circuit Board 2 46 Table 2 10 Cabinets Internal Cables 2 47 Table 2 11 Communication Communication Cables 2 48 Table 2 12 Miscellaneous 2 49 Table 2 13 Function List with an Outline of Controller System Configuration Information 2 59 Table 2 1...

Page 19: ...f Redundant Processor Modules 4 7 Table 5 1 Replacement Aspects of Individual Board Types Controller Hardware 5 55 Table 5 2 Replacement Aspects of Individual Board Types S100 I O 5 59 Table 5 3 Adjustment Possibilities on Analog Circuit Boards 5 75 Table 5 4 Full Scale Voltages 5 81 Table A 1 List of Hardware Modules A 1 Table A 2 Pin Designation for Channel 1 and 2 Connector X4 and X5 A 7 Table ...

Page 20: ... Table I 2 System Message Types I 2 Table I 3 Type 2 Code 46 I 3 Table I 4 Type 5 Code 21 I 3 Table I 5 Type 10 Code 19 I 4 Table I 6 Type 17 Code 1 2 3 7 8 9 and 11 I 5 Table I 7 Type 18 Code 8 and 11 I 8 Table I 8 Type 20 Code 1 I 9 Table I 9 Type 22 Code 9 12 13 and 20 I 10 Table I 10 Type 26 Code 12 I 12 Table I 11 List of Common Concept Numbers in System Messages I 13 Table I 12 Type 28 I 14 ...

Page 21: ...age Regulation in Controller Subrack 1 42 Figure 1 15 Voltage Regulation in I O Subrack 1 43 Figure 1 16 Input and Output Signal Paths in principle 1 47 Figure 1 17 Input and Output Signal Paths in principle 1 48 Figure 1 18 Example of Connection Unit for S100 I O 1 49 Figure 1 19 Application of Object Oriented Connection of S100 I O 1 50 Figure 1 20 Principle of HART Implementation 1 52 Figure 1 ...

Page 22: ...e 1 49 Arrangement of Redundant I O Modules 1 116 Figure 1 50 Cabinet type RM500 1 117 Figure 1 51 Typical Cabinet minimum Configuration Redundant Power Supply 1 119 Figure 1 52 Advant Controller 450 Controller Subrack 9S 1 120 Figure 1 53 Front of I O Subrack 1 121 Figure 1 54 I O Subrack Configuration 1 122 Figure 1 55 Carrier Module and Submodule Mechanics 1 123 Figure 2 1 Standard Central Cabi...

Page 23: ...agram of S100 I O Output Channel Test Points 2 76 Figure 2 30 Graphic Diagram 2 78 Figure 2 31 Program List 2 78 Figure 2 32 Grounding of Connection Units 2 84 Figure 2 33 I O Subrack 2 85 Figure 3 1 External Synchronization of System Clock 3 2 Figure 3 2 Run Alarm Relay Connection 3 2 Figure 3 3 Connection of Additional Supervisory Inputs 3 3 Figure 3 4 Power Supply Terminal Settings 3 3 Figure 3...

Page 24: ...re 4 14 Interpreters 4 22 Figure 4 15 Function consisting of two Execution Units 4 23 Figure 4 16 Order of Execution for PC Elements AND Gate with two Inputs 4 24 Figure 4 17 Printout from the Command LTREE 4 25 Figure 4 18 Example of Reading in Phase 4 26 Figure 4 19 Example Reading out Phase 4 27 Figure 4 20 Data Transport 4 28 Figure 5 1 Warning Label regarding ESD 5 3 Figure 5 2 System Status ...

Page 25: ... of Mounting Planes D 1 Figure D 2 Cabinet with Door Removed D 2 Figure D 3 Item Designation in Controller Subrack 12 SU D 3 Figure D 4 Item Designation in Controller Subrack 18SU D 4 Figure D 5 Addresses in Controller Subrack 12 SU D 4 Figure D 6 Item Designation in I O Subrack D 5 Figure D 7 Item Designation in Modem Subrack 19 inches D 6 Figure D 8 Item Designation in Modem Subrack 24 inches D ...

Page 26: ...Advant Controller 450 User s Guide Table of Contents 3BSE 002 415R701 Rev A xvi ...

Page 27: ...1 54 Table 1 14 Digital Output Boards 1 57 Table 1 15 Analog Input Boards 1 59 Table 1 16 Analog Output Boards 1 63 Table 1 17 Pulse Counting Frequency Measurement Boards 1 65 Table 1 18 Positioning Board 1 67 Table 1 19 Converter Connection Board 1 67 Table 1 20 S400 I O Units 1 69 Table 1 21 Communication Interface Module 1 72 Table 1 22 S800 Digital Modules 1 73 Table 1 23 S800 Analog Modules 1...

Page 28: ...Used Links and Interface to Application Program 3 25 Table 3 9 Calculation of RAM requirement 3 36 Table 3 10 Technical Data of CPU and Memory 3 44 Table 3 11 Load from Process I O Handling 3 46 Table 3 12 Example of Execution Times of Digital Signals 3 48 Table 3 13 Clock Synchronization Electrical Data for Minute Pulse 3 59 Table 3 14 Estimated System Power Consumption 3 60 Table 3 15 Size of Bu...

Page 29: ...Dissipation S100 I O Boards E 3 Table E 3 Current Consumption and Power Dissipation Power Supply and Sundry E 5 Table F 1 Calculation of CPU load from S100 and S800 Inputs F 1 Table F 2 Calculation of CPU load from S100 and S800 Outputs F 2 Table F 3 Calculation of CPU load from User Defined Type Circuits F 3 Table G 1 Calculation of RAM requirement G 1 Table H 1 List of Halt Codes H 2 Table I 1 S...

Page 30: ...Advant Controller 450 User s Guide Table of Contents 3BSE 002 415R701 Rev A xx ...

Page 31: ...ily for plant designers and commissioning and maintenance personnel providing them with information about the Advant Controller 450 system its capabilities and its limitations References are made to other manuals when necessary Section 1 2 Manual Organization provides further details about both this manual and other related manuals LJXUH DPSOH RI GYDQFHG RQWURO 6 VWHP ZLWK GYDQW RQWUROOHU Advant S...

Page 32: ...ities Because of the activity oriented structure of the document you may find information regarding an actual function distributed to for example Overview Configuration Operation and so on Sometimes you can find device information gathered in the hardware descriptions in the appendices LJXUH DVLF RFXPHQWDWLRQ 6WUXFWXUH Introduction Installation Configuration Application Building Runtime Maintenanc...

Page 33: ...uting and connections switch settings and jumper positions setup procedures and so on You can find common instructions as well as instructions for specific subsystems in this section Activities prior to power up are also described Section 2 3 Shut down Procedures This section provides in addition to some safety regulations basic shut down procedures You should know how to shut down the product if ...

Page 34: ...ion provides you with a guide through the different phases of a controller design project Section 3 5 Application Procedures Not applicable For information from a configuration viewpoint how to achieve an application function see the appropriate individual manuals In this manual Chapter 2 Installation treats the subject of concrete setup work on site KDSWHU 5XQWLPH 2SHUDWLRQ addresses the controll...

Page 35: ...sed for Advant Open Control System with Master software throughout this manual 5HODWHG RFXPHQWDWLRQ This manual is the main document of the system product Advant Controller 450 Many of the available options are briefly described in this manual For additional detailed information about options see the appropriate individual manuals Special subjects are also thoroughly treated in separate documentat...

Page 36: ... Controller 110 160 from a Advant Station 500 Series Operator Station Functional Units Part 1 Summary and Common Properties An introduction to the concept of Functional Units in Advant OCS with Master software Functional Units Part 2 AI AO DI DO Describes the functional units AI AO DI and DO Functional Units Part 3 SEQ GROUP Describes the functional units SEQ and GROUP Functional Units Part 4 PIDC...

Page 37: ...WLRQ 2SWLRQDO XQFWLRQV RFXPHQW HVFULSWLRQ S100 I O Hardware Reference manual describing the S100 I O hardware HART Protocol Interface User s Guide describing how to include and use the HART protocol with S100 I O Intrinsic Safety Support S100 I O User s Guide describing how to include and use the Intrinsic Safety System with S100 I O S800 I O User s Guide This is a complete manual on the S800 I O ...

Page 38: ...ace Modbus with MVB CI534V02 AC 400 Series Contains technical descriptions instructions for configuration installation start up and fault tracing of Modbus in AC 410 450 MultiVendor Interface Siemens 3964 R AC 400 Series Contains technical descriptions instructions for configuration installation start up and fault tracing of Siemens 3964 R in AC 410 450 Advant Fieldbus 100 Describes how to configu...

Page 39: ...owerful CPU New hardware in central parts and voltage regulators New type of cabinet RE500 Number of certain I O channels has increased Increased use of data base element for definition of the computer configuration One flash PROM module for standard system SW load modules Basic system Options 7DEOH 5HODWHG RFXPHQWDWLRQ 7RROV RFXPHQW HVFULSWLRQ Advant Station 100 Series Engineering Station Contain...

Page 40: ...seven MasterFieldbus Shortest log interval is 1 sec Some limitations apply and some changes were made with reference to MasterPiece 200 1 MasterView 100 is not included it is however supported by the software Communication board DSCA 160A is not included PC elements removed MasterFieldbus only supported via new hardware not DSCS 131 Backup in PROM of application program is removed PC element STATU...

Page 41: ...450 on Advant Fieldbus 100 New configuration of MVI protocol MODBUS CI534V02 New highlights in the GYDQW RQWUROOHU include Redundant S100 I O bus Redundant Advant Fieldbus 100 New processor module PM511 New S100 I O bus extender DSBC 174 New Advant Fieldbus 100 interface module CI522 Object Support via Advant Fieldbus 100 Extended range of S800 I O modules New highlights in the GYDQW RQWUROOHU inc...

Page 42: ...H A backplane is part of a subrack which interconnects inserted electronics PRGXOHV with the help of a communication bus DVLF 6 VWHP Basic system is the abstract name of a minimal composition of functional units forming a system DVLF 8QLW Basic unit is used for ordering purposes for example in the Price Book as a name for the smallest unit to be ordered or a platform for further enlargement with a...

Page 43: ...r stations linked together via MasterNet is called a control network DCN It provides real time communication 6 6 stands for lectro6tatic ischarge XQFWLRQDO 8QLW A functional unit is an ABB Master specified denomination It is a package of different software functions such as PC elements data base elements and man machine interface for an operator station 57 A protocol for connection of intelligent ...

Page 44: ... of establishing a multi drop network that is a network with two endpoint QRGHV any number of intermediate QRGHV and only a single path between any two QRGHV 1RGH A node in general a point in a data network A node in an application Any logically addressable unit directly connected to the plant or FRQWURO QHWZRUN Examples are controller process station operator station Any logically addressable uni...

Page 45: ...ITION and SUBMODULE POSITION are used instead 6XEPRGXOH DUULHU A submodule carrier is a module circuit board which houses smaller PRGXOHV submodules 6XEUDFN According to IEC 916 subracks are the mechanics which house rows of boards Different types of subracks are available for example controller subrack I O subrack 7 SH LUFXLW Type circuit is an application specific standard solution in connection...

Page 46: ...RGXFWLRQ 1 16 3BSE 002 415R701 Rev A 3URGXFW 2YHUYLHZ Advant Controller 450 is a programmable system for control and supervision of processes and equipment in industrial environments LJXUH DELQHW IRU GYDQW RQWUROOHU 6HULHV 50 LQ D URQW 9LHZ ...

Page 47: ...roller 450 system These subracks are installed in one cabinet or several cabinets You can include an Advant Controller 450 in a network with other ABB Master products for example other Advant Controllers and products from the Advant Station 100 Series the Advant Station 500 Series and the Advant Station 800 Series These series include operator stations information management systems IMS and engine...

Page 48: ... elements to form a PC module which in turn can be incorporated in further modules Several modules form a PC program which is the solution to automate an addressed process control function Such a PC program executes the PC modules element by element with a periodicity which you can normally select from 10 ms up to 2 s You can document the complete program automatically in graphic form on a printer...

Page 49: ... a version number minor version number and revision number See Figure 1 6 A third part separated by another asterisk is available for program modules only It includes compatibility codes used by the configuration tool engineering station for checks when loading and dumping The information display on the configuration tool indicates upon connection into the system the current product versions of th...

Page 50: ... Product Guide and other tendering and sales documentation For example you will encounter the concept of a basic unit Basic unit is used when you are ordering as a name for the smallest unit to be ordered or a platform for further enlargement with alternatives and options DUGZDUH Controller and process I O are separate products This means that in this manual you will find only short presentations ...

Page 51: ...available are different distributed autonomous units including I O for example PLC type controllers LJXUH DPSOH RI GYDQW RQWUROOHU DUGZDUH RQILJXUDWLRQ LQFO D 9DULDQW RI 3URFHVV 2 I O 30 DFNXS 6 9ROWDJH 5HJ 65 7 6 X S H U Y 30 65 9ROWDJH 5HJ MVI EXCOM Printer and so on MasterBus 300 300E MasterFieldbus Advant Fieldbus 100 RQWUROOHU VXEUDFN 2 VXEUDFN Engineering 6 DFNXS option op tion option 3RZHU ...

Page 52: ...ier w slave CPU CPU Comm module Comm module Comm module Comm module SW backup Communication for example MasterBus 300 GCOM EXCOM MVI Advant Fieldbus 100 MasterFieldbus Futurebus parallel bus communication Voltage regulator 24 V 5 V Power supply unit Processor module Processor 68040 RAM Bus interface System clock Eng tool comm Engineering station a c or d c mains Superv Run relay Backup power Exter...

Page 53: ...xtra software and extra hardware The memory system containing the Advant Controller 450 functionality is modular The fixed VWDQGDUG system software is stored in one single flash PROM module a program card Additional program cards containing specific function libraries can be developed and used LJXUH GYDQW RQWUROOHU XQFWLRQDO QWHUIDFHV Printer AC 110 AS 100 Series ES Terminal for MasterView 320 Oth...

Page 54: ... redundancy power supply cabinetry marshalling and so on You can find general information regarding principles and capabilities in this manual but no details of the different product packages are included Please refer to relevant tendering and sales documentation for that information HQHUDO 6 VWHP 8WLOLWLHV 38 The central processing unit of the Advant Controller 450 comes in two versions with 8 or...

Page 55: ...Structure under the heading Functional Modularization The functional content is treated in the next section Section 1 7 3 3 Program Module Contents 6 VWHP 3URJUDP DFNXS The system program is backed up in flash PROM and automatically loaded to the RAM in connection to system start Physically the standard system software is stored in a program card PCMCIA The basic system program card must always be...

Page 56: ... the system program The illustration in Figure 1 11 apply The flash card is contained with a 8mp of pplication 3rograms DUAP preferably taken while the controller is in the operation mode At need the controller system configuration and the application program is likewise automatically loaded from its flash card into the controller RAM No manual intervention is needed to get into operation after th...

Page 57: ...output signals XQFWLRQDO 6HUYH Logic and time delays Sequence control Data and text handling Calendar time functions Arithmetic Positioning Fast pulse counting and frequency measurement Reports Functional units binary 1 Functional units analog 1 Functional units motor and valve control group start 1 Table handling EXCOM Data Set communication Support for MasterBus 300 Support for GCOM Support for ...

Page 58: ...Time of day and date elements and element for generating output signals at certain dates and times of day DATE TIME TIMER Registers Shift and queue registers and register with retentive memory FIFO REG REG RET SHIFT SHIFT L Group data elements Register assembling single data into a group data and elements for expanding group data or arrays into single data items EXPAND EXPAND A REG G Queue registe...

Page 59: ...OS A POS O POS L Pulse counting and frequency measurement elements Synchronize the board DSDP 110 for low speed pulse counting Pulse count ing and frequency measurement when used with DSDP 150 and DSDP 170 COUNT DP FREQ MP FREQ SP PULSE S PCU COM PCU I PCU O PCU SS Pulse counting and frequency measurement elements Provide pulse counting and frequency measurement with S800 module DP820 DP820 I DP82...

Page 60: ...S Network LON R LON S MasterFieldbus communication elements Provide communication with MasterPiece 51 MasterPiece 90 Advant Controller 110 TYRAK or SAMI via MasterFieldbus COM CVI1 COM CVO1 COM MP51 MFB OUT MFB IN Advant Fieldbus 100 communication elements Provide fast communication with other AC 400 Series nodes and Motor Drive Control DSP R DSP S DRI CNV DRI R DRI S Data Set elements Initiate ex...

Page 61: ...converters DRICONE Integration to engineered Drive DRICONS Integration to Drives of ACS600 type GENUSD General user defined device controller GENBIN User defined on off controller GENCON User defined regulatory controller GROUP Device group controller MOTCON Motor controller MOTCONI Motor controller with INSUM SEQ Sequence controller TEXT Text in data base VALVECON Valve controller 7DEOH GGLWLRQDO...

Page 62: ...FWLRQDO 6XUYH Feedback control Self tuning adaptive control NOVATUNE Functional units PID loop control PIDCON PIDCONA Time controlled elements Square and sine wave oscillators OSC SQW OSC SIN Function gen erators Generate an output from one or two input variables according to a function described by data tables or as a function of time FUNG 1V FUNG 2V FUNG T Filter ele ments Low pass filters with ...

Page 63: ...QV 6XSSRUW 4 23 The optional program module QC07 OPF41 extends the functionality given by the basic system program module with functions listed below QC07 OPF41 adapts the Advant Controller 450 to an Advant Workplace and IMS Station or a MasterView 800 1 operator station 7DEOH GGLWLRQDO 3 OHPHQWV LQ 3URJUDP 0RGXOH 4 7 SH XQFWLRQ 3 HOHPHQW Elements for functional units Contain two variants of advan...

Page 64: ... the possibility to define your own library of user defined PC elements The user defined PC element is created in the Advant Station 100 Series Engineering Station and built up of a combination of normal PC elements found in the standard PC elements libraries of the Advant Controller 450 After the user defined PC element is installed in the Advant Controller 450 it can be used freely in all PC pro...

Page 65: ... external synchronization of the calendar clock RQILJXUDWLRQ You configure the system in accordance with the hardware and software selected for example the number of I O boards communication lines functional units and PC programs This is performed using commands from a configuration tool such as the Advant Station 100 Series Engineering Station and results in the internal organization and activati...

Page 66: ...a slave processor unit in Advant Controller 450 It is used to execute application programs written in the high level language C With respect to its function such a program is a part of the main application program PC program PU535 communicates with the PC program via a number of special PC elements These elements are used for control of the application program on PU535 and for data exchange betwee...

Page 67: ...er supply in cabinets with a controller subrack and three I O subracks Figure 1 13 shows an alternative with redundancy Supply from a c mains supply including use of the optional mains supply C is illustrated A d c alternative only differs in the use of alternative power supply units Depending on differing needs for circuit breaker capacity there are different types of power switch and distributio...

Page 68: ...24V A 24V B 24V A 24V B 24V distr Power supply for field equipm LIVE Test Rw Pw Tw F 2V 5V BF F IP FC BP Run P Rx Tx SR511 Power supply Power switch 24V distribution Controller subrack Regulator Power distr Expansion Power distr Expansion MFb modem Modem subrack Fan unit Supervision Backup power supply 2V 5V 24V 0V Battery DSSR 122 I O subrack 1 Regulator Power supply for I O rack I O subrack 2 I ...

Page 69: ...B 24V A 24V B SA1XX I O 4 o 5 Field equipment SA16X I O 2 o 3 LIVE Test LIVE Test Rw Pw Tw F 2V 5V BF F IP FC BP Run P Rx Tx A B B A Fail Fail Live A B PBC 24V Fail Live Diagnostics Diagnostics B A SR511 Modem subrack 2V 5V 24V 0V Supervision Power supply Power switch Controller subrack 24V distr I O subrack 3 I O subrack 2 Power supply for I O rack Fan unit Power distr Power switch Power supply 2...

Page 70: ... SX542 SX542 SV543 SV542 Mains C category III 2 SV541 SV540 SV543 SV542 3RZHU 6XSSO Controller I O subrack 1 SA167 SA168 SD150 DSSB 170 SD150 2 SA167 2 SA168 2 SD150 2 SD150 I O subrack 2 SA161 SA162 2 SA161 2 SA162 I O subrack 2 and 3 SA167 SA168 2 SA167 2 SA168 I O subrack 4 SA161 SA162 2 SA161 2 SA162 I O subrack 4 and 5 SA167 SA168 2 SA167 2 SA168 Power supply units for field equipment 24 V d ...

Page 71: ...and the I O installation that is the hard related cabinets Variants can exist Please refer to the actual delivery documentation for further information 3RZHU 6XSSO The power supply units provide the regulators in the subracks with 24 V unstabilized d c voltage They can also be used to supply other circuits which do not require stabilized 24 V voltage such as sensors indicators and so on There are ...

Page 72: ...ocation in a controller subrack The regulator module SR511 is intended to be installed from the front side of the controller subrack Redundancy is achieved by adding an extra module n 1 redundancy You can equip an I O subrack with a single voltage regulator DSSR 122 or redundant regulators of the type DSSR 170 The number of DSSR 170 is always three two of which are needed with respect to capacity ...

Page 73: ...ackplane Cable 0 V to DSSR 122 and backplane Cable 24 V to DSSR 122 for connection of 24 V Input fuse F1 for the regulator Rear of subrack DSSR 170 L F I V E A I L DSSR 170 L F I V E A I L DSSS 171 DSSR 170 L F I V E A I L X9 X4 X6 X7 X2 X1 L F I V E A I L A B PBC X8 Voting Unit 666 Regulator 1 3 665 Backplane DSBB 188 Fuses Fuse Connections OWHUQDWLYH DW 5HGXQGDQF Regulator ...

Page 74: ...it SB511 connected to a 24 V or 48 V external battery system Isolation is provided by SB511 Max input power to the backup power supply is 25 VA The resulting backup time at for example 24 V is then better than 1 5 h per 1 Ah external battery capacity single processor module or 1 h per 1 Ah external battery capacity redundant processor modules The internal battery SB522 must be in position to get t...

Page 75: ...buted too by using an optical S100 bus extension This facilitates for example the location of I O cabinets close to a remote switch gear It is of course possible to mix the different I O systems in the same application if you wish This manual gives an overall presentation of the I O systems Since the I O systems are common to several Advant Controller products the detailed information is collected...

Page 76: ...ing units which are described in principle below S100 I O External signal cable Connection unit Internal cable I O board Bus extension to S100 I O Internal system bus S400 I O External signal cable I O unit MasterFieldbus LDB long distance bus Bus cable Modem MasterFieldbus SDB short distance bus Modem Connection Unit TC570 Communication module for MasterFieldbus Internal system bus S800 I O Exter...

Page 77: ...v A 1 47 LJXUH QSXW DQG 2XWSXW 6LJQDO 3DWKV LQ SULQFLSOH Processor Internal system bus FB Comm module I O board Connection unit Parallel data bus Bus extension max 12 m 39 ft el RQWUROOHU VXEUDFN 2 VXEUDFN 6 2 max 500 m 1640 ft opto DSBC 174 module S100 I O interface DSBC176 ...

Page 78: ...el max 3000 m 9842 ft opto 6 2 RQWUROOHU VXEUDFN Comm module CI570 Processor module Internal system bus FB SDB FCI Modem Modulebus Twisted pair media max bus length of the configuration 1700 m 5500 ft 6 2 RQWUROOHU VXEUDFN Comm module CI522A Processor module Internal system bus CI810 Advant Fieldbus 100 TC512V1 2 LQWHUIDFHV RQ D 1 UDLO FCI Fieldbus Communication Interface I O module I O module Mod...

Page 79: ...dually or group by group to isolate the I O channels from the process for fault tracing and test measurements Circuits for interference suppression fuses and for analog inputs a shunt resistor are located on the connection unit The shunt resistor is located so that you can replace an analog input board without breaking any current loops A connection unit relates to an I O board in different ways T...

Page 80: ...ards are joined by prefabricated cables Ribbon cable is used to connect I O boards intended for currents under 1 A and voltages under 60 V Shielded cable is used for signals particularly sensitive to interference LJXUH SSOLFDWLRQ RI 2EMHFW 2ULHQWHG RQQHFWLRQ RI 6 2 6 6 2 I O boards Connection cable MCB Fuses Terminals Mounting bar DI DI DI DO M Contactor Ready Run Trip 8 objects per row Up to 8 ro...

Page 81: ...nits are divided into the following groups Digital basic units Digital expansion units Analog units You can connect process cables directly to the I O unit s terminal blocks You can exchange an I O unit while the system is running You can also install new I O units live provided they are predefined in the data base A newly inserted I O unit is taken into operation within 10 seconds 2 0RGXOH 6 2 An...

Page 82: ...elivered in separate cabinets You are referred to the separate documentation QWULQVLF 6DIHW 6XSSRUW IRU 6 2 6 VWHP 57 QWHUIDFH 6 2 Intelligent transducer using the Highway Addressable Remote Transducer protocol HART may be applied in an Advant Controller 400 installation utilizing the S100 I O System External products and a PC compatible complement the Advant Controller thus making an integrated s...

Page 83: ...ion supporting HART and its integrated HART configuration tools are conditions for this function HART specific data is not available in Advant Controller 450 which is acting as a router between the S800 I O modules and the HART configuration tool The principle is illustrated in Figure 1 21 LJXUH 3ULQFLSOH RI 57 LPSOHPHQWDWLRQ XVLQJ 6 2 Advant Engineering Workplace with HART configuration tool that...

Page 84: ...ll digital inputs are opto isolated from the system potential Grouping of channels with respect to isolation can exist See information given with the actual board type and connection unit type You can select the mode of data base updating either by interrupts or by scanning The scan cycle times are normally selected from the range 10 ms to 2 s Some boards offer pulse extension for example to avoid...

Page 85: ...pt 24 V d c 4 x DSTD 196 1 This connection unit provides 48 V d c over open sensor contact DSTK 226L3 DSDI 110AV1 32 4 x 8 channels 24 V d c controlled by scanning or interrupt 24 V d c 4 x DSTD 196P 2 This connection unit provides 48 V d c over open sensor contact DSTK 226L3 DSDI 110A 32 4 x 8 channels 24 V d c controlled by scanning or interrupt Variants below provide object oriented connection ...

Page 86: ...ls 48 V d c controlled by scanning or interrupt DSTD 150A DSTD 190 DSTK 221L3 DSDI 120AV1 32 channels 48 V d c controlled by scanning or interrupt DSTD 150A DSTD 190V1 DSTK 221L3 1 Optionally you can combine the connection units DSTD 195 DSTD 196 DSTD 197 and DSTD 198 for their respective board 2 Optionally you can combine the connection units DSTD 195 DSTD 196P DSTD 197 and DSTD 198 for their res...

Page 87: ...SDO 115 32 channels 24 V d c Variants below provides object oriented connection to DSDI 110A and DSDO 115 various rated input voltages 24 V d c DSTD 145 120 V a c DSTD 147 230 V a c DSTD 148 These connection units include 8 relay outputs each 24 250 V a c d c max 3 A DSTK 226L5 DSTK 226L5 DSTK 226L5 DSDO 115A 32 channels 24 V d c Variants below provides object oriented connection to DSDI 110AV1 an...

Page 88: ...ieve increased availability A board is offered which combines analog inputs and analog outputs loop dedicated I O QDORJ QSXW IRU 3W 0DLQ 3RLQWV Different temperature ranges for optimization of measurement accuracy A 13 bit resolution unit is available This very high resolution requires special precautions when it comes to cabling The unit can optionally be used with 12 bit resolution DSDO 115A 32 ...

Page 89: ...s Optional software filtering and deadband limits for updating can be selected QDORJ QSXW RDUG 7 SHV Table 1 15 presents available analog input boards 7DEOH QDORJ QSXW RDUGV RDUG W SH HVFULSWLRQ RQQHFWLRQ XQLW DEOH DSAI 130 16 channels differential inputs resolution 12 bits sign 0 to 10 V 0 to 5 V 0 to 2 5 V 0 to 1 25 V or 0 to 20 mA 0 to 10 mA 0 to 5 mA 4 to 20 mA elevated zero obtained by SW shu...

Page 90: ...SW shunt 250 Ω 0 1 CMV 50 V DSTA 138 provides object oriented connection to DSAI 130A and DSAO 130A DSTK 150 DSAI 133 32 channels directly grounded inputs single ended transducer supply fused channel by channel resolution 12 bits unipolar 0 to 10 V 0 to 5 V 0 to 20 mA 4 to 20 mA elevated zero obtained by SW shunt 250 Ω 0 05 2 x DSTA 002A DSTK 222L3 DSAI 133A 32 channels directly grounded inputs si...

Page 91: ...DORJ RXWSXW Eight channels resolution 12 bits unipolar 0 to 20 mA 4 to 20 mA elevated zero obtained by SW 0 to 10 V over shunt 500 Ω 0 1 on DSTA 001A DSTA 001A DSTK 223L3 DSAX 110A QDORJ LQSXW Eight channels directly grounded inputs single ended resolution 12 bits unipolar 0 to 10 V or 0 to 20 mA 4 to 20 mA elevated zero obtained by SW shunt 250 Ω 0 05 QDORJ RXWSXW Eight channels resolution 12 bit...

Page 92: ...ucer actuator Figure 1 25 illustrates an application with redundancy LJXUH QDORJ QSXW 6LJQDO ORFN LDJUDP LJXUH QDORJ QSXW 2XWSXW 6LJQDO ZLWK 5HGXQGDQF ORFN LDJUDP 3URFHVV Process 6LJQDO DGDSWDWLRQ XQLW Connection Analog input board RQWUROOHU Test point X3 VRIWZDUH transducer Program Data base unit Inputs Outputs Board 1 Trans Connection Unit Program 3URFHVV 6LJQDO GDSWDWLRQ 8QLW RQWUROOHU Actuator...

Page 93: ... 12 bits incl sign 0 to 10 V or 0 to 20 mA 0 to 10 mA 4 to 20 mA elevated zero obtained by SW galvanic isolation channel by channel DSTA 160 DSTK 223L3 DSAO 120 Eight channels resolution 12 bits incl sign 0 to 10 V or 0 to 20 mA 4 to 20 mA elevated zero obtained by SW DSTA 170 DSTK 223L3 DSAO 120A Eight channels resolution 12 bits incl sign 0 to 10 V or 0 to 20 mA 4 to 20 mA elevated zero obtained...

Page 94: ...AX 110A QDORJ LQSXW Eight channels directly grounded inputs single ended resolution 12 bits unipolar 0 to 10 V 0 to 20 mA 4 to 20 mA elevated zero obtained by SW shunt 250 Ω 0 05 QDORJ RXWSXW Eight channels resolution 12 bits unipolar 0 to 20 mA 4 to 20 mA elevated zero obtained by SW 0 to 10 V over shunt 500 Ω 0 1 on DSTA 001 DSTA 001B DSTK 223L3 2 x DSAX 110 Redundant coupling Data otherwise the...

Page 95: ...HQF 0HDVXUHPHQW RDUG 7 SHV Table 1 17 presents available boards LJXUH QDORJ 2XWSXW 6LJQDO ORFN LDJUDP 7DEOH 3XOVH RXQWLQJ UHTXHQF 0HDVXUHPHQW RDUGV RDUG W SH HVFULSWLRQ RQQHFWLRQ XQLW DEOH DSDP 150 12 channels 5 12 24 V d c max 10 kHz DSTD 150A DSTD 190 DSTK 225SL3 DSDP 170 Four measurement systems each containing inputs for pulse generator Two channels and strobe 5 12 24 V or 13 mA max 2 5 MHz DI...

Page 96: ...rection Filter 8 bit counter LUFXLW ERDUG RQWUROOHU VRIWZDUH Program Data base Pulse board Pulse RQQHFWLRQ XQLW RDUG 6 3 RQWUROOHU VRIWZDUH Discrimination level 5 12 or 24 V Function selector Channel 1 Channel 2 Signal adaptation 16 bits counter Internal data exchange Q 3 HOHPHQW Function selector Reading and calculation Frequency calculation Error supervision Number of pulses Frequency measuremen...

Page 97: ...e heading RQYHUWHU RQQHFWLRQ RQYHUWHU RQQHFWLRQ RDUG 7 SHV Table 1 19 presents the available board 7DEOH 3RVLWLRQLQJ RDUG RDUG W SH HVFULSWLRQ RQQHFWLRQ XQLW DEOH DSDP 140A One positioning loop input for pulse generator three channels 15 mA max 80 kHz DI DO 24 V d c AO Resolution 11 bits sign 0 to 10 V or 0 to 20 mA DSTD 150A DSTD 190 DSTK 225SL3 7DEOH RQYHUWHU RQQHFWLRQ RDUG RDUG W SH HVFULSWLRQ ...

Page 98: ...0 data base and transferred to the unit at start up Normal operation is resumed when the connection is re established 6 2 8QLWV 2XWOLQH HVFULSWLRQ A basic S400 I O unit for binary signals has 32 channels You can expand it with another 32 channels by adding an expansion unit Analog units have 20 channels and cannot be expanded Basic units are ready for direct connection to MasterFieldbus Expansion ...

Page 99: ...720 VA with cosϕ 0 4 d c max 44 44 W with L R 40 ms Relay data for units with L outputs for low current Loading min 1 mA but min 0 05 VA max 200 mA but max 5 VA Breaking capacity a c max 200 mA or 5 VA with cosϕ 0 4 d c max 200 mA or 5 W with L R 40 ms LJLWDO H SDQVLRQ XQLWV DSDX 451 DSDX 451L DSDX 453 DSDX 453L DSDI 451 DSDI 453 DI DO Supply DI Supply 20 channels 24 V d c for DSDX 451 and DSDX 45...

Page 100: ...e user These safe values are set in the Advant Controller 450 data base and transferred to the unit at start up Normal operation is resumed when the connection is re established 0HFKDQLFV The mechanics components of the S800 I O are characterized by the following features Highly modularized mechanics with four basic parts Communication Interface modules or Field Communication Interface module Opti...

Page 101: ... outlet connector to connect to a MTU A MTU has a bus inlet and a bus outlet connector By adding on the DIN rail a MTU to a communication interface module or an Optical Modulebus modem the bus is automatically expanded offering optional further expansion of MTUs to a maximum of 12 MTUs Unique position codes are automatically assigned to each MTU as the bus is expanded An inserted I O module is ass...

Page 102: ...can be inserted removed without interrupting AF 100 communication between other stations The single PROFIBUS FCI module have one connector and built in modems for PROFIBUS twisted pair cables a connector for the Modulebus Optical port module and galvanically isolated RS 232 service port to allow trouble free tools connection The front plate of the FCI modules provides LEDs for diagnostic and statu...

Page 103: ...rning LED and channel status set to error 120 250 V and modules with intrinsically safe interface modules have individually isolated channels The input module can be configured to monitor field power status Outputs do not need external inductive load suppression components 7DEOH 6 LJLWDO 0RGXOHV 0RGXOH W SH HVFULSWLRQ DI810 Digital Input 24 V d c 2 x 8 channels Current sink Rated isolation voltage...

Page 104: ... channels Rated isolation voltage 50 V DO820 Digital Output Relay 8 x 1 channels 24 230 V a c 3 A cos ϕ 0 4 Normal Open d c 42 W Varistor protected Rated isolation voltage 250 V DO821 Digital Output Relay 8 x 1 channels 24 230 V a c 3 A cos ϕ 0 4 Normal Closed d c 42 W Varistor protected Rated isolation voltage 250 V DO890 Digital Output Intrinsically safe interface 4 x 1 channels Rated isolation ...

Page 105: ...Input 1 x 8 ch Pt100 80 80o C 200 250o C 200 850o C Ni100 60 180o C Ni120 80 260o C Cu10 100 260o C Resistor 0 400Ω 14 bit Rated isolation voltage 50 V AI835 Analog Input 1 x 8 ch Termo Couples TC type B 0 1820o C type C 0 2300o C type E 270 1000o C type J 210 1200o C type K 270 1372o C type N 270 1300o C type R 50 1768o C type S 50 1768o C type T 270 400o C linear 30 75 mV 14 bit Rated isolation ...

Page 106: ...up wise or individually fuses maximum 6 3A glass tube type for powering field objects Extended MTUs which offer two or three wire terminations allows direct field object cable termination The need for external marshalling is therefore drastically reduced or eliminated when extended MTUs are used AO890 Analog Output with Intrinsically safe interface 1 x 8 ch 0 4 20 mA 12 bit 0 1 Rated isolation vol...

Page 107: ...nals and one row of 5 pcs L Rated isolation voltage 50 V Conductor area 0 2 2 5 mm2 AWG 24 12 TU811 Compact MTU 58 mm wide 2 x 8 uncommitted terminals Rated isolation voltage 250 V Conductor area 0 2 2 5 mm2 AWG 24 12 TU812 Compact MTU 58 mm wide 25 pin D sub Connector for field connection Rated isolation voltage 50 V TU814 Compact MTU 58 mm wide Crimp Snap in Connectors for field connection Rated...

Page 108: ...or power status in 1 1 redundant mains configurations TU836 Extended MTU 120 mm wide Two isolated groups with one row of 4 uncommitted terminals individually fused 3 A one row of 4 uncommitted terminals 2 pcs L and 2 pcs N terminals Rated isolation voltage 250 V Conductor area 0 2 2 5 mm2 AWG 24 12 TU837 Extended MTU 120 mm wide 16 individually isolated terminals 8 ch each channel has one process ...

Page 109: ...otary switches is used for setting of the cluster address Labels for optional user text and item number are also provided 0RGXOHEXV 2SWLFDO 3RUW The Modulebus Optical port have connectors for optical cables and connector for connection to the communication interface module 7DEOH 3RZHU 6XSSOLHV 0RGXOH 7 SH HVFULSWLRQ SD811 SD811 Power Supply 100 240 V a c 185 250 V d c 24 V d c 2 5 A Rated isolatio...

Page 110: ...ple Access Collision Detection medium access control In short this means that there is no specific master station but all stations controllers have equal access to the bus A connection oriented transport protocol according to ISO class 4 ensures flow control and reliability Use MasterBus 300E Extended when communicating via bridges and radio links satellites and so on to interconnect MasterBus 300...

Page 111: ...M to achieve full redundancy XV WHQVLRQ WR 6 2 The processor module and optional communication boards are located in a controller subrack This cannot accommodate any process I O One way you can connect such I O is to use I O subracks With an electrical bus extension the I O subracks can be located close to the controller subrack For increased availability you can duplicate CPUs bus extension and c...

Page 112: ...100 I O In addition it also connects local processing units such as MasterPiece 90 MasterPiece 51 and converters for motor drives TYRAK L or SAMI to Advant Controller 450 You can connect several buses to one Advant Controller 450 and each bus can take up to 16 remote units LJXUH DPSOH LQFOXGLQJ 1RQ UHGXQGDQW 2SWLFDO XV WHQVLRQ PM511 Controller subrack DSBC 176 I O subrack 1 Modem TC560V01 Modem TC...

Page 113: ...his speed is used for example when communicating with MasterPiece 90 For increased availability you can duplicate the cables and modems physical redundancy Figure 1 33 gives an example of a physical configuration LJXUH DPSOH RI 3K VLFDO RQILJXUDWLRQ RI 1RQ UHGXQGDQW 0DVWHU LHOGEXV DQG 6 2 8QLWV Modem DSTC452 Bus controller CI570 TC570 Distr unit Modem DSTC454 Exp unit Modem DSTC452 Modem DSTC452 M...

Page 114: ...f one or several controllers are lost the bus is not affected and operations continue Three types of transmission media coaxial cable twisted pair cable and optical fibre are supported The maximal bus length is depending on which transmission media is used For increased availability you can duplicate the cables and modems physical redundancy or for full redundancy also duplicate the bus interface ...

Page 115: ...pair termination AC 70 S800 I O Station AC 450 CI522A PM810V1 TC516 External Device Advant Fieldbus 100 TT TT TC515V2 CI820 TT TT AC 70 TT TT TT TT TT CI820 TB815 I O Modules Grounded twisted pair termination TT AC 110 CI626 Optical media Coaxial media Coaxial media 75 Ohm BNC termination Twisted pair media AC 450 CI522A AC 110 CI626 AC 70 PM810 TC512V1 TC513 TC630 TC630 CT CT CT CT TT TT CT S800 ...

Page 116: ...ed and inexpensive hookup It features reliable cyclic data transfer PROFIBUS DP is designed especially for communication between automation control systems and distributed I O at the device level Network Configurations Up to 125 slave nodes can be connected to one bus Up to eight buses can be configured in an Advant Controller 450 Figure 1 37 PROFIBUS DP configuration example AC 400 Series or AC 1...

Page 117: ...st and very low per node cost It features event handling and reliable cyclic data transfer Network Configurations Up to 128 supervised devices can be connected to one bus Meaning that more devices can be connected to the bus but can not be supervised by the Advant Controller 450 Up to eight buses can be configured in an Advant Controller 450 Figure 1 38 LONWORKS network configuration example AC 40...

Page 118: ... a MasterBus 5 20 2XWOLQH HVFULSWLRQ RCOM Remote COMmunication enables Advant Controller 450 to communicate transmit data to other units over long distances via a serial V 24 RS 232 C asynchronous communication bus You can connect the following Advant OCS product lines and alien equipment to the Advant Controller 450 Advant Controller 50 series Advant Controller 100 series Advant Controller 400 se...

Page 119: ...Q MultiVendor Interface MVI is communication with other manufacturers control systems The following MVI protocols are available as standard MODBUS Siemens 3964 R Allen Bradley DF1 In addition there is an MVI free programmable communication interface which you can use to support user defined protocols This function enables you to connect intelligent transducers of different types to an Advant Contr...

Page 120: ...OS MasterBus 300 300E E S C Advant Station 500 Series IMS MasterBus 300 300E E S C Advant Station 500 Series ES MasterBus 300 300E MasterPiece 200 1 MasterBus 300 300E RCOM R I B EA MasterView 800 1 MasterBus 300 300E E S C MasterBatch 200 1 MasterBus 300 300E MasterGate 230 1 MasterBus 300 300E E S C Advant Station 100 Series IMS GCOM E S C SuperView 900 GCOM E S C AdvaSoft for Windows GCOM R I B...

Page 121: ...Advant Controller 70 Advant Controller 450 sends the information to operator stations for presentation in lists High accuracy in time also indicates handling of time stamped events Events originated in certain distributed units are time stamped in the Advant Controller 450 Time delay due to communication must be reflected When Data Set is used a supporting application program is needed in the Adva...

Page 122: ...ABB Master Programming Language AMPL a function block language with graphic representation which has been developed especially for process control applications The language is characterized in this way each function is seen as a building block with inputs and outputs The function of such a block can be simple such as a logic AND function or complex such as a complete PID regulator A program writte...

Page 123: ...rcuits that is control solutions that are repeated frequently in an application area or in a specific application project For instance a type circuit may comprise all the functions required to control motors of a certain type or pumps valves temperature loops and so on including all the necessary controller data base definitions for I O and operator communication LJXUH DPSOH RI XWRPDWLF 03 RFXPHQW...

Page 124: ...e illustration in Figure 1 41 By designing your application with user defined PC elements you are gaining Significant reduction in translation time Memory saving with reuse Similar documentation in Function Chart Builder and On line Builder User defined PC element hierarchy Reduced man hours in commissioning and maintenance LJXUH 3URFHVV 2EMHFWV PSOHPHQWHG DV 8VHU HILQHG 3 OHPHQWV SR VALVEC OR AND...

Page 125: ...signals available in the data base are linked to the AMPL application program LJXUH 6LPSOH RQWURO XQFWLRQ 5HDOL HG LQ 03 DSDO 120 DO1 TYPE NAME START PC program DI 1 1 START DI 1 2 CONDI TION DI 1 3 STOP PC element D 10 DO 1 1 START M1 START M1 Switch gear Protection DB element defining board signals DI 1 DO 1 1 IV IV S R T DSDI 110 TYPE NAME DI1 1 ...

Page 126: ...n requiring an advanced face plate for the operator You can use several functional units in combination The functional units are also used individually Examples of this can include a measuring circuit with alarm activation deactivation and display screen presentation or a simple command function from the operator to the process You can freely combine the functional units with other PC elements Fig...

Page 127: ...lean functions Composite Boolean functions On off delay pulse generation 6HTXHQFH RQWURO General structuring functions Sequence control influenced by standard IEC 848 DWD DQG 7H W DQGOLQJ You can arrange text strings to be presented on the operator station display screen or used in event printouts DOHQGDU 7LPH XQFWLRQV Date and time can be used when an automatic function shall be started or when a...

Page 128: ... OFF with pulsed control At low speed the output signal is not constant but is pulsed forward to the correct position with pulse lengths varying with the deviation from the correct position Functions on the board are supervised by means of self testing Faults are indicated by the illumination of LEDs on the board For a detailed explanation of the positioning system see the manual 3RVLWLRQLQJ 6 VWH...

Page 129: ...ther Advant Controller on the control network Advant Controller 450 has a REPORT PC element which makes it possible to initiate a hard copy printout of a display in an operator station The printouts can be made upon operator demand event driven and cyclic The print out of application information that is data base lists and PC program diagrams is done on a printer connected to the configuration too...

Page 130: ... you to perform excellent analyses of cause and effects in complex situations Events can be defined further as alarm points The operator s attention can be drawn by audible signal or a flashing light requiring acknowledgment Such handling can be built up in an application program with the support of the powerful FAULT element An operator station which is part of the MasterView 800 1 or Advant Stat...

Page 131: ...e inputs Differentiation either of the measured value or the control deviation Parameter scheduling Forcing control of the output signal Limitation of set point and output with respect to amplitude and rate of change Limit supervision with event and alarm handling Powerful operator interface Self tuning and adaptive PID algorithm It is easy to combine such a loop controller with supplementary func...

Page 132: ...drive systems is made via Advant Fieldbus 100 Each fieldbus node connects up to 24 drives through an optical ring Information from the drives Process values are sent as cyclic data with an updating frequency decided by the application engineer The data enables the control system to have access to basic information such as speed current torque and diagnostic information Information from the control...

Page 133: ...ocess control For further information see the appropriate operator station documentation The main areas of support from Advant Controller 450 are summarized as follows Object data base Alarm and events Group Alarm Reports Trend Data Storage Status List System Status List 2SHUDWRU V QWHUIDFH Advant Controller 450 offers a range of interfaces to operators of different categories A short presentation...

Page 134: ...oller 450 You can connect two MasterView 320 terminals You can create and present process displays in each MasterView 320 terminal Each display can include both static and dynamic information The static information that is those parts of the display which remain the same during operations consists of an optional number of text strings Dynamic variables with optional appearance which are presented ...

Page 135: ...rd displays curve displays and reports An effective operator s dialog for manual control Alarm and event presentation Presentation of the status of the control system Display design on line directly on the display screen Handling of group alarm Presentation of the status of signals Presentation of trend curves The central operator station communicates with the application program and the process i...

Page 136: ...on 1 7 8 3 Control Functions under the heading Reports The printer requirement specification is given in Section 3 2 6 3 Printer YDLODELOLW DQG 6HFXULW Many factors affect the reliability and availability of a control system Redundancy is perhaps the first thing to reflect upon but it is never the most important factor Basic system properties of the Advant OCS are in general more important Advant ...

Page 137: ... unintentional interrupts is very important Advant OCS has a straightforward philosophy all process outputs are controlled to zero loss of elevated zero and relay outputs are de energized Unintentional interrupts are caused for example by the following events Fault in central processing unit and memory Loss of power supply Fault in power supply Fault in parallel bus communication backplane bus on ...

Page 138: ...cs support the maintenance philosophy of fault isolation and replacement down to module or subassembly level A survey of the fault announcement in Advant Controller 450 follows The diagnostics built in to different modules and system functions are mentioned briefly You can also find more information on LED indications and so on in connection to module descriptions For a detailed description of the...

Page 139: ...WDWXV If the controller is included in a control network with a central operator station such as Advant Station 500 Series Operator Station or MasterView 800 1 the following facilities apply System messages Give information about probable cause of malfunction in coded form or plain language System status displays showing fatal or non fatal errors in Controller total function Redundant functions Pr...

Page 140: ...iagnostics and error handling For further information on this topic see Chapter 5 Maintenance LDJQRVWLF RI 3RZHU 6XSSO Supervision of the internal 24 V supply and the stabilized 5 V supply Applicable supervision of power supply for sensors Supervision of the battery backup supply 2WKHU LDJQRVWLFV DQG UURU DQGOLQJ Adequate diagnostics and error handling are also available possible for the following...

Page 141: ...ouncement and adequate unit exchangeability 0DLQV LVWULEXWLRQ 1HWZRUN Redundant a c networks or a combination of an a c network and a d c network are primarily connected to separate circuit breakers and power supply units Secondarily at 24 V level the two networks are wired by diodes The controller always needs an a c supply for use by certain external equipment such as modems In the case of redun...

Page 142: ...module is acting as primary the other is backup hot stand by The primary processor module controls the process The backup stands by to take over in case of a fault in the primary The changeover is done bumplessly and in less than 25 ms During the changeover the process outputs are frozen Following a changeover the system operates as a system without redundancy with only one processor module in ope...

Page 143: ...og buffer in the backup unit At a rollback point the processor s total register contents are also written into the data memory so that this information is also logged Once the rollback point is established the logged write operations are transferred to the backup unit s data memory If the primary unit fails because of an error the backup unit resumes execution from the last rollback point which me...

Page 144: ...and by implementation This means that the primary network has the communication responsibility The secondary network stands by to take over in case of a fault in the primary network In the stand by mode of operation basic messages for diagnostics are continuously sent and received 20 The information given above for the network communication is also applicable to GCOM except for the communication s...

Page 145: ...xists when any of the primary bus extenders is detected as faulty the faulty primary bus extender is marked as erroneous and a system message is presented You can replace the malfunctioning bus extender when the system is running If an error arises in a backup bus extender you can also replace the backup unit while the system is running Errors which occur in the backup unit can never affect the pr...

Page 146: ...DELQHWV YDLODEOH DELQHW 7 SHV An Advant Controller 450 is normally installed in one or several cabinets depending on the number of centrally connected process I O signals The cabinet type is RM500 and it is available in two versions with different dimensions RM500V1 and RM500V2 Single as well as double cabinets are used to house an actual installation or a combination of single double cabinets not...

Page 147: ...es the 19 inch installation width Entrance to the rear of the cabinet is not necessary Controller hardware is physically installed and electrically connected from the front Certain equipment like the S100 I O subrack is mounted in a hinged frame in the cabinet This enables entrance and possible maintenance and repair of parts of the subrack which are only accessible from the rear for example units...

Page 148: ...ations for example a heat exchanger can be installed OHFWUR 0DJQHWLF RPSDWLELOLW DQG PDUNLQJ Advant Controller 450 meets the requirement specified in EMC Directive 89 336 EEC and in Low Voltage Directive 73 23 EEC provided appropriate cabinetry is used You should request for compliance and CE marking when you order the equipment You can obtain CE marking for all standard cabinets For further infor...

Page 149: ...bracks connection units and power supply equipment is standardized However the design is always adapted to the actual application and shown in the delivery specific documentation All units in the cabinet are identified in accordance with the item designation system used for the Advant OCS products See Appendix D Item Designations LJXUH 7 SLFDO DELQHW PLQLPXP RQILJXUDWLRQ 5HGXQGDQW 3RZHU 6XSSO Main...

Page 150: ... with a locking device All connections are made from the front 2 6XEUDFN The controller subrack cannot accommodate any I O boards If S100 I O is desirable you must expand the system with one to five I O subracks An I O subrack can contain up to 20 19 in case of S100 I O Bus Extension redundancy I O boards plus one or two bus extension boards which has both voltage supervision and bus extension fun...

Page 151: ...e rear of the subrack A connection unit with screw terminal blocks for field connection of the process signals is provided for each I O board You can usually disconnect process objects individually or in groups with a disconnectible type of terminal block The connection units are connected to the I O board via standard cables and are mounted in the rear plane of the cabinet LJXUH URQW RI 2 6XEUDFN...

Page 152: ...A The rear side of an I O subrack must be accessible This is achieved by mounting the I O subrack in a hinged frame LJXUH 2 6XEUDFN RQILJXUDWLRQ Connection to the process Connection cable Mounting bar for connection units Backplane for parallel communication bus Plug in units ...

Page 153: ...submodule This means you can insert start stop and remove the one submodule without affecting the other submodule The submodule carrier is a single point of failure Damaging the carrier module may affect one or both submodules Replacing the carrier module however obviously affects both submodules Mechanically any submodule fits into any submodule position on Advant Controller 450 The software does...

Page 154: ...spect to their applications Operator s interface for process control Operator stations Mimic panels Printer User interface for the controller seen as a computer resource System maintenance These different facilities are presented in the product overview description see Section 1 7 9 Operator s Interface The user interface application is described in detail in Chapter 4 Runtime Operation and in Cha...

Page 155: ...ation and a requirement is clearly defined as necessary Installation of options is often described in dedicated user s guides For information about available documents corresponding to desired options see Section 1 4 Related Documentation All information given in this chapter relates to standardized models Where alternatives exist a typical alternative is described 2 1 Site Planning Environment 2 ...

Page 156: ...ressed by a suitable solid design and particular installation rules Equipment is to be located in a control room or an electric room or distributed in the process area The common requirements for the building where the system is to be stored or installed are NOTE The building should provide an environment such that established environmental conditions are not normally exceeded The environmental co...

Page 157: ...n a stable floor deck or supporting structure free from vibrations If the system equipment is installed in a control room adjacent to large machinery such as shakers or large presses where frequent major vibrations occur shock absorbers or an isolation pad may be required to protect the system equipment Shock absorbers normally protect the equipment from sustained low level vibrations vibrations t...

Page 158: ...inet if separated Standard cabinet RM500 is EMC proof in its basic design for protection class IP21 IP41 and IP54 Open compartment is not permitted for any part of the controller and its I O including distributed connection units Immunity against electromagnetic fields can generally be guaranteed with the cabinet containing metallic doors only Arrangement of Cabinets Advant OCS mounted in a RM500 ...

Page 159: ...Up to six cabinets for example three double cabinets for the five possible I O subracks can be connected to the same electrical bus extension With optical bus extension other rules are applied You can add an extra seventh cabinet if necessary to house connection units This cabinet is placed to the right and cannot contain an I O subrack Cables with extended length have to be used from the I O subr...

Page 160: ...he same double single cabinet that houses the corresponding I O subrack Distributed Location of S100 I O Cabinets With an optical bus extension you can distribute the I O cabinets up to 500 m from the controller cabinet The configuration of distributed cabinets is illustrated in Figure 2 2 Normal start configuration is a double cabinet The building direction is to the right Figure 2 2 Distributed ...

Page 161: ...uble cabinet for the connection units and a single cabinet for the I O subrack Split delivery is possible You can obtain information about deviations from these rules upon request Figure 2 3 S100 I O with Object Oriented Connection Units Example of Cabinet Configuration PS I O 1 SW Mains PS I O 1 I O 2 SW Mains PS I O 1 I O 2 SW Mains PS I O 3 SW Mains Opto El alt Bus Extension Ex 1 subrack Ex 2 s...

Page 162: ...s normally most effective to ground the signals from transducers directly in the grounding bar in the Advant Controller For freedom from interference it is also advantageous to ground supply voltages for transducers sensing voltage for contacts load supply voltage and so on You may have to deviate from these two basic rules in order to adapt to other requirements such as measurement techniques or ...

Page 163: ...nt can be obtained from the plant a c or d c supply A summary of the main requirements of the supply from a planning viewpoint follows Primarily an A B and C network should be available as applicable Supply A and B refer to redundant networks Supply C is feeding the battery backup unit and modems which use a c power supply In the tropical cabinet version the heating element is also included Supply...

Page 164: ...ble 1 11 Single and return class II as well as two phase class III connection of a standard controller are possible d c Supply Essential information includes When using a d c supply only battery supplied systems with a non grounded battery can be used for direct supply of Advant OCS With this type of supply the battery is grounded in the Advant OCS equipment Supply from a grounded battery requires...

Page 165: ...h a connection unit and the signals are distributed by dividing the cables entering the cabinet and connecting the separate conductors to different I O board s connection units You can install delivery adapted cross couplings in the cabinet making it convenient to use the connection units as the board oriented half of the cross coupling As an alternative there is a series of connection units for o...

Page 166: ... the voltage supply and the neutral from the controller or marshalling The costs of cable and cable installation work can often be reduced by routing a multi core cable to coupling boxes mounted nearby from which cables can be connected to individual objects More detailed voltage distribution and object fusing is possible in a coupling box than in a connection unit The fusing used in the connectio...

Page 167: ...trial installations and power plants are normally provided with well integrated grounding nets installed together with the power distribution system In installations with such grounding systems it is not necessary to install lightning stroke protection unless you are using overhead wiring or suspended cables outdoors Large dispersed plants water supply installations refineries and so on can howeve...

Page 168: ...ve the space available should be at least 1000 mm high to provide working space The distance between the rear and the sides of the cabinet and an adjacent wall shall be no less than 40 mm This also ensures good ventilation If hinged frames or front doors of end cabinets are to open fully without touching adjacent walls increase the distance as follows At hinged side of hinged frame cabinet RM500V1...

Page 169: ...hat the equipment is assembled and delivered in type RM500 cabinets If you are using other types of cabinets see separate documentation regarding questions such as proper levelling and how to screw cabinets together The equipment to be set up is ordered for and adapted to a specific application When process I O Series 100 is used the delivery is normally comprised of several cabinets single or dou...

Page 170: ...ocation of the safety switch and the main power supply switch to the Advant Controller 450 equipment and how to use it When the subsections of the process are checked and a test run has been performed a responsible person is to check out interlocking chains and so on Inform all assembly personnel about test runs to be performed Process technicians are to be present when testing and operating the p...

Page 171: ...he system rack Always switch off the voltage before extracting a board which cannot be exchanged while under voltage See Chapter 5 Maintenance Wait a sufficient time for the capacitors to discharge Switch off voltage to the system and withdraw all boards at least 20 mm before electrical welding is performed near the controller system A warning label is fixed in the system to draw attention to poss...

Page 172: ...erminals to be used When the cabinet is finally installed supply the element according to the information given in Section 2 2 7 Power Supply Connection 2 2 3 Location The cabinet is to stand on a stable floor deck or supporting structure free from vibrations and is to be screwed to the surface Minimum distances to walls and ceiling are listed in the Figure 2 6 Access to the rear of the cabinet is...

Page 173: ...rcuit diagram enclosed at delivery You are directed to use cable lug connectors when connecting to any earth screw 2 2 5 3 Earth Line Ground the cabinet with a copper lead 35 mm to the plant earth line Use the left front M10 marked Protection Ground of the four screws placed in the corner of the cabinet floor You are directed to use a cable lug connector One common connection from a row of cabinet...

Page 174: ...nnection units according to Figure 2 8 Use a short lead 50 mm and thread cutting screws If there is a requirement of local grounding of a cable shield for for example a thermocouple application cable with double shield should be used The inner shield is grounded locally at the transducer while the outer shield is grounded according to Figure 2 8 Shielded cables of the category A which are grounded...

Page 175: ...ver it is most practical 2 2 5 5 Grounding of Communication Cable Shields General Communication cables shall be routed directly to the actual connection unit modem or communication module in a subrack Never open up a cable shield when entering the cabinet The grounding of the shield to the chassis directly or via a capacitor is normally determined by the type of communication You must reflect the ...

Page 176: ...2 10 At direct grounding of the communication cable shield the illustration in Figure 2 9 is applicable The grounding via a capacitor is based on a Capacitive Decoupling Unit which is mounted on the horizontal mounting bar The cable then passes the cabinet bottom unstripped See Figure 2 11 Figure 2 10 Principles of Grounding of Communication Cable Shields in a CE marked Design Cabinet Cabinet Fiel...

Page 177: ...f at least 100 ohms in the frequency range 50 300 MHz The application of method with respect to communication type is given in Table 2 1 Figure 2 11 Communication Cable Shield Grounded by Capacitor and Ferrite Coil Table 2 1 Methods of Handling Communication Cable Shields Type of Communication Grounding of Shield Directly Grounding of Shield via Capacitor Advant Fieldbus 100 Coaxial Yes Advant Fie...

Page 178: ...process connection units and I O boards in a subrack Note that the internal cable must be routed separated from other cables Ground the shield in both ends Use sheet cable lugs and self tapping screws ST3 5x9 5 B6x9 5 See Figure 2 12 LONWORKS Communication Twisted pair Yes on one end Yes PROFIBUS DP Yes V24 RS 232 C for example for a printer Yes Bus Extension to S100 I O Refer to Section 2 2 9 Bus...

Page 179: ...me board types require grounded signals while others can be applied to non grounded signals and grounded Please see the connection unit documentation on a case by case basis 2 Signals can be commonly grounded by grounding the reference 0V of centralized power supply for loads and sensing Such a power supply system must be grounded to the same earth line as the Advant OCS If the power supply unit i...

Page 180: ...in Cabinets Cables are practically routed on either side of the cabinet depending on the final destination The physical item destination for an actual apparatus and thereby the connection point appears in the circuit diagrams and other installation drawings enclosed at delivery The assigned space for cables that are entered in the floor opening is shown in Figure 2 14 For your information the spac...

Page 181: ...les with cable straps Figure 2 14 Assigned Space for Cables in a Cabinet Table 2 2 Cable Categories in a Cabinet Cable Application Category Power supply a c or d c 1 Process I O shielded and unshielded cables 2 Communication 2 Clock sync STAL alarm and so on 2 Distributed Connection unit 3 Bus extension to S100 I O 1 1 Bus extension for S100 I O is normally routed between cabinets in a special way...

Page 182: ...pply units in I O cabinets are connected to the switch unit via ready made cables and plug in contacts In certain applications using object oriented connection units and distributed S100 I O cabinets divergences from the main principle illustrated in Figure 2 16 below exist Please see Figure 2 2 and Figure 2 3 Figure 2 15 Plant Cable Routing in OOCU Cabinet Table 2 2 Cabinet seen from above Indica...

Page 183: ...tion 3BSE 002 415R701 Rev A 2 29 Figure 2 16 Main Principle of Power Supply Connection and Distribution Cabinet 1 Cabinet 2 Cabinet 3 Controller I O I O Power Supp Power Supp Power Supp Power Switch Supply Protective earth 3 wire cables Mains net filter CE marked design ...

Page 184: ...tions CE marked Design Protection against line conducted radio emission is obtained by means of a special filter placed in the bottom part of the cabinet on the incoming supply One filter for each supply is utilized The cable length between the entrance of the cabinet and the net filter should be as short as possible and mounted inside a protective screen After connection to the net filter s the p...

Page 185: ...c installation Grounding of the cabinet equipment cable shields and power supply connection are covered in the general setup instructions above In addition to that make the following connections of functions when appropriate Run Alarm relay External clock synchronization Additional supervisory inputs The location of the connections within the cabinet are specified in the terminal diagram form encl...

Page 186: ...ally factory installed FAIL 24 A 1 2 3 STATUS A1 STATUS A2 COMMON A System status display in operator station or F1 or F2 4 5 6 STATUS B1 STATUS B2 COMMON B F3 F4 FAIL 24 B 0V Description Configuration I O 24VA I O 24VB A1 A2 AG B1 B2 BG Application notes 24 V d c inputs A1 A2 B1 B2 A1 A2 Alternative applic configurable According to figure Supervision of I O 24 VA I O 24 VB Error state 24 V Free d...

Page 187: ...module front PM511 in the CLEAR position Preparation for Start up Please see the general checklists in Section 2 2 15 Checklists Leave the battery for memory backup disconnected until the mains supply is switched on and the application configuration is started Otherwise it will be discharged in a few hours 2 2 9 Bus Extension to S100 I O You can use the following basic information when you install...

Page 188: ...re illustrated with a thick line Since no intermediate side walls or plates are used on a cabinet within a row draw the ribbon cables directly between the cabinets The ribbon cables are sensitive to interference Locate them at least 100 mm away from other cables and wires in the cabinet Ensure that there is no tension in the wiring especially with respect to possibly swinging the hinged subframe f...

Page 189: ...d For information regarding the location of equipment see the actual delivery documentation Assembly drawings for example also give the cross reference between the following structures Physical location of circuit boards and connection units Functional item designation of circuit boards and signal channels Board address The functional item designation for example AI1 and the board hexadecimal addr...

Page 190: ... cabinets see Section 2 2 6 Cable Routing in Cabinets Grounding of cable shields see Section 2 2 5 Grounding Grounding of process signals see Section 2 2 5 Grounding Regarding cable selection and external cable routing see general information in Interference Free Electronics Design and Applications A carefully accomplished electric installation is the basis of future interference free operation Fu...

Page 191: ...ods which are time consuming activities An alternative method is to make an integrated check of the process equipment and wiring and the corresponding controller function which can be accomplished with a circuit by circuit procedure Preferably the controller is loaded with application data base The data base is then used as one checkpoint Status values can be read and control signals to process ob...

Page 192: ...is equipment see the actual delivery documentation For other information including all questions of installation see the separate documentation For S800 I O the manuals Advant Fieldbus 100 User s Guide S800 I O User s Guide For S400 I O the manual MasterFieldbus and S400 I O User s Guide Preparation for Start up The general information given for a check of external wiring in Section 2 2 10 S100 I ...

Page 193: ...se network to a single phase network From a fusing viewpoint Given the above rules you can use any spare power outlet in the cabinet or you can arrange for an additional branching socket Figure 2 21 Supply of Peripheral Unit without Modem N L PE a c mains supply C socket Advant Controller Printer Video terminal N L PE a c mains supply C socket Advant Controller Printer Video terminal Advant Contro...

Page 194: ...portant that they be powered from the same mains supply See general instructions in Section 2 2 12 Peripheral Units heading Power Supply Long Distance Connection If you use a communication modem the distance between the controller and printer can be a maximum of 300 m The different cables prescribed are shown in Figure 2 23 below Rules for cable shielding are given in Figure 2 24 See the actual de...

Page 195: ...f Printer Figure 2 24 Connections and Grounding of Communication Cable Shields Comm module CI531 Advant Controller Modem Modem TC562 DSTC X008 Cable Cable DSTK 156V0 5 0 5 m 1 6 ft TK577 Cable Two twisted pairs each pair individually shielded min conductor area 0 22 mm2 max length up to 1000 m 3280 ft at 19200 bps DSTC X008 1 2 3 4 5 1 2 3 4 5 3 4 1 2 5 Shield Shield Modem Modem Supplied internall...

Page 196: ...on The user s guide for the actual communication link Assembly drawings terminal diagram forms and so on enclosed at delivery of the Advant Controller These show you the location of the hardware The following instructions apply Cable routing in cabinets see Section 2 2 6 Cable Routing in Cabinets Grounding of cable shields see Section 2 2 5 Grounding Regarding cable selection external cable routin...

Page 197: ...ent of earthing and same supply The controller and the engineering station are galvanically isolated from each other by the communication interface 2 2 15 Checklists In the setup instructions you are occasionally referred to a separate document Interference free Electronics Design and Applications The following checklist is a summary of important information addressed to the actual Advant Controll...

Page 198: ... X008 TC562 Grounding Communications pulse transducers Same position as signal circuit At both ends Shielding Double shield Grounding Outer shield Inner shield Both ends As signal circuits Cable without shield Grounding All signal circuits grounded at the same end a c digital inputs 120 V 230 V Max cable length Approx 115 V 230 m 230 V 115 m Shield connections in EMC proof cabinet Connection Cable...

Page 199: ...ection to the PE terminal In phase phases No unsuppressed load on same finale circuit from distribution box Special isolation transformer for electronics supply must be used Incoming power supply 120 230 V must be separated from other cables by 5 cm or more d c floating battery Earthing supply Negative pole to PE terminal of cabinet directly at entry to cabinet d c earthed battery Connection Via d...

Page 200: ...refore is not generally allowed within the EEC area EU EFTA Electrical connection to cabinet from both ends of mounting rail Internal or external cabling to connection unit must be kept apart R 100 mΩ A 10 mm2 in tele rack 2 5 mm2 in the cabinet Spacing 100 mm Circuit board with 0V at X2 Grounding of 0V Connection to chassis from X2 0V 50 mm Connection Quality Only correctly made screwed or clampe...

Page 201: ...il joining the PE terminals in each cabinet Hinged frame Electrical connection to chassis copper bar 2 cables top and bottom of hinged frame L 250 mm A 10 mm2 Cabinet parts plates All parts electrically connected to each other and to the copper bar Divided cabinets R 100 mΩ Connection with special screws and nut bars Earthing in cabinet Design Only a single grounding system for Advant OCS equipmen...

Page 202: ...nly 1 Max specified length must not be exceeded Communication with out modem Routing of cables More than 100 mm 3 9 inch away from other cables MasterBus 300 MasterBus 300E GCOM Ethernet Cable length Joints Outdoor installation Routing Transceiver Drop cable Multiple of 23 4 m max 500 m 1640 ft At odd multiple of 23 4 m 77 ft 1 3 5 Teflon cable in conduit which is grounded at both ends An addition...

Page 203: ...and associated equipment Please read the instructions carefully One instruction is highlighted DANGER Work with care when supply voltage is applied in the system The voltage in the cabinet can cause injury and can even kill a human being Table 2 12 Miscellaneous Item Concerning Action Relays and contactors in cabinets Suppression Cabling to non suppressed inductive loads in Advant OCS cabinets mus...

Page 204: ...ection Section 2 1 7 Power Supply and Fusing there should be a common safety switch installed within 3 m from the cabinets NOTE Check the location of the safety switch and use it when working with the equipment The safety switch should shut down the power supply of not only the electronics system but also the adequate transducers and other process objects In other words a total power shut down for...

Page 205: ...vant If however the distributed S100 I O system the S400 I O system and the S800 I O system are powered by a separate mains separate safety switch and so on then you must make a distinction between a central and local shut down S100 I O A central shut down causes the S100 I O outputs to go to zero A local shut down causes the S100 I O outputs to go to zero S400 I O A central shut down causes the S...

Page 206: ...e However when there is a fault involved other behavior must be taken into account After necessary measures a restart can take place 2 3 3 Peripheral Equipment Shut down of peripheral equipment like a printer or local operator station MasterView 320 is treated below from the viewpoint of power supply disconnection only Regardless of whether the peripheral equipment is powered common to the control...

Page 207: ...ltage in the cabinet can cause injury and can even kill a human being 2 4 2 Controller and I O Conditions given by Setup If you finish the setup activities by using the checklists given in Section 2 2 15 Checklists the equipment is almost ready for start Please read the following security information first Measures by Security Means Power up of a controller and I O presents a small but real risk o...

Page 208: ...tch on all bus extenders DSBC 174 in position RUN 4 Switch on the mains supply to the cabinet and check for correct mains voltage with a multimeter at the connection terminals on the power switch unit See the terminal diagram form enclosed at delivery 5 Switch on the circuit breaker S1 on the power switch unit s in any order mains A and B Also switch on the miniature circuit breaker F1 for mains C...

Page 209: ...s are not implemented 7 If a LAN communication interface CS513 exists and if it is addressed and set properly by on board switches during the setup see Section 2 2 Setup it gives the following indications Communication Interface CS513 green LED RUN ylw LED TX LAN flash ylw LED RX flash Indicating a successful automatic configuration of the LAN communication 8 The target system is now ready for con...

Page 210: ...station communication cable into the service port X10 on the Processor Module PM511 front at any time First connect the communication cable Then switch on the power supply to the engineering tool Prepare for a session of programming Advant Controller 450 Follow the instructions on the screen Work with the engineering station is supported by adequate documentation For detailed information about dif...

Page 211: ...k with the controller should result in a system definition which is used as a basis for the next step of the start up procedure the controller system configuration This is performed in the working mode CONFIGURATION The start mode selector on the processor module front is kept in 1 AUTO position which was set after the power up The controller system configuration is the practical work required to ...

Page 212: ...ine of controller system configuration information Dimensioning creating and data entry are described in detail in separate documentation For a detailed description of the principles of the controller system configuration work the dimensioning and creation of records and the interactive work using an engineering station see the manual AMPL Configuration Advant Controller 400 Series See Chapter 3 C...

Page 213: ... disposition See text below LAN Local Area Network MasterBus 300 executed in main CPU MasterBus 300 executed in slave CPU MasterBus 300E executed in main CPU MasterBus 300E executed in slave CPU No Autom CS513 LANx No GCOM Yes CRDB CI543 MVIx Demand Bus extension to S100 I O No Autom DSBC_174 BEx Demand Also valid for DSBC 176 S100 I O boards Yes CRDB Misc 5 Misc 5 Demand ABB MasterFieldbus No CRD...

Page 214: ...CRDB CI532 MVIx Demand Function variant RCOM or MVI type is defined by the used hardware module For example RCOM uses CI532V01 MultiVendor Interface Standard protocol Yes CRDB CI532 or MVIMOD 6 MVIx Demand MVI Free programmable communication Yes CRDB CI535 or MVIMOD MVIx Demand DB element CI535 for module CI535 and MVIMOD for module CI538 1 CRDB stands for the engineering tool command CReate Data ...

Page 215: ...mber of S800 AI MODULES Number of S800 AO MODULES Number of S800 DI MODULES Number of S800 DO MODULES Number of S800 DP MUDULES Number of AI BOARDS Number of AO BOARDS Number of DI BOARDS Number of DO BOARDS Number of AI SIGNALS Number of AO SIGNALS Number of DI SIGNALS Number of DO SIGNALS Data Transfer Communication Number of DAT Number of DS Number of MS Number of TEXT Number of TS Number of DS...

Page 216: ...er of MANSTN Number of RATIOSTN Number of GRPALARM Number of GRPMEMB Drives Number of DRISTD Number of DRIENG Fire Gas Number of GI_BOARDS Number of FI_BOARDS Number of GI_SIGNALS Number of FI_SIGNALS Redimensioning of the Data Base You can redimension at a later stage 1 Make a copy of the data base Use the command DUTDB This copy includes the DIMDB information 2 Load the copy Use the command LOTD...

Page 217: ...ing At regular intervals make a backup copy of the data base content and the PC program After dimensioning and populating the data base in working mode CONFIGURATION dump it and re load it with compression to minimize the memory space occupied See the list below of available dump and load commands which are further described in the manual AMPL Configuration Advant Controller 400 Series For a descr...

Page 218: ...ated For example working mode OPERATION Source code of data base 1 DUDBS DUmp Data Base Source TRDBS TRanslate Data Base Source Source code of PC program See text below 2 DUPCS DUmp PC Source TRPCS TRanslate PC Source 1 DUTDB LOTDB is sometimes a faster alternative than source code handling source code is always possible The compatibility code for the data base of the system software decides Possi...

Page 219: ...sioning of data base DIMDB b Creating the data base CRDB c Data entry of data base MDB d Dumping and loading compress the data base DUTDB LOTDB e Dimensioning of PC program tables DIMPC have to be done to enable update of I O signals 4 Configuration application building a Populating the data base MDB b Entering and editing PC program miscellaneous commands c Dumping and loading PC programs DUTPT L...

Page 220: ... hand side When the controller is started connect the battery Disconnectible connectors are found close to the battery unit You know that the battery backup is functioning when you see the following indications On the Backup Power Supply SB510 SB511 front by green LED IP indicating mains supply available and converter in operation by switch off of the red LEDs F Fault and BF Battery Fault Low ambi...

Page 221: ...estion The basic settings correspond to the settings of the unit when delivered by ABB Automation Products AB The language parameter is pre set for English printout Table 2 16 Programmable Parameters Parameter Basic setting Font DRAFT CPI 12 CPI LPI 6 LPI Country E US ASCII Emulate Epson FX 850 CharSet Extended C6 Tab Graphic Sl Zero Off Auto CR Off Auto LF Off Skip 0 5 Inch AutoTear ViewTear Off ...

Page 222: ...PRINT are needed to define the printer communication For a detailed description of the PRINT and TEXT PC elements and how to use them see the reference manual PC Elements Advant Controller 400 Series and the manual AMPL Configuration Advant Controller 400 Series 2 5 Product Verification Since the test requirements vary considerably among different installations the designer is responsible for dete...

Page 223: ...ecution of an application program see Section 2 4 2 7 Summary of the Controller Start up and Verification of the Start Below you can find general information on some function tests which you can perform to verify the product Short notes on adequate facilities provided by the engineering station are also listed For a more detailed description see the AMPL Configuration Advant Controller 400 Series ...

Page 224: ...ing a test of the application program you can prevent the control system from affecting the process in two ways By opening terminal switches on the connection units or likely locations to physically isolate output signals from the process By blocking the updating of the data base with the help of certain commands Blocking commands and their use are listed below BL Blocking of individual or all exe...

Page 225: ...hical element symbol Further commands to use to read the values allocated to operational parameters PC variables and constants are MV Modify Value LV List Variable Changing of Data in the Data Base You can make changes in the data base with the commands MDB Modify Data Base or MV Modify Variable Parameter Change in PC Program Read and change the values of the operational parameters during program ...

Page 226: ...e the command DS Delete Statement to remove the element to be moved You can then insert IS the element in another place in the PC list The above change can be made during operation by authorized personnel An alternative to rebuilding the PC program is to dump the PC program as source code then edit and reload the source code This is effective when there are considerable changes 2 5 3 6 Tuning of F...

Page 227: ...input by connecting a voltage which corresponds to the nominal value of the input The 1 and 0 status is simulated by opening and closing the terminal switches Activate the input as close to the process transducer as possible to test the process wiring as far as possible Manual operation of transducers for example limit switches can also give the required change for the input signals Analog input s...

Page 228: ...Modify Data Base to present the data base element Use GETAB as an alternative Ensure that the connections of the data base element are filled in correctly for the signal to be examined See the data sheet for the data base element Simulate the digital input signal as close to the process transducer as possible or activate the transducer itself Check that the corresponding yellow LED on the input bo...

Page 229: ...hat solder straps for voltage signals are removed or clipped Simulate the analog input signal as close to the process transducer as possible Use the command MDB to present the element GVD gives dynamic updating Use the command GETAB which gives dynamic updating as an alternative Check that the simulated signal is available at the screw terminal of the corresponding connection and at test terminal ...

Page 230: ...n the data base set the VALUE and check that the corresponding output shows this value Then measure the value on the screw terminal block of the corresponding connection unit end and if practical at the process as well Check that the corresponding yellow LED on the digital output board concerned illuminates When you are checking analog output signals use a multimeter to test that an output signal ...

Page 231: ...l is obtained over the complete signal range For a description of adjustment of analog output signals see Chapter 5 Maintenance Readjustment of Analog Output Signals AO boards are factory adjusted for voltage output signals If current signal is desired jumpered you must readjust for maximum accuracy Please follow the instructions given in Section 5 5 12 Channel Adjustment on AO Board 2 5 3 10 List...

Page 232: ...NDUSTRIAL SYSTEMS 1994 02 01 18 04 15 D 1 D 0 5 D 1 D 0 D 0 5 6 1 D 1 0 D 2 000 5 6 1 PC1 1 RUN 1 PC1 1 2 1 2 3 P P 2 3 ABB INDUSTRIAL SYSTEMS IDENTITY PC1 NAME PCPGM ON R RUN CONTRM ON SINGLE R RUN MODP OSC SIN EN TC AMP O ERR TYPE IB IB OB 20 2 IB IB IB OB OB IB ITR IR OR OB SOURCE D 1 D 0 D 1 D 0 D 0 PC1 1 5 D 1 0 D 2 000 AO1 1 DO1 1 UNIT PAGE 1 1 NOTES PC1 1 1 1 AO1 1 P DO1 1 P 20 1 PCD PAGE 1...

Page 233: ...the command LOAP For a description of the commands see the manual AMPL Configuration Advant Controller 400 Series 2 6 Implementation of Functions in Systems Already Operating Enlargement of the system with additional functions differs from a from scratch installation The main reason they differ is that the system is or has been in operation which means that on line off line aspects are important T...

Page 234: ...ystem already in operation Among other things you may want to reflect upon Hardware types and location Type of carrier board eventually needed Restrictions in function combinations Software program modules needed to produce the total application you desire for example MasterBus 300 aimed at central operator station communication which requires in addition to the communication equipment the central...

Page 235: ...ta Set MVI Set These application requirements are not included in the statement of Yes or No concerning dimensioning of the data base in Table 2 18 Do not overstress reserving spares You can always redimension the data base You must do it however off line See below for a brief description of how to perform the dimensioning redimensioning look under the heading Dump of Application Program See the m...

Page 236: ...ubrack meant to reorganize available boards requires no dimensioning I O unit S400 I O X Yes Redundant processor module X No It is recommended that you shut down the controller See alternative instructions below Redundant regulator 5 V X No MasterBus 300 all types X No GCOM X No MasterFieldbus X Yes 1 Bus extension to S100 I O X No The data base for S100 I O Bus Extension is pre dimensioned When a...

Page 237: ...not possible on line or LDBD Determine I O address to be used Use the documentation of the data base or the delivery documentation if applicable 2 If no spares are available make a dump of the controller system configuration and the application program Engineering station dump command DUTDB and DUTPT 3 Switch off the supply voltage to the control system recommendation NOTE Remember that the contro...

Page 238: ...Push in the new board quickly and decisively 11 Ensure that the board contacts mate properly with the contacts in the rear plane Screw the locking bar in place 12 Connect the process cables to the connection unit Reflect upon all installation rules regarding cable routing and grounding As an alternative first make a functional verification when the process is not connected Then connect Figure 2 32...

Page 239: ... deblocked You can of course switch off the power supply during the installation work Then switch on the power supply keeping the start mode selector on the processor module in 1 AUTO position The system is restarted and in full operation apart from the additional board The different I O channels are put into operation as the adequate data base is created and the application functions are built an...

Page 240: ...base MDB b Enter and edit PC program if relevant c Dump and load PC programs DUTPT LOTPT 4 Back up the entire RAM DUAP 5 Disable working mode CONFIGURATION DICONFIG In addition to those indications obtained at power up All red LED F Fault on S100 I O board fronts are switched off The yellow LEDs INIT and INHIB on S100 I O Bus Extenders DSBC 174 DSBC 176 board front are switched off 6 The processor...

Page 241: ... Process safety Need to test the newly installed equipment Need to test earlier logic and connectors not utilized in the existing equipment Note possible years of operation and environmental influence Power supply redundancy is sometimes introduced at the same time In that case system shut down and power supply disconnection become compulsory Extension On line 1 Check module identities 2 Check mod...

Page 242: ... describe an installation with increased safety by checking basic changeover functionality in working mode CONFIGURATION without affecting the process controlled Normal Installation 6 Set the start mode selector on the existing processor module in 1 AUTO position Push the ENTER button The display shows P1 Process control starts 7 Set the start mode selector on the new processor module in the same ...

Page 243: ...tware Below you can find instructions on how to change a program card with the system software to a variant with another assembly of program modules that is another functional assembly Revision of system software is dealt with in the same way An exchange procedure is assumed After reception of a new program card the used one is returned to the sender For a detailed description of the connection an...

Page 244: ...w program card CAUTION At insertion use the grounded wristband Start up Suitable data base and PC program dumps per point 4 in the setup instructions above are presupposed The following instructions do not include any utilization of the new software functionality but only aim at restoring the old application Enlargement of the application may require redimensioning of the data base and the PC prog...

Page 245: ...rder If this circuit breaker has been used to switch off the power supply to the system Several power switch and distribution units can exist in the controller cabinet or in adjacent I O cabinets 3 Check for the following positive indications of a successful power up Distribution Unit SX554 green LED LIVE 24 V Regulator SR511 green LED 5 V Backup Power Supply SB511 or 510 green LED RUN S100 I O Bu...

Page 246: ...flash Indicating a successful automatic configuration of the LAN communication 5 The target system is now ready for configuration or program load by connecting the engineering station directly to the processor module If redundant processor modules connect to the primary module Configuration is also possible via the network if applicable and desirable 6 Finally set the mode selector on Processor Mo...

Page 247: ...DQFH 3URGXFW 6WUXFWXUH The product structure deals primarily with general functional modularization In that context questions regarding number of supported functions possible combinations of functions and so on are relevant For the answers to such questions see Section 3 2 Technical Data Including Capacity Performance Regarding the realization of functions please note that the hardware structure a...

Page 248: ...n input electrical data is given in Section 3 2 1 4 System Clock 5XQ ODUP 5HOD SSURSULDWH DUGZDUH DQG 6RIWZDUH No extra hardware or software is needed The System Status Collector TC520 is used according to Figure 3 2 Contact data see the module description in Appendix A Hardware Modules LJXUH WHUQDO 6 QFKURQL DWLRQ RI 6 VWHP ORFN LJXUH 5XQ ODUP 5HOD RQQHFWLRQ 7 12 13 SYNCIN COMMON SYNC Configurati...

Page 249: ...XUH 3RZHU 6XSSO 7HUPLQDO 6HWWLQJV 7HUPLQDO 6HWWLQJ F1 NO Because normally the signal I O 24V A error is connected to digital input A1 of TC520 1 1 See sections Power Supply modules and TC520 in the Data Base Elements Advant Controller 400 Series Reference Manual YES if there is a user defined signal connected to digital input A1 of TC520 1 F2 NO if the signal I O 24V B error is connected to digita...

Page 250: ...s See Table 3 2 below Normally you do not have to deal with current consumption calculations There are however occasions with special requirements special designs and so on when detailed information regarding current consumption is valuable Please find a description under the heading Guidelines below XLGHOLQHV For a summary of the main requirements of the plant supply from a planning viewpoint see...

Page 251: ...y equipped subracks is assumed Current at nominal 24 V is given for example 25 A For special utilization of the power supply units you are advised to calculate the current consumption 7DEOH 5XOHV IRU WKH DOFXODWLRQ RI 1XPEHU RI 3RZHU 6XSSO 8QLWV OWHUQDWLYH 6WDQGDUG RQILJXUDWLRQ 0D 3RZHU 6XSSO 5HTXLUHPHQW OWHUQDWLYH Controller subrack 25 A OWHUQDWLYH Controller subrack I O 1 subrack 25 A OWHUQDWLYH...

Page 252: ...Heat Dissipation 0 37 conversion factor This current is used as output current for analog outputs in addition to supplying the internal electronics See Table E 1 E 3 in Appendix E Current Consumption and Heat Dissipation for information about the current consumption of the available units in Advant Controller 450 These tables hold typical data relevant to the actual type of calculation It also hol...

Page 253: ...actual number and type of circuit boards in the different subracks D F 1HWZRUN The in rush current at power switch on must be considered at the fuse dimensioning Consequently you must include redundant power supply units connected to the same line in the calculation of number of units Normally redundant power supply units are connected to separate lines D F 1HWZRUN To reflect the in rush current a...

Page 254: ...t 24 V d c mains supply FDC Load effect 1 0 7 1 19 1 25 At 48 V d c mains supply FDC Load effect 1 0 7 1 38 1 25 In addition these formulas are also applicable when a detailed current consumption and thus the load effect for a subrack is available and when it should be transformed into fuse dimensioning current The figures in Table 3 4 are almost worst case The in rush current at redundant power s...

Page 255: ... 25A 50 25A Controller subrack I O subrack 1 Power supply Power switch and distribution unit d c d c Advant Controller 450 Distribution board Power supply d c d c Field equipment e g load effect 240 W D 9 9 E 9 9 F 9 50A 50A Controller subrack I O subrack 1 Power supply Power switch and distribution unit d c d c Advant Controller 450 Distribution board Power supply d c d c Field equipment e g load...

Page 256: ...eeded the basic system QC07 BAS41 is sufficient No extra hardware is needed besides the desired I O unit if Spare slot in an I O subrack is available S100 I O MasterFieldbus communication is available S400 I O Advant Fieldbus 100 and an S800 I O station is available S800 I O Supported I O boards S100 I O I O units S400 I O and I O modules S800 I O are listed in Section 1 7 Product Overview Besides...

Page 257: ...dule The following PC elements are used for communication with the module DP820 I Read values from one channel DP820 O Issues commands for one channel Positioning Board DSDP 140A The following PC element are used for communication with the board Pos A Positioning Analog control Pos L Positioning Length Pos O Positioning On off Pulse Counter and Frequency Measurement Board DSDP 150 Three different ...

Page 258: ...itable The geographical spread of the process is often limited It may be necessary to supplement a central operator s function including a display screen with a conventional panel function independent of the control system For example a panel instrument in a current loop showing a process measured value which is to be placed in the central control room The control system interacts closely with cen...

Page 259: ...sistance may not exceed the resistance through which the sensor output can be driven The referred type designations below are valid to circuit board connection unit and internal cable respectively DSAI 130 DSTA 131 DSTK 221L3 DSAI 130A DSTA 131 DSTK 227L3 Differential inputs for applications with considerable accuracy requirement Common Mode Voltage up to 100 V 50 V DSAI 130A is acceptable These a...

Page 260: ...uts are handled by the application programmer in the same way as the other analog inputs DSAI 146 DSTA 145 DSTK 229SL3 A design for three wire connected Pt 100 transducers which compensates for the length of lead provided that the lead resistance is the same for the cable conductors A conductor break in a transducer does not affect other measurement channels DSAI 155A DSTA 156 DSTK 160 Used for gr...

Page 261: ...ad provided that the potential difference between the ground of the load and the ground in the controller is low The equivalent resistance caused by the ground voltage drop and the load resistance together is not to exceed 500 Ω with a current signal DSAO 120A DSTA 171 DSTK 221L3 Used when considerable accurancy and galvanic isolation between control system and load channel by channel are required...

Page 262: ...anned or interrupt controlled 24 V d c inputs You can configure the inputs for pulse catching that is with filter times of 100 ms at switch on and 2 s at switch off This function is especially well suited for setting keys push buttons In the connection unit the current supply is divided into two groups of 16 channels each Each group has a common 0 V This does not prevent external voltage supply an...

Page 263: ...ture of DSDI 110A are Thirty two scanned or interrupt controlled digital inputs Pulse catching can be configured The properties of the inputs for example 24 V d c 120 V a c 230 V a c are decided by the selected connection unit Different sets of I O boards and connection units are offered to match various object types requiring different input voltages and number of inputs per object DSDI 120A DSTD...

Page 264: ...properties of the inputs For example 24 V d c 120 V a c 230 V a c are decided by the selected connection unit Different sets of I O boards and connection units are offered to match various object types requiring different input voltages and number of inputs per object DSDO 115 DSTD 110A DSTD 190 DSTK 221L3 DSDO 115A DSTD 110A DSTK 221L3 DSTD 190V1 DSTK 234L3 These give short circuit protected stat...

Page 265: ...To obtain acceptable accuracy the frequencies which the two channels in a channel pair are to measure should be fairly similar DSDP 170 DSTX 170 DSTK 228L3 Four channel high speed pulse counter board for up to 2 5 MHz The board is primarily intended for control of motor operation where there is a need for position length and speed frequency measuring XLGHOLQHV RQQHFWLRQ RI 6WDWLF RQYHUWHUV DSDC 11...

Page 266: ...fferent voltage sources must be capable of being connected The 32 channels are galvanically isolated from the internal electronics in the unit DSDI 454 DSDI 453 expansion unit Thirty two scanned inputs for 48 V For further properties see DSDI 452 DSDX 452 L DSDX 451 L expansion unit Combination unit for 20 digital 24 V inputs and 12 digital outputs The inputs have the same qualities as the inputs ...

Page 267: ...o the 6 2 8VHU V XLGH RPPXQLFDWLRQ 3URYLGHG LQN 7 SHV SSURSULDWH DUGZDUH DQG 6RIWZDUH From the hardware viewpoint the concept of submodule and submodule carrier is used to build a function Please refer to Section 1 8 11 3 Submodule Carrier and Submodules for a description For information on the possible number of instances please see Section 3 2 4 1 Provided Link Types Information given is valid t...

Page 268: ...n main CPU See the separate manual 0DVWHU1HW 8VHU V XLGH MasterBus 300 executed in slave CPU X 1 2 MasterBus 300E executed in main CPU X X 1 2 MasterBus 300E executed in slave CPU X 1 2 GCOM CI543 X X Bus extension to S100 I O 3 3 Connection for S100 I O Bus Extension is located on the front of Processor Module PM511 MasterFieldbus CI570 TC570 X X 4 4 A range of modems and connection units are ava...

Page 269: ...ule carrier with no slave processor support is normally used SC510 MasterBus 300 executed in slave CPU A submodule carrier with slave processor support is used SC520 The application is in no way affected by the selection XLGHOLQHV RFDWLRQ DQG SORLWDWLRQ RI DUGZDUH No restrictions in location of submodule and submodule carrier in controller subrack Use leftover slot on a submodule carrier provided ...

Page 270: ...nterface CI531 has two ports V 24 RS 232 C Each port can be used for any combination of EXCOM printer or MasterView 320 XLGHOLQHV 5 20 Communication interface CI532V01 has two ports Both ports have the same protocol XLGHOLQHV 0XOWL9HQGRU QWHUIDFH 6WDQGDUG 3URWRFRO Communication interface CI532Vxx or CI534Vxx has two ports Both ports have the same protocol CI532Vxx is delivered with a standard prot...

Page 271: ...00 1 MasterBus 300 300E CS513 2 6XEVFULSWLRQ RPPDQG YHQWV MasterBatch 200 1 MasterBus 300 300E CS513 2 GENUSD 3 ref types PC defined by the prog module QC02 BAT21 MasterGate 230 MasterBus 300 300E CS513 2 Advant Station 100 Series IMS GCOM CI543 6XEVFULSWLRQ RPPDQG YHQWV Advant Station 800 Series IMS GCOM CI543 6XEVFULSWLRQ RPPDQG YHQWV S100 I O Bus Extension to S100 I O DSBC_174 I O element S400 ...

Page 272: ...2 MS DAT MultiVendor Interface MODBUS via CI534V02 Allen Bradley DF1 MVIMOD MVICHAN MVINODE MVB DAT MVI Free programmable communication via CI535 via CI538 CI535 MVIMOD MVICHAN MVINODE MS DAT MVB DT 1 Generally data base elements are given for establishing the link and the interface to the application program PC denotes PC element 2 The user straps network node slave number and protocol on dip swi...

Page 273: ...acters 3HUIRUPDQFH RQVLGHUDWLRQV Information given in Section 3 2 Technical Data Including Capacity Performance shows that receiving Data Sets generate more load than transmitting Data Sets To minimize the load you can create data base elements for receiving Data Sets in an Advant Controller 450 before transmitting Place data base elements for the Data Set which receives data most frequently at th...

Page 274: ...arily used are PCPGM CONTRM and FUNCM SEQ and STEP are also used with sequential control The elements PCPGM CONTRM and SEQ are execution controlling You can activate and deactivate these elements from outside do this when high performance is required The elements are only activated when execution of the subsidiary program section is necessary Place the execution control in its own module with a sh...

Page 275: ...FH RFDO 2SHUDWRU SSURSULDWH DUGZDUH DQG 6RIWZDUH Communication with a local operator s station MasterView 320 is an application of V 24 RS 232 C For further information see Section 3 1 5 Communication In that section you will also find an overview of the application interface used and some guidelines for the link implementation In other respects Masterview 320 and its application are described sep...

Page 276: ...on in a production unit it is often found that the fault is in a motor a contactor a valve or field mounted instrumentation It can thus in theory appear more appropriate to duplicate an important measuring sensor or valve than to duplicate the control system but errors in the controller have more serious consequences When considering whether redundancy of the control system really is the best conf...

Page 277: ...rdware From the configuration viewpoint a redundant pair of I O modules are kept together by a common data base element Normally the element used in a single application has the extra parameters needed for a redundant application XLGHOLQHV Always base your investment in redundancy on a relevant reliability and availability analysis Reflect on for example Not only the control system itself but also...

Page 278: ...the subracks in the cabinet is 55 C The permissible amount of heat generated depends on the type of cabinet and its location Appendix B RM500 Cabinet Data Sheet indicates the heat generated to give a 15 C temperature rise and a 30 C temperature rise in the cabinets The figures are valid for cabinet type RM500 The standard design and assembly of cabinets aim to give a maximum of 15 C temperature ri...

Page 279: ...ndix E Current Consumption and Heat Dissipation for the power dissipated as heat by hardware modules in Advant Controller 450 and the available I O system It is assumed that 70 of the channels of an I O board are active simultaneously A power supply unit located beneath the subracks contributes to the total power dissipation with 100 W Do not include redundant power supply units in the calculation...

Page 280: ...and other systems Operator functions Application program Redundancy Of course there are some limitations such as maximum number of possible instances and functionality offered by the available library You can however exchange program modules if certain optional functions are required For limitations see Section 3 2 Technical Data Including Capacity Performance If desirable you can carry out most e...

Page 281: ...rea available for each PC program is limited to 32 kByte If the application program is well structured and divided into several PC programs this limit normally has no relevance Structuring of the application is strongly recommended for other reasons as well It is the basis of easily interpreted documentation for example circuit diagram effective maintenance and simple future system enlargement SOD...

Page 282: ...WFK The number for PROCESSES is based on 50 storage vessels four sections and 20 operations with six recipe variables each 6SDFH IRU VWRUDJH RI 8VHU LVNHWWH FRQWHQW Included only if you choose the user diskette as a backup option in Advant Controller 450 The memory space can be dimensioned 100 kByte is a space suitable for most requirements 6SDUH 5 0 DUHD Reserve RAM capacity is required because i...

Page 283: ...x 0 02 TEXT No of DB elements x 0 14 Table handling No of tables 2 x 4 90 MasterView 320 Basic requirements for QC07 LOS41 1 x 240 00 No of displays 3 x 2 00 No of MasterView 320 with event lists 4 x 9 00 AS 500 Series operator station and IMS Station or MV800 1 Basic requirement for QC07 OPF41 1 x 799 00 No of trend data storage logs 5 x 12 00 Group alarm No of group objects No of group members x...

Page 284: ...3 00 Basic requirements for QC07 BAS41 1 x2207 00 Spare RAM area 8 1 x 40 00 40 00 SSUR LPDWLYH WRWDO 5 0 UHTXLUHPHQW LQ NE WHV 1 The figures are calculated for 8 steps MOTCON not included 2 The figures are calculated for 1 table with 10 rows and 100 values per row 3 The figures are calculated for 40 text strings with 20 characters and 30 dynamic values 4 The figures apply to 100 events per list 5...

Page 285: ...y application to be It also provides a survey of how the software functions in an Advant Controller 450 In conclusion you can find recommendations for the reduction of system load KDW LV WKH 38 WR GR The different functions in an Advant Controller 450 are allocated different priorities This means that a function with a higher priority takes precedence over a function with a lower priority if both ...

Page 286: ...eir tasks The user is not normally concerned with priority levels since these are managed automatically by the system but the user should be aware of the priority system and stall level if the system is heavily loaded LJXUH GYDQW RQWUROOHU 3ULRULW 6 VWHP GYDQW RQWUROOHU 3ULRULW 6 VWHP Clock Timer task PC and I O with cycle times 10 20 40 ms Interrupt controlled DI PC and I O with cycle times 50 10...

Page 287: ...fective if it is necessary to lower the CPU load Two calculation methods are presented below The main differences between the methods are the accuracy obtained and the work required Approximations of course provide less accuracy but rapid results The equation for calculating the total CPU load for several similar functions is where NF number of functions for example feedback control loops T execut...

Page 288: ...dividual PC elements GGLWLRQDO QIRUPDWLRQ IRU 5HGXQGDQW 3URFHVVRU 0RGXOHV The performance of redundant processor modules is reduced to 95 in relation to a single system Divide all load figures given by 0 95 LJXUH 38 RDG DOFXODWLRQ 0HWKRGV Base load PC and Process I O Application Subscription Command Events Data Set EXCOM Master View 320 Logging Others Reserve FFXUDWH PHWKRG 2 6KRUWFXW PHWKRG 2 App...

Page 289: ...ary to scan AI quickly because of the frequency content of the input signal The signal can be low pass filtered in AI software thus providing frequency components with lower frequency in the signal which the application program uses This means that the application program can be run more slowly than the corresponding AI is scanned Select as large dead band for the AI channel as possible Of course ...

Page 290: ...ical information given is maximum number of instances magnitudes distances and so on 3HUIRUPDQFH Typical information is accuracy for example CPU load HQHUDO 6 VWHP 8WLOLWLHV 38 HQHUDO 7HFKQLFDO DWD DSDFLW 3HUIRUPDQFH HQHUDO The load caused by different subsystems in the controller is reported below To start with you will find an overview The following headings cover details to respective subsystem...

Page 291: ... links redundancy or type of communication interface module that is utilization of slave CPU or not PC and Process I O related load 2 5 This latter load does not exist in working mode CONFIGURATION A variable base load exist Each additional node on the network will increase the load 0 15 if SC510 is used This extra load will not appear if the SC520 is used LJXUH RDG IURP FOLF XQFWLRQV 2YHUYLHZ Bas...

Page 292: ...C element Reading and writing of data to from the data base Each time a value is read from the data base to a PC element or written to the data base from a PC element 2 microsecs are spent When a process output channel is written add the time for I O handling 7DEOH RDG IURP 3URFHVV 2 DQGOLQJ KDQQHO W SH DVLF WLPH each execution GGLWLRQ RQ FKDQJH VALUE changed 1 Channels with NORMAL_TREAT 1 event h...

Page 293: ... Complexity 1 PI element 1 AI 1 AO and 5 simple arithmetic and or logic elements One ratio station or manual station takes approximately 0 5 ms Complexity 1 RATIOSTN alt MANSTN 1 AI some arithmetic and logic elements One AI or AO takes approximately 0 25 ms The load figure is valid to different AI signal types standard signal Pt 100 and thermocouple signal Fifty AI with cycle time 1000 ms gives ap...

Page 294: ...nger than the time between PC element executions determined by the PC program scan rate High means that the time between changes has the same magnitude as the time between PC element executions Complexity 2 4 input AND gates per digital signal 7DEOH DPSOH RI HFXWLRQ 7LPHV RI LJLWDO 6LJQDOV 6LJQDO W SH RQGLWLRQ KDQJH IUHTXHQF RDG H DPSOH VLJQDOV 3 HOHPHQW F FOLF WLPH PV DI Interrupt low change freq...

Page 295: ...mance calculation See separate documentation attached the used bus Load data is given by a diagram Figure 3 10 By extrapolation you may obtain the load figure for an extended number of objects First an example and some general comments A display with 100 objects from one Advant Controller 450 with an update cycle of 3 sec generates a load of approximately 1 in the controller Use of 7 different obj...

Page 296: ...of objects Load 3 2 1 10 20 30 40 50 60 70 80 90 100 110 Number of objects Load 3 2 1 10 20 30 40 50 60 70 80 90 100 110 Number of objects Load 3 2 1 10 20 30 40 50 60 70 80 90 100 110 Number of objects Load 6 REMHFW W SHV 6 REMHFW W SHV 6 REMHFW W SHV 6 REMHFW W SHV 1 s Update 3 s 9 s 1 s 3 s 9 s 1 s 3 s 9 s 1 s 3 s 9 s time utilization of slave CPU utilization of slave CPU ...

Page 297: ...nged DI or LIMIT exceeded AI However this is taken care of by having the stipulated reserve capacity 3HUIRUPDQFH DWD 6HW ZLWK 0DVWHU XV Full data sets that is with 24 DAT values are assumed However the length of the data sets has little effect on the load in Advant Controller 450 Figure 3 11 sending data sets and Figure 3 12 receiving data sets show the additional load from these applications The ...

Page 298: ... VFUHHQ Note that the load caused by for example 20 variables updated every second is the same as the load from 40 variables updated every other second If several MasterView 320 is used at the same time with a display on screen you have to add the load figures from each terminal LJXUH RDG DXVHG E 5HFHLYLQJ DWD 6HW 0DVWHU XV LJXUH RDG DXVHG E D 0DVWHU9LHZ 3 2 1 4 8 12 16 18 Number of DS sec Load 4 ...

Page 299: ...diagrams In that way the different load caused by a momentary log and a mean value log is practically considered A primary and a secondary log is treated in the same way when analyzing the CPU load The secondary log normally gets its data from a primary log This means that the load data from the primary log and the secondary log must be added up 6KRUW RJ QWHUYDOV V V LJXUH RDG DXVHG E D RJ 6KRUW Q...

Page 300: ... individual sending receiving is considered 127 The capacity of the communication link must also be considered in a performance calculation See separate documentation attached the used link DWD 6HW 3HULSKHUDO ZLWK GYDQW LHOGEXV Data set peripherals DSP are cyclically transmitted to their respective destinations with a cycle time selectable in the range 32 ms to 4096 ms The Advant Controller 450 CP...

Page 301: ...nding receiving The basic cycle time of the DSP scan task i 512 ms default value Add the basic link load 0 2 no sending receiving LJXUH RDG DXVHG E 63 ZLWK GYDQW LHOGEXV DVLF FOH 7LPH PV LJXUH RDG DXVHG E 63 ZLWK GYDQW LHOGEXV DVLF FOH 7LPH PV 3 2 1 50 100 150 200 250 No of DSP sec Load 4 300 5 6 R Receiving S Sending R S 3 2 1 50 100 150 200 250 No of DSP sec Load 4 300 5 6 R Receiving S Sending ...

Page 302: ...rates bps given in figures below The load algorithm is quite complex and the straight lines in the figures are practical approximations only Limit values for maximum number of messages with a given number of signals in the message is given A limit value within parenthesis is estimated You should consider the individual signals included in a data set package in the same way as AI AO DI DO signals T...

Page 303: ...eserve of 15 to 20 is recommended See Section 3 1 14 CPU optimization Load Calculation LJXUH RDG DXVHG E 20 ELW VHF LJXUH RDG DXVHG E 20 ELW VHF 3 2 1 50 100 150 200 250 Messages sec Load 2 signals message 4 signals message 8 signals message 50 125 270 4 3 2 1 50 100 150 200 250 Messages sec Load 2 signals message 4 signals message 8 signals message 70 345 4 300 5 6 167 ...

Page 304: ...QHUDO 7HFKQLFDO DWD DSDFLW 6 VWHP 6RIWZDUH DQG SSOLFDWLRQ 3URJUDP Read write memory RAM total 8 alt 16 Mbyte Residing on processor module available for application program min 5 5 alt 13 5 Mbyte DWWHU DFNXS 7LPH single CPU system 8 or 16 MByte min 4 hours redundant CPU system min 2 hours after 20 h of recharging 6 VWHP 6RIWZDUH DFNXS Program card with flash PROM PCMCIA Number of program cards min ...

Page 305: ...lated to the master clock accuracy Relative error in time when synchronized via network max 3 ms You can synchronize one or several controllers via external minute pulse signal The aim is to synchronize to an accurate external clock and in the case of several controllers to keep the relative error in time low Relative error in time when synchronized via external minute pulse signal max 2 ms Relati...

Page 306: ...cts such as technical data and so on please refer to separate documentation Individual power supply units Data sheets included in Appendix A Hardware Modules Voltage regulator units 6 2 DUGZDUH 5HIHUHQFH 0DQXDO 3RZHU 6XSSO QWHUUXSWLRQ 10 ms 1 Unaffected operation 10 ms 1 Safety shutdown At battery supply the Advant Controller is equipped with an energy reservoir to comply with this specification 3...

Page 307: ...thin a subordinated autonomous controller for example Advant Controller 110 1 ms Events locally time tagged Events handled within separate controllers Advant Controller 450 Advant Controller 410 Advant Controller 110 not S400 I O With external time synch 1 4 ms No external time synch 5 ms For S800 I O without SOE functionality the relative time error between events DI signals in one controller can...

Page 308: ...s of device 1 2 sec For system clock accuracy see Section 3 2 1 4 System Clock 7DEOH 5HODWLYH 7LPH UURUV EHWZHHQ YHQWV 6LJQDOV XV YHQWV JHQHUDWHG E 5HODWLYH WLPH HUURU PV RQWUROOHU 0RGXOH DOF Advant Fieldbus 100 Advant Controller 110 DI650 2 Advant Controller 110 Calculated in AMPL 2 Sct 1 1 Sct means scan cycle time of reading I O signals in the Advant Controller 55 70 or 110 Advant Controller 70...

Page 309: ... 19 when S100 I O Bus Extension redundancy is used No of DI boards DI signals 3 3 This total includes S100 I O signals S400 I O signals and calculated signals 48 max 2300 No of DO boards DO signals 3 48 max 1489 No of AI boards AI signals 3 4 4 When any combination of the following analog input boards is used the total number of analog input channels on these boards is limited to 400 DSAI 146 with...

Page 310: ...elow is applied for example Space aspects CPU load Integrity aspects Availability aspects 7DEOH DSDFLW 6 2 DWD 9DOXH No of buses max 7 No of I O units per bus 1 1 Including products like MasterPiece 51 TYRAK L SAMI etc max 16 No of DI signals 2 2 This total includes S100 I O signals S400 I O signals S800 I O signals and calculated signals max 2300 No of DO signals 2 max 1489 No of AI signals 2 max...

Page 311: ...orresponding number of stations 3 1RWH that the total number of I O modules cannot exceed 24 4 This total includes S100 I O signals S400 I O signals S800 I O signals and calculated signals 5 The practical limit depends on number of other PC elements and theres memory size Se PC Element Advant Controller 400 Series Reference manual 7DEOH 3URYLGHG LQN 7 SHV DSDFLW LQN 7 SH 1XPEHU RI LQVWDQFHV Master...

Page 312: ... Advant Fieldbus 100 max 8 buses Tot max 8 PROFIBUS DP max 8 buses LONWORKS Network max 8 buses 3 EXCOM max 2 links V 24 RS 232 C application of basic physical layer max 1 printer max 4 MasterView 320 4 RCOM max 9 links Tot max 9 5 MVI available protocol max 9 links MVI free programmable facility max 9 links GCOM max 5 links 1 You cannot mix MasterBus 300 executed in main CPU and MasterBus 300 exe...

Page 313: ... application program for process control The main key data are listed below 7DEOH 0D LPXP 1XPEHUV 3URFHVV RQWURO XQFWLRQ 0D LPXP QXPEHU I O signals See Section 3 2 3 Process Interface PC programs 99 Levels in structure 9 practical limit is 4 5 Control modules for structuring and execution control See Figure 3 21 Structuring Limits Functional Units and Group alarm SEQ GENOBJ GENUSD GENBIN GENCON MO...

Page 314: ...s log 127 Max no of storable values variables common to all variables in the log 32767 The free amount of RAM usually sets a lower limit Log sampling intervals in discrete steps 1 2 3 4 5 6 10 12 15 20 30 s 1 2 3 4 5 6 10 12 15 20 30 min 1 2 3 4 5 6 12 24 h 1 week 3 3 0 Structuring element max 999 max 99 Structuring element max 999 or Block PC element max 256 Max deep is 9 levels 1RWH Structuring ...

Page 315: ...D DSDFLW The number of local operator stations is limited to 4 HQWUDO 2SHUDWRU 6WDWLRQ HQHUDO 7HFKQLFDO DWD DSDFLW The number of operator stations of the types Advant Station 500 Series and MasterView 800 1 is limited to 16 3ULQWHU HQHUDO 7HFKQLFDO DWD DSDFLW You can use printers which satisfy the following requirements with Advant Controller 450 ...

Page 316: ...nclude all Advant OCS equipment in an automation system 7DEOH 3ULQWHU DWD ZKLFK 0XVW EH XOILOOHG DWD 9DOXH Character code Standard 7 bits ASCII Parity None Number of stop bits 1 Data word length 8 bits Type of interface RS 232 C Baud rate 9600 bits s Protocol XON XOFF No of characters per line 72 Printer speed 160 characters s Limit for Xoff Busy Min 226 bytes 7DEOH 3ULQWHU 6LJQDOV 56 3LQ 6KRUW HV...

Page 317: ...ader will preferably read the Introduction Chapter 1 and Section 3 1 Design Considerations in this manual completely before starting the design work QWURGXFWLRQ WR WKH HVLJQ The realization of a control system is normally based on a range of different documents On the highest level there are Plant Descriptions which give basic and general requirements like Function Operation Security Availability ...

Page 318: ...cation functions You can regard this phase more or less as an installation activity See Section 2 4 2 4 Controller System Configuration RQILJXUDWLRQ SSOLFDWLRQ XLOGLQJ This phase is to a certain extent supported by the same chapters as the system definition phase However most information is available in separate reference documents as follows Configuration and Programming PC Programming PC Element...

Page 319: ... cabinetry Mechanical design Cabinet lay out When the design work reaches this stage the hardware and the system software for the controller have been determined Sufficient information should also be available to permit a controller system configuration The information should include a rough estimation of application functions needed thus facilitating a dimensioning and disposition of the RAM RQIL...

Page 320: ... the reason for providing the signals with plain language names even with a stand alone controller The philosophy behind the naming of the signals is to also be applicable to calculated signals As an example the values provided by two level transducers are averaged to give a calculated signal The physical signals are named LT 104A and LT 104B and the calculated signal is named LT 104 The designati...

Page 321: ...ogram is reduced Instead of designing X program parts one part is designed and used X times at different places perhaps with the addition of a minor PC element for adaptation in certain cases When the function of a type circuit is thoroughly verified in one application the commissioning of the remainder is much simpler Another advantage is that the operator s functions based on type circuits becom...

Page 322: ...d MultiVendor Interface that are to be included in the system 3 Dimension the data base 4 Populate the data base 5 Dump the data base 6 Restart the controller for configuration and load the data base dump 7 Dimension the space for the PC program 8 Build the PC program In this context the input of the program 9 Make a backup of the entire system 127 The command files that control the menu handling ...

Page 323: ...de OFFLINE The processor module executes low level fault tracing commands only Usually performed by ABB personnel The process outputs have defined states zero During the boot phase and during the time of transition between certain working modes the display will indicate intermediate states with the help of a sequence of special codes These codes are relevant at fault finding and system analyses by...

Page 324: ...up unit is about to be synchronized with the primary unit A few seconds 90 after the b2 is displayed the display normally reads b1 STANDBY 3 working mode STOPPED Corresponds to the primary unit see above 4 working mode OFFLINE Corresponds to the primary unit see above 4 1 2 Ordering Working Modes You order working modes in either of the following ways Use a start mode Use Advant Station 100 Series...

Page 325: ...ng initialization of a system including redundant processor modules one of the processor modules is automatically selected as PRIMARY while the other becomes BACKUP The respective processor modules subsequently assume working modes which correspond to those entered by means of the start mode selector on each module The system selects the primary unit according to the following priorities with rega...

Page 326: ...on 2 Press the initialization button on the desired primary unit ENTER 3 When the system begins to operate turn the switch on the backup unit to the same position as the primary unit s switch normally AUTO 4 Restart the backup unit ENTER 4 1 5 Relations between Start Modes and Working Modes The relation between start modes and working modes is described in figures as follows First power up the sys...

Page 327: ...ssor modules then the left module is PRIMARY Resulting working modes PRIMARY P2 CONFIGURATION BACKUP Start in b2 UPGRADING and then transition to b1 STANDBY Figure 4 2 First Power up Starting point Uninitialized controller for example Event Power up Start mode selector Actions executed by the controller Resulting working mode newly delivered controller or controller without memory backup voltage I...

Page 328: ...rough 1 Stop the backup a Set the start mode selector on the backup module in position 2 STOP b Depress the ENTER button on the backup 2 Depress ENTER on the primary module Wait for indication P1 or P2 3 Start the backup module a Set the start mode selector on the backup module in the same position as the primary b Depress the ENTER button on the backup Figure 4 3 Power up of Controller which Cont...

Page 329: ...rking mode CONFIGURATION See Figure 4 5 RECONFIG Reconfigure the controller Clears the RAM that is erases the whole application and orders the controller to working mode CONFIGURATION Also called COLD START See Figure 4 6 Table 4 1 Working Modes at Power Up of Redundant Processor Modules Start mode selection Resulting working mode Primary Backup Primary Backup 1 AUTO 1 AUTO See Figure 4 3 The back...

Page 330: ...s is PRIMARY P2 CONFIGURATION P1 OPERATION BACKUP b1 STANDBY b2 UPGRADING b1 STANDBY LEDs DUAL turned on both processor modules Figure 4 4 Working Mode Caused by DICONFIG Starting point Event Start mode selector Actions executed by the controller Resulting working mode OPERATION P1 CONFIG P2 STOPPED 3 OFFLINE 4 Compulsory setting Controller executing in working mode CONFIGURATION User enters engin...

Page 331: ...he sequence of working modes is PRIMARY P1 OPERATION P2 CONFIGURATION BACKUP b1 STANDBY b2 UPGRADING b1 STANDBY LEDs DUAL turned on both processor modules Figure 4 5 Working Mode Caused by ECONFIG Starting point Event Start mode selector Actions executed by the controller Resulting working mode OPERATION P1 CONFIG P2 STOPPED 3 OFFLINE 4 Controller executing in working mode OPERATION User enters en...

Page 332: ... modes is PRIMARY P2 CONFIGURATION BACKUP b1 STANDBY b2 UPGRADING b1 STANDBY LEDs DUAL turned on both processor modules Figure 4 6 Working Mode Caused by RECONFIG Starting point Event Start mode selector Actions executed by the controller Resulting working mode OPERATION P1 CONFIG P2 STOPPED 3 OFFLINE 4 Controller executing in working mode CONFIGURATION User enters engineering station command RECO...

Page 333: ...rocess Start module and time limits and start method for the restart alternative are defined in the data base element For a detailed description of the start up function see the reference manual AMPL Configuration Advant Controller 400 Series A redundant processor module does not complicate the application and the operation The information given in the previous sections are applied See the overvie...

Page 334: ...the controller Resulting working mode OPERATION P1 CONFIG P2 STOPPED 3 OFFLINE 4 Recommended setting Controller containing an application and executing in working mode OPERATION or CONFIGURATION Power fail Power up Install system SW Erase application CON OP Starting point C R A R A C S Programmed start option RESTART AUTO CLEAR STOP Programmed start Initialize and start application 2 3 4 AUTO 1 S ...

Page 335: ...Start mode selector Actions executed by the controller Resulting working mode OPERATION P1 CONFIG P2 STOPPED 3 OFFLINE 4 Controller executing in working mode OPERATION User presses ENTER button Install system SW Erase application Programmed start A A Programmed start option AUTO Initialize and start application Recommended setting 2 3 4 AUTO 1 2 3 4 1 CLEAR 2 3 4 1 STOP 2 3 1 OFFLINE 3 4 ...

Page 336: ... Start mode selector Actions executed by the controller Resulting working mode OPERATION P1 CONFIG P2 STOPPED 3 OFFLINE 4 Controller executing in working mode CONFIGURATION User enters engineering station Programmed start A A Programmed start option AUTO command DICONFIG Initialize and start application 2 3 4 AUTO 1 Compulsory setting 2 3 1 OFFLINE 3 4 2 3 4 1 STOP 2 3 4 1 CLEAR ...

Page 337: ...mable board connection of thyristor converter with analog speed control and communication with intelligent transducers are implemented as direct interaction between PC elements and the different circuit boards MasterView 320 mainly works with the data base but receives for event printout information directly from PC elements Transverse communication on MasterBus 300 works with the data base and th...

Page 338: ...CI538 free pr comm CI532Vxx MVI Handlers EXCOM MV 320 RS 232 C Printer Applic Program System Program Data Set comm Dialog Pres TTD COS Data Base Data Area for PC program PC program Process comm Console comm Interpreter PC element execution code PM511 DSA__ DSD__ Master Fieldbus Advant Fieldbus 100 CI570 CI522A DSXW 110 Weighing DSDP 140A Positioning DS__ Misc RS 232 C Engineering Station CI534Vxx ...

Page 339: ...e kernel It is also responsible for that part of the data exchange between the different program modules which is not performed in the data base The kernel also organizes interrupts at regular intervals for the cyclic execution for example from DI and communication boards and from the interval clock to activate for example the interpreter Figure 4 11 Survey of Processor Module and Operating System...

Page 340: ...ature measurement boards Pt100 and thermocouple boards the conversion is started cyclically When the conversion is completed the board generates an interrupt The inputs are handled so that the measurement signal is filtered and converted to process related units The limits are checked and then stored in the data base The reading is normally performed synchronous with the execution of PC modules wi...

Page 341: ... for process I O and functional units and is handled as DB elements The data base contains data for for example the following functions Input and output boards Analog input boards AI For standard current and voltage signals For temperature measurement Analog output boards AO Digital input boards DI Digital output boards DO Pulse counter boards Parameters for S100 I O Bus Extension MasterFieldbus A...

Page 342: ...divided into function modules and several execution units which in turn consist of PC elements Each execution unit can be given its own periodicity and its own execution conditions for connection and disconnection PC elements are the smallest building blocks in a PC program They are described in detail in the manual PC Elements As an example Figure 4 12 shows the graphical symbol for the PC elemen...

Page 343: ...the RESET of any unit is activated and so on In an Advant Controller 450 there is a large difference between the shortest and the longest possible cycle times Cycle times of 5 ms and 32 s can be used in one and the same system Normally with no reconfiguration the cycle times are between 10 ms and 2 s An internal allocation of priorities is therefore necessary The system has three interpreters desi...

Page 344: ...interpreter C can be interrupted for the execution of PC elements with cycle times associated with the interpreters A and B The execution of PC elements with cycle times associated with interpreter B can however only be interrupted by the execution of PC elements with cycle times associated with interpreter A The execution of PC elements which are associated with interpreter A cannot be interrupte...

Page 345: ...at a function is divided into execution units which exchange data with each other and that these units have the same cycle time see Figure 4 15 It is also assumed that execution unit 1 is required to execute before unit 2 When the conditions for an execution unit are defined it is possible with the call parameter Place in the cycle table to specify a place number between 1 and 255 This place numbe...

Page 346: ...m code for the function AND from the element library Current values at the storage places pointed out by inputs 1 and 2 are read and the logical AND condition is formed with the help of the program code AND The result is stored at the storage place specified for output 20 The interpreter then resumes control and searches for the next PC element to be executed Figure 4 16 Order of Execution for PC ...

Page 347: ... elements have no effect on the order of execution The PC element DIV with item designation PC1 1 1 4 is thus executed before the PC element ADD PC1 1 1 3 4 1 10 6 Resetting Execution Resetting or RESET execution is performed when some RESET input on an execution unit is activated This means that all variables in the local data area adopt an original status which for most variables is the zero val...

Page 348: ...s is not synchronized 4 1 11 Data Transport 4 1 11 1 Reading in Phase Each execution of an execution unit begins with a reading in phase This means that all PC elements in the execution unit have input data which is read on the same occasion The weight of associated data during the complete execution is illustrated with the example in Figure 4 18 Assume that execution of element 20 is followed by ...

Page 349: ...t with a fixed value MAX or with the calculated signal VALUE Assume that when element 10 has been executed but not 11 an interrupt signal with the cycle time 50 ms is received from the execution unit The PC element in this unit works with the values of the signals VALUE LIMIT and VALUE which are not associated with one another To prevent this the system automatically introduces a reading out eleme...

Page 350: ...NTRM 100 4 CONTRM 500 10 1 2 3 PCPGM 20 1 PC 1 X X X G G G G G G P P P P P DB DB DB DB DB DB Control module executed under interpreter A Control module executed under interpreter B Control module executed under interpreter C GET element for data from data base PUT element for data to data base GET element for data from module with higher priority GET element for data from module with higher priori...

Page 351: ...munication When the system is started the fault indicating red LEDs on the I O boards illuminate If the system goes to the working mode CONFIGURATION the LEDs remain active If the mode goes to OPERATION the process communication starts and the following start sequence is executed Check and initialization of I O boards The internal functions on each board are checked Analog input boards are tested ...

Page 352: ...his is done however in specific situations such as at the time of installation work and maintenance Accordingly operating instructions are spread out in this manual See where the specific activity is treated For general descriptions see the beginning of this chapter For concrete instructions see Chapter 2 Installation and Chapter 5 Maintenance 4 3 Runtime Tutorial See the reference made in Section...

Page 353: ...n is to be replaced by authorized service personnel only Work with care when supply voltage is applied in the system The voltage in the cabinet can cause injury and can even kill a human being Make sure that everyone working on the installation knows the location of the safety switch and the mains power supply switch to the Advant Controller 450 equipment and how to use it When the subsections of ...

Page 354: ...ed by authorized service personnel only Work with care when supply voltage is applied in the system The voltage in the cabinet can cause injury and can even kill a human being Make sure that everyone working on the installation knows the location of the safety switch and the mains power supply switch to the Advant Controller 450 equipment and how to use it When the subsections of the process are c...

Page 355: ...stalled in the system rack Always switch off the voltage before extracting a board which cannot be exchanged while under voltage Wait a sufficient time for the capacitors to discharge Switch off voltage to the system and withdraw all boards at least 20 mm before electrical welding is performed near the controller system A warning label is fixed in the system to draw attention to possible damage by...

Page 356: ...such washings The new filter must be an approved spare part 5 2 6 Backup Batteries Replace the rechargeable battery package mounted inside the controller cabinet on the right hand side after every three years of service Also replace it after each complete discharge the memory contents are lost which introduces the risk of battery cell damage See Section 5 5 10 7 Battery Exchange 5 2 7 Forced Cooli...

Page 357: ...fore the system is stopped The information can then be read by starting the system in working mode OFFLINE Typical halt codes and corrective measures are listed in Appendix H Halt Codes If this method does not function the fault is probably caused by a serious CPU malfunction The fault must then be determined without the use of an engineering station 5 4 1 1 Reading of Halt Codes Detailed informat...

Page 358: ...gineering station Enter the command HARDCOPY ON 6 Enter the following commands one at a time and wait for the printout a LSYSHI List system halt information b LTSL List task switch log c LSYSM ALL List system messages There are cases where it is impossible to connect the engineering station to the Advant Controller or impossible to use all commands In such cases contact ABB NOTE A message is delet...

Page 359: ...ection 1 7 10 1 Diagnostics The following indicating facilities apply on different levels The Controller and I O Cabinet LED indicators on circuit boards Green LED RUN indicates normal function Yellow LED indicates an active signal for example status of digital input DI or digital output DO Red LED FAULT indicates malfunction Character display on processor module front Show working mode error or h...

Page 360: ...s as well In many cases the system status function points out the faulty replaceable unit Please find information of such possibilities in Section 5 5 2 1 System Status and Plain Language System Messages Process Control Certain controller faults for example those related to process I O board channels will probably be detected indirectly when a control function goes wrong For most I O board types t...

Page 361: ...or station is shown The lay out of the display is not identical in an MasterView 800 1 application However the information can be applied Figure 5 2 System Status Display Advant Controller 400 applied to Advant Controller 450 Controller Power Supply Controller Subrack Fan Terminal 24 V supply A Processor module L Controller fan Terminal 1 24 V supply B Processor module R I O fan Terminal 2 Reg red...

Page 362: ...24VA 24VB 24 V distribution Controller Power Supply 24 V supply A B faulty Net xx Nod yy 1 See Section 5 4 9 5 Check of Power Supply Reference in Advant Controller 400 Display Presentation Function Actions at fault Block Diagram Reg redundancy green Normal all regulators present and OK red cr Fault any regulator missing or erroneous Supervision of redundant 5 V regulators in the subrack containing...

Page 363: ...ware DB AC450 System status OS Regulator 1 Hardware REG1_ERR Y N REG1 DIAGN SR511 PM511 24VA 24VB 24 V distribution 2 1 5 V 3 Controller Power Supply POW SUPP ST Voltage Regulator faulty Net xx Nod yy 2 See Section 5 4 9 5 Check of Power Supply Reference in Advant Controller 400 Display Presentation Function Actions at fault Block Diagram Batt volt 2 green Normal red cr Fault Supervision of the ba...

Page 364: ...t Controller 400 Display Presentation Function Actions at fault Block Diagram Processor module L R green filled Processor is primary green empty Processor in backup mode Supervision of redundant 1 Replace the pointed out processor module Plain System Message at fault 6 yellow cr Processor is stopped red cr Processor is erroneous processor modules Software System status OS Processor module L Hardwa...

Page 365: ...AM CARD Memory error Missing card Wrong card pos Net xx Nod yy yellow cr Normal Fault wrong check sum or missing card Warning Initial check in progress Reference in Advant Controller 400 Display Presentation Function Actions at fault Block Diagram Program card 3 1 2 4 1 Supervision of program card including system software check sum 1 Install or replace program card PCMCIA Plain System Message at ...

Page 366: ...m module 1 green Normal red cr Fault Hardware or application program Supervision of free programmable module PU535 1 Replace PU535 Plain System Message at fault 9 2 Load the specific application program C program Software System status OS Free pgm module 1 Hardware DIAGN PM511 DIAGN PU535 DB PU535 ERR IMPL 1 0 MISC ST FPB board out of order Net xx Nod yy PC FPM COM ERROR User connection ...

Page 367: ... redundant branches are installed Hardware POW SUPP ST 24 V I O supply A B faulty Net xx Nod yy Software DB AC450 System status OS 24 V supply A IO24VA_ERR Y N IO24VA DSSS 171 A B 24VA 24VB 24 V distribution I O Power Supply TC520 A1 DIAGN DIAGN A2 AG 0V I O Subrack n 2 1 Fault 24 V DIAGN 1 1 If the inputs A1 A2 are applied to I O 24 V Supply A B supervision then the F1 F2 terminals on the AC450 d...

Page 368: ...DSSS 171 DSBC 174 176 REGFAIL REGMISS POW SUPP ST I O voltage regulator faulty Net xx Nod yy See Section 5 4 9 5 Check of Power Supply Reference in Advant Controller 400 Display Presentation Function Actions at fault Block Diagram Controller fan green Normal red cr Fault all or any of three fans erroneous Supervision of the fan unit in the controller subrack Note The Fan Unit requires 24V dc 1 Che...

Page 369: ... Normal red cr Fault any of the fans erroneous Supervision of fans in all I O subracks collecting signal 1 Check function in cabinet Plain System Message at fault 13 2 Check fuses in the fan unit 3 Check electrical signal 4 Replace fan unit Fan Unit DSBC 174 176 Software DB AC450 System status OS I O fan Fault 0 V 0V Hardware IOFANERR Y N IOFAN DIAGN DSBB 172B Back plane rear side X207 P Fan for I...

Page 370: ...ector Plain System Message at fault broken wire etc 2 Replace the faulty bus extender DSBC 174 or DSBC 176 Software DB PM1 System status OS Bus Extension L Hardware ERR1 DIAGN PM511 S100 BUS EXT STATUS Bus extender error Net xx Nod yy Reference in Advant Controller 400 Display green Normal all left right bus extenders 14 are present and OK erroneous Left right bus extenders are connected to left r...

Page 371: ...ult 0 V A2 B1 B2 Fault 0 V Fault 0 V F1 F2 F3 F4 User defined error 1 Net xx Nod yy 1 1 If the inputs A1 A2 are applied to I O 24 V Supply A B supervision then the F1 F2 terminals on the AC450 data base element must be set to NO That is the indication F1 F2 deleted 15 Reference in Advant Controller 400 Display Presentation Function Actions at fault Block Diagram PCF1 PCF2 PCF4 or user defined gree...

Page 372: ...le on the element For example Terminal 1 2 4 Name RS 232 CI531 missing Net xx Nod yy Reference in Advant Controller 400 Display Presentation Function Actions at fault Block Diagram User defined name green Normal red cr Fault Hardware or software Supervision of printer and its communication 1 Check the communication link with respect to damage loose connector broken wire and so on Plain System Mess...

Page 373: ...ernal computer 1 Check the communication link with respect to damage loose connector broken wire and so on Plain System Message at fault System status OS EXCom 1 Hardware DIAGN PM511 DIAGN CI531 RS 232 C External computer 2 Check the computer 3 Replace hardware modules Modems Computer CI531 one at a time using V 24 RS 232 C and EXCOM protocol 4 See the separate manual EXCOM Name For example EXCom ...

Page 374: ...formation for an S100 I O board 1 If stat indicates erroneous the board should be replaced Plain System Message at fault 1 default DB item designation for Stat Status the board green The board is in service yellow cr Theboard is out of service Act Activated 2 If the board is out of service see respective data base item terminal SERVICE Software DB XX board System status Hardware ERR 1 0 IMPL DIAGN...

Page 375: ...tions at fault Block Diagram User defined name green Normal red cr Fault the board is erroneous Status information for an application specific S100 I O board 1 Replace the board Plain System Message at fault 1 default DB item designation for the board Software DB Misc Board System status Hardware ERR 1 0 IMPL DIAGN XX board NAME Name S100 I O bus extension HW Name PROC I O ST Misc Board error Net ...

Page 376: ...hould be replaced Plain System Message at fault 1 default DB item designation for Stat Status the board green filled The board is in service and primary yellow cr board is out of service Act Activated See Section 5 4 10 1 Board and Subrack Mounted Unit Exchange 2 If the boards are out of service see respective data base item terminal SERVICE Software DB AX Redundant System status Hardware ERR1 1 0...

Page 377: ...al Advant Fieldbus 100 and Data Base Elements AC 400 Series Plain System Messages at fault 1 DB item designation for the bus unit Status green The A B branch is OK red cr The A B branch is erroneous A B physical comm media redundancy Software DB AF100S System status Hardware ERR 1 0 IMPL DIAGN XX Station status DB item design Incl Advant Fieldbus 100 comm HW DIAGN modem CI522A SC5xx status DB item...

Page 378: ...stations 1 See the separate manual PROFIBUS DP and Data Base Elements AC 400 Series Plain System Messages at fault 1 DB item designation for the bus unit Status red cr Fault the bus unit is erroneous Software DB PBS1 System status Hardware ERR 1 0 IMPL DIAGN XX Station status DB item design Incl PROFIBUS comm HW DIAGN modem CI541 status DB item design Bus Station DB CI541 CI541 ERR ERR_I1 2 DIAG_I...

Page 379: ...te manual Advant Interface to LONWORKS User s Guide Plain System Messages at fault 1 DB item designation for the LONWORKS Status Software DB LONDEV1 System status Hardware ERR 1 0 IMPL LONWORKS Device status DB item design DIAGN status DB item design Bus Station DB LONCHAN CI572 CI573 ERR DIAG Network Device or a user unique name 2 1 2 or Name or Name IMPL 1 0 NAME Name NAME Name Fieldbus Fatal bu...

Page 380: ...5 Maintenance 5 28 3BSE 002 415R701 Rev A Advant Fieldbus 100 Bus Unit Display Figure 5 9 System Status Display Advant Fieldbus 100 Bus Unit 1 AF100_2 1 2 Pos Advant Fieldbus 100 Bus 1 Stn 2 Stat Act Type CI522A Subpos Name 1 AF100_2 CI522A 4 3 ...

Page 381: ... manual MasterFieldbus and S400 I O Plain System Messages at fault 1 DB item designation for the bus unit Status green The A B branch is OK red cr The A B branch is erroneous A B physical comm media redundancy Software DB XX unit1 System status Hardware ERR 1 0 IMPL DIAGN XX unit status DB item design A B ERRTYPE Incl MasterFieldbus comm HW DIAGN modem CI570 SC5xx status DB item design A B Bus Sta...

Page 382: ...sages at fault 1 DB item designation for the Status green The 1 2 branch is OK red cr The 1 2 branch is erroneous 1 2 physical comm media redundancy 2 Fieldbus Module error bus no stn no pos no Net xx Nod yy Fieldbus Power supp A error bus no stn no Net xx Nod yy Fieldbus Module warning bus no stn no pos no Net xx Nod yy Station Module yellow cr The Station Module is in warning status green The St...

Page 383: ... O Module1 System status Hardware ERR DIAGN I O Module Status DB item design DIAG DIAGN Status DB item design A B Station Module DB CI810 CI810 ERR DIAG or Name NAME Name 1 Ex of I O Modules AI820 AO810 DI821 DO820 1 2 or Name WARNING Act B Power Supply A Text2 Text1 EX_STAT1 EX_STAT2 EX_TEXT1 EX_TEXT2 Act WARNING SERVICE SERVICE NAME Name ...

Page 384: ...System Messages at fault 1 DB item designation for the Status green The 1 2 branch is OK red cr The 1 2 branch is erroneous 1 2 physical comm media redundancy 2 Fieldbus Module error bus no stn no pos no Net xx Nod yy Fieldbus Power supp A error bus no stn no Net xx Nod yy Fieldbus Module warning bus no stn no pos no Net xx Nod yy Station Module yellow cr The Station Module is in warning status gr...

Page 385: ...illed The board is primary red cr The board is erroneous Supervision of S100 I O Bus Extenders 1 Check the communication link with respect to damage Plain System Message at fault 1 default DB item designation Status L R R is only relevant when redundant yellow cr The board is in warning status loose connector broken wire etc 2 Replace the faulty bus extender DSBC 174 or DSBC 176 green empty The bo...

Page 386: ...d especially watch for opportunities to point out a faulty replaceable unit outgoing from a system message and information given in the system status displays See Section 5 5 2 1 System Status and Plain Language System Messages You can treat most fault finding then in principle as indicated under the heading Typical Simple Scenario below In a more complicated situation other measures are applicabl...

Page 387: ...tructions Replacement instructions Replacement Instructions I II III Classification 1 Taken advantage of Product Reference information LEDs System Status Documentation AdvaCommand System Status Presentation Description Indication description Faulty unit function Pointer to Separate advanced fault finding Documentation documentation Advanced fault finding methods 2 2 Covered by ABB Industrial Syste...

Page 388: ...ng may happen 1 An audible alarm initialized by the run alarm relay indicates controller shut down 2 If installed in any redundant system process alarm and process shut down indications appear as a consequence 3 In the controller cabinet perhaps a complex indication exists Different red LEDs light up An halt code is shown on the processor module character display 4 The fault is classified by you w...

Page 389: ...and try to define the limited part of the controller which fail Then see a suitable Check instruction in this Chapter 5 Maintenance C Faults which stop the system The red HLT indicator on the processor module front is turned ON to indicate that the system has stopped It is probably meaningful to try a system restart Especially if a software error is verified by halt code or system message See Sect...

Page 390: ...he mains supply disconnected On line means that all work is carried out while the controller is in full operation Off line here means that the controller is shut down to a safe position working mode STOPPED The mains supply is still switched on This is a question of system availability possibility of fault finding and safety If redundant functions are included then the system availability probably...

Page 391: ...e which is PRIMARY P1 or P2 on the number display The operation of the engineering station target system does not differ from its operation in a system without redundancy Following a changeover the engineering station loses contact with the target system since the processor module to which it is connected has failed In order to reconnect the aid with the target system connect the engineering stati...

Page 392: ...control functions while operating normally Voltage failure component fault or manual restart usually affect the control system function Control system failure affects the process in different ways more or less serious In a control system with a monitoring character changes in the process status are not registered but there is no immediate danger to the process Control of continuous processes in fo...

Page 393: ...NTER button on the proposed backup module Operation The backup module will pass through the phases of boot loading L UPGRADING b2 and end up in working mode STANDBY b1 Indication Primary module indicates P1 or P2 unaltered Backup module indicates b1 DUAL LED s on both processor modules lit That is the changeover is completed 5 5 9 5 Check of Power Supply The following instructions convey principle...

Page 394: ...re I O subrack functionality including all the I O modules Scenario B These situations are notified by Scenario A An operator station connected to this controller Indications obtained by System message System status display see Section 5 5 2 1 System Status and Plain Language System Messages Lost communication Run Alarm relay contact opens Process behavior Green RUN LED on processor module PM511 i...

Page 395: ...e Scenario A Fault Finding Total shut down is verified First guidance and measures to be taken see Figure 5 15 Figure 5 15 First Guidance Scenario A SR511 LEDs Diagnostic F 5 V 2 V ON ON ON ON ON OFF ON OFF ON OFF OFF OFF Overvoltage Low 5 V voltage Low 2 V voltage Lost 24 V voltage Replace SR511 1 Replace SR511 1 2 Replace SR511 1 Replace or continue with ON OFF OFF Low 24 V voltage or 5 V reg fa...

Page 396: ...n Replace fuse 24 V Check for a disconnection in the 24 V power supply distribution 24 V ok rear side Low voltage N Y Fuse blown F1 Replace fuse Replace DSSR 122 Terminal blocks DSSR 122 Fuse protected 24 V to the backplane for connection of 24 V Regulator 5 V 0V 5V Test 5 V Test 24 V Fuse F1 Fuse 24 V Location of fuses and testpoints I O Subrack 1 I O Subrack 2 3 Valid to the power supply units f...

Page 397: ... an I O subrack power supply Scenario D These situations are notified by Scenario C An operator station connected to this controller Indications obtained by System message System status display The faulty power supply branch A or B is pointed out Failure in the 5 V regulators is pointed out see Section 5 5 2 1 System Status and Plain Language System Messages Scenario D An operator station connecte...

Page 398: ... see Figure 5 15 Figure 5 17 First Guidance Scenario C SR511 LEDs Diagnostic F 5 V 2 V ON ON ON ON ON OFF ON OFF ON OFF OFF OFF Overvoltage Low 5 V voltage Low 2 V voltage 5 V regulator fault Replace SR511 1 Replace SR511 1 Replace SR511 1 Replace SR511 1 Replace or continue with ON OFF OFF 5 V regulator fault Replace SR511 1 OFF ON ON Normal operation See Section 5 5 10 5 Replacement of 5 V Regul...

Page 399: ... with ON OFF ON Normal operation OFF OFF ON OFF ON ON ON ON OFF ON ON ON ON OFF OFF OFF ALIVE AFAIL BLIVE BFAIL PBC LIVE FAIL DSSS 171 DSSR 170 24 V power supply distribution I O Subrack 2 3 LEDs Diagnostic ON OFF ON OFF ON ON ON OFF OFF Regulator fault Supply branch A fault Supply branch B fault Replace actual DSSR 170 1 ON OFF ON Normal operation OFF OFF ON OFF ON ON ON ON OFF ON ON ON ON OFF OF...

Page 400: ...4V distribution SX554 Mains supply A B Take measures Replace 5 V Regulator ON OFF U min Y N LIVE Power switch SX5xx Power supply SA16x Reset MCB Y N N Y MCB tripped output U 19 V Y N Fuse blown Reset Replace fuses Check for a disconnection in the 24 V power supply distribution 19 V Test See Section 5 5 10 5 Replacement of 5 V Regulator See Section 5 5 10 4 Replacement of Power Supply Unit Replace ...

Page 401: ... the character display and analyses the problem primarily as described in Section 5 4 Error Messages Take recommended measures If not successful you should methodically follow the fault finding instructions elsewhere in this chapter Figure 5 20 Check of Backup Power Supply SB510 511 L Diagnostic F BP BF OFF OFF OFF OFF OFF OFF ON ON OFF Normal operation Lost supply voltage or Battery fault 1 See n...

Page 402: ...ludes two processor modules both of them should normally indicate DUAL The character display normally show the working mode of the controller P1 P2 and so on See Chapter 4 If anything else is presented the system has probably stopped and the stop code can be read from Section 5 4 Error Messages This section also includes corrective actions The four LEDs close to the service port show the status of...

Page 403: ...ation can be found in the manual S100 I O Hardware Check the power supply units for the actual I O subrack Check for blown fuses and other reasons for voltage disconnection Check fuses for process signals Most connection units contain fuses The coupling is shown in the circuit diagram for the equipment delivered Check signal levels on the connection unit screwed terminal Use a digital voltmeter an...

Page 404: ...ue at step 5 If the system starts the fault is probably in the communication or the I O system Continue as follows a Expand the system by returning modules to their original location b First add Backup Power Supply SB510 511 System Status Collector TC520 and remaining submodule carriers with communication interface modules then the S100 I O boards one at a time until the fault reappears c Replace ...

Page 405: ...e board and associated signals are marked as faulty in the data base While the fault marking persists the value VALUE is not updated in the data base The system software checks that the board is inserted and correct If this is the case the fault diode extinguishes after 10 s the fault marking in the data base is reset and the board resumes its normal function Under the following headings you can f...

Page 406: ...plastic 11 Ensure that the board unit contacts mate properly with the contacts in the rear plane Screw the locking bar in place I O subrack Fasten the screws in the handles controller subrack 12 Connect the cables controller subrack 13 Switch on the supply voltage if it is switched off With the start mode selector in the AUTO position the system is automatically initialized and restarted 14 Boards...

Page 407: ...ssible Described in MultiVendor Interface MODBUS with MS and CI532V02 Advant Controller 400 Series CI532V03 No jumpering On line replacement possible Described in MultiVendor Interface Siemens 3964R Advant Controller 400 Series CI534V02 No jumpering On line replacement possible Described in MultiVendor Interface MODBUS with CI534V02 Advant Controller 400 Series CI534V04 No jumpering On line replac...

Page 408: ...ement possible Described in MasterFieldbus and S400 I O CI572 CI573 No jumpering On line replacement possible Described in Advant Interface to LONWORKS User s Guide CS513 Switches are used to Set node address Select MB 300 or MB 300E Select function executed in main CPU or executed in slave CPU On line replacement possible Described in MasterNet User s Guide MB510 No jumpering On line replacement ...

Page 409: ...Described in Appendix A Hardware Modules SB511 No jumpering On line replacement possible however not during a mains supply interruption while the battery is used See Section 5 5 10 6 Replacement of Backup Power Supply Described in Appendix A Hardware Modules SB522 No jumpering See Section 5 5 10 7 Battery Exchange Described in Appendix A Hardware Modules SC510 No jumpering On line replacement poss...

Page 410: ...ment of TC560 when S100 I O bus redundancy is used see Section 5 5 10 3 Replacement of Redundant S100 I O Bus Extenders Described in S100 I O Hardware TC561V1 No jumpering On line replacement possible however not practical Reflect the consequences to all S100 I O boards The outputs will be forced to the safe position 0 V open contact You are recommended to switch off the mains supply during the re...

Page 411: ...ev A 5 59 Table 5 2 Replacement Aspects of Individual Board Types S100 I O Board type Jumpering Comments DSAI 130 On line replacement possible DSAI 130A On line replacement possible DSAI 133 On line replacement possible DSAI 133A On line replacement possible S2 S1 S2 S1 S2 S1 S2 S1 ...

Page 412: ...unit Disconnect cable which joins the board an the connection unit DSAO 120 On line replacement possible Note In general the electrical connections between output boards and the process is to be broken before the board is extracted Alternative methods includes Open terminal switches on the connection unit Disconnect cable which joins the board and the connection unit Table 5 2 Replacement Aspects ...

Page 413: ...n unit Disconnect cable which joins the board and the connection unit DSAO 130A On line replacement possible Note In general the electrical connections between output boards and the process is to be broken before the board is extracted Alternative methods includes Open terminal switches on the connection unit Disconnect cable which joins the board and the connection unit DSAX 110 On line replaceme...

Page 414: ...BC 174 DSBC 176 is installed Important process objects are then to be switched off externally or disconnected to avoid damage When all of the red Fault LEDs on I O boards are extinguished the process may be reconnected and returned to operations in a controlled manner preferably in stages with the inputs first and the most critical outputs last Note If the supply to a subrack is switched on before...

Page 415: ...5 63 DSDI 110A On line replacement possible DSDI 110AV1 On line replacement possible DSDI 120A On line replacement possible DSDI 120AV1 On line replacement possible Table 5 2 Replacement Aspects of Individual Board Types S100 I O Continued Board type Jumpering Comments S1 S2 S1 S1 S2 S1 ...

Page 416: ... to be broken before the board is extracted Alternative methods includes Open terminal switches on the connection unit Disconnect cable which joins the board and the connection unit Switch off relevant field power supply DSDO 120A On line replacement possible Note In general the electrical connections between output boards and the process is to be broken before the board is extracted Alternative m...

Page 417: ... 002 415R701 Rev A 5 65 DSDP 150 On line replacement possible DSDP 170 On line replacement possible Table 5 2 Replacement Aspects of Individual Board Types S100 I O Continued Board type Jumpering Comments S104 S110 S109 S112 X3 S10 S20 S1 S9 S10 S11 S12 S13 S14 S2 S1 ...

Page 418: ...ant pair and which can not For example you can not mix 8 and 16 Mbyte versions 6 Prepare the replacement module by putting it s start mode selector in position 2 STOP 7 Insert the new module carefully without reaching the rear plane contacts Ensure that the module slides in the guides in the subrack 8 Push in the new module quickly and decisively 9 This new processor module now becomes the backup ...

Page 419: ... decisively 7 Set the front switch on the new board to position RUN The RUN and DC OK LEDs are turned on 8 Depress the ENTER button on the stopped processor 9 The processor will now start up as a backup 10 Store the extracted board in an envelope of conductive plastic Replace a primary TC560V1 TC561V1 1 A primary optical modem should never be replaced Stop the primary processor by setting the star...

Page 420: ...100 I O Bus connection cable 3 Remove the optical fibres 4 Replace the optical modem 5 Connect the optical fibres 6 Connect the S100 I O Bus connection cable 7 Connect the power supply to the optical modem The LEDs P TX and RX are turned on 5 5 10 4 Replacement of Power Supply Unit DANGER Power supply units should be replaced by authorized service personnel only The branch A or B which is to be re...

Page 421: ...harged When the power supply system is loaded the discharge takes 10 secs and when unloaded 60 secs Use the switch S1 on the actual power switch unit 2 Gain access to the connectors on the voltage supply unit 3 Check with a volt meter that the voltage supply unit is dead on both the primary and secondary sides Any faulty voting diode can give a secondary back voltage 4 Disconnect actual connectors...

Page 422: ... 9 Check the regulator LED indications F should be OFF while 2 V and 5 V should be ON 10 Store extracted unit in envelope of conductive plastic Redundant SR511 1 The replacement is made on line That is with the mains supply on The controller operation will not be disturbed 2 Provide access to the unit by loosening the screws in the handles 3 Grip the faulty unit firmly and extract it decisively Us...

Page 423: ...er DSSR 170 1 The replacement is made on line That is with the mains supply on The controller operation will not be disturbed 2 Open the hinged frame to gain access to the unit on the rear side of the I O subrack 3 Unscrew the two fixing screws and remove the regulator 4 Check that the new unit can replace the old Check for lowest revision approved variant to be used for the equipment and use repl...

Page 424: ... and decisively Use both handles 4 Check that the new unit can replace the old Check for lowest revision approved variant to be used for the equipment and use replacement of the same or higher revision number 5 Insert the new unit carefully without reaching the rear plane contacts Ensure that the unit slides in the guides in the subrack 6 Push in the new unit quickly and decisively 7 Ensure that t...

Page 425: ...the outputs via some application function for example a closed loop control Practical Execution Replace faulty or suspect connection units as described below 1 See that process connections signals and power supply are disconnected before starting the replacement work Determine where it is easiest to disconnect on a case by case basis because of the differences in different applications In some cas...

Page 426: ...nstructions below The detailed information for individual circuit boards for example location of test terminals location of potentiometers jumpering function descriptions and so on is provided in the manual S100 I O Hardware If the potentiometers are not accessible on the front place the board on an extension board DSFB 110 On the units which can be adjusted channel by channel adjust the channels ...

Page 427: ...nel adjustment Common adjustment Req of DSFB 110 1 1 If a potentiometer is not accessible from the front place the board on an extension board DSFB 110 DSAI 110 Z G DSAI 130 Z B G Z G S 2 2 Symmetry S which is adjusted in a test during manufacture has the same effect as Gain G but only on positive values Yes DSAI 130A The module is calibrated at production DSAI 133 G Automatic adjustment 3 3 DSAI ...

Page 428: ...with G2 0 Adjust the signal U to 0 000 V with the channel potentiometer Z CMRR Adjustment Channel by Channel With G1 short circuited and G2 100 V Adjust the signal U to 0 000 V with the channel potentiometer B With the same connections change G2 to 100 V and check that the signal U 0 000 V Full Scale Adjustment Channel by Channel With G1 Full scale value FS usually 10000 mV for voltage input and 2...

Page 429: ... ensure that ACT is set to 1 and afterward reset to 0 Select a signal with CONV_PAR 10 10 V exception in accordance with the above or change CONV_PAR in the data base element concerned Make the updating continuous by setting DEADB 1 and FILTER_P 0 note previous values so that they can be reset after the adjustment The reference voltage for the adjustment is connected to the connection unit and the...

Page 430: ...Boards DSAI 145 146 and DSAI 151 It is easiest to perform the adjustment of the Pt100 temperature board with accurate resistors as references Select an input and corresponding data base element for the adjustment If you select an unused input ensure that ACT is set to 1 and afterward reset to 0 Select a signal with CONV_PAR 640 C or change CONV_PAR in the data base element selected Make the updati...

Page 431: ...ing can be of interest Adjustment of the zero point Z Adjustment of gain G Adjustment of the variable gain V Setting of the limits L1 L2 It is not certain that all circuit boards encountered in this connection have all of these adjustment possibilities Before the adjustment jumper the circuit board for the mode voltage current in which it is to be used The connection required is shown in Figure 5 ...

Page 432: ...AO channel for example MDB AO1 X CR M10 CR Modify property 10 VALUE 3 87 New value 0 CR End X channel number The text underlined is presented by the engineering station Measure the voltage over the channel output on the connection unit and adjust the zero point with the potentiometer Z until the instrument shows 0 000V Figure 5 23 Adjustment of Current Output Z G L1 L2 Connection unit Current outp...

Page 433: ...th the potentiometer R8 output voltage reference X3 3 4 5 5 12 3 Adjustment of Variable Gain Channel by Channel The variable gain is intended for special applications in which it is necessary for some reason to adjust a signal within the complete range 0 100 Use the potentiometer V for the adjustment If the variable gain is not used screw out the potentiometer completely so that it does not affect...

Page 434: ...ance Activities Maintenance carried out On line If fault finding and module replacement has been made on line the new module and its system function will be automatically initialized and restarted within a few seconds Maintenance carried out Off line It is assumed that the controller has been manually stopped by the start mode selector set in position 2 STOP followed by depressing of the ENTER but...

Page 435: ...y a restart A processor module which has stopped indicate HLT and a certain halt code This information and if any system messages available in the computer disappears after a restart or after they have been read by any engineering tool 1 Make a note of the halt code indicated on the processor module character display 2 If an engineering station is available and you have the time and knowledge proc...

Page 436: ...e maintenance organization of the plant is responsible for well developed and adapted routines in this area Below one possible scenario is described to get an overview of the loading You may see the instruction directed to the not so experienced maintenance personnel which has to take care of a program load in an emergency situation The controller has stopped the processor module indicate HALT and...

Page 437: ...eering station boot Windows start up 7 If necessary start Application Builder in Appropriate node found AdvaBuild window to select project and node 8 Start On line Builder from within the Booting engineering board Application Builder or in AdvaBuild Press Ctrl Break window 9 Press Ctrl Break to activate the engineering tool 10 Select 1 Advant Controller 400 CR 11 Select 1 Advant Controller 400 pro...

Page 438: ...ts indications of the system load as a basis you can adjust for example the chosen cycle times and thereby optimize the use of the available performance The ANPER command is made up of a number of options The first choice is between analysis of the load of the entire Advant Controller system load or the load per system part task load Please refer to the separate reference manual AMPL Configuration...

Page 439: ...elect the On line Builder menu for Flash Card Write 4 Select the desired DUAP 5 Pushing the Enter button will start the creation of the backup flash card which is now denoted an application program card 6 Move the application program card to the Program Card Interface MB510 of the controller The program card can be inserted on line No configuration work needed The green LED on MB510 front will lig...

Page 440: ...he original DUAP file The same apply to any replacement or later installation of an application backup program card Always perform a functional test for safety s sake 5 8 System Upgrade How to change a program card including the system software to a variant with an other assembly of program modules that is an other functional assembly is described in Section 2 6 6 Enlargement of the System Softwar...

Page 441: ... V XLGH CI522A AF 100 Communication Interface GYDQW LHOGEXV 8VHU V XLGH CI531 RS 232 C Communication Interface two channels Section A 2 CI531 RS 232 C Communication Interface CI532V01 RCOM Communication Interface 5 20 6HULHV CI532V02 MODBUS Communication Interface 0XOWL9HQGRU QWHUIDFH 02 86 ZLWK 06 DQG 9 6HULHV CI532V03 Siemens 3964R Communication Interface 0XOWL9HQGRU QWHUIDFH 6LHPHQV 5 6HULHV CI...

Page 442: ...ut Output Units 0DVWHU LHOGEXV DQG 6 2 8VHU V XLGH DSBC 17x Bus Extension Board 6 2 DUGZDUH 5HIHUHQFH 0DQXDO DSDC 111 Motor Drive Control 6 2 DUGZDUH 5HIHUHQFH 0DQXDO DSDI 1xx Digital Input Boards 6 2 DUGZDUH 5HIHUHQFH 0DQXDO DSDI 4xx Digital Input Units 0DVWHU LHOGEXV DQG 6 2 8VHU V XLGH DSDO 1xx Digital Output Boards 6 2 DUGZDUH 5HIHUHQFH 0DQXDO DSDP 1xx Pulse Frequency Measuring Board 6 2 DUGZD...

Page 443: ...UHQFH 0DQXDO DSTY 101 Isolation Amplifier 6 2 DUGZDUH 5HIHUHQFH 0DQXDO MB510 Program Card Interface Section A 4 MB510 Program Card Interface PM511V Processor Module Section A 5 PM511V Processor Module PU535 Free Programmable Module C language UHH 3URJUDPPDEOH 0RGXOH HYHORSPHQW QYLURQPHQW RB5xx Dummy Modules Section A 6 RB5xx Dummy Modules RC527 Fan Unit Section A 7 RC527 Fan Unit RE810 Wall Cabine...

Page 444: ...Switch and Distribution Units SX551 Power Distribution Unit Section A 17 Power Switch and Distribution Units SX555 Power Switch and Distribution Unit Section A 17 Power Switch and Distribution Units SX554 Distribution Unit 60 V d c Section A 18 SX554 Distribution Unit 60 V d c TB8xx Module Bus Modem 6 2 8VHU V XLGH TB805 TB806 Cable Adaptor 6 2 8VHU V XLGH TB807 Terminator 6 2 8VHU V XLGH TB815 In...

Page 445: ... Westermo Teleindustri AB TC570 MasterFieldbus Connection Unit MasterFieldbus and S400 I O User s Guide TC625 Advant Fieldbus 100 Coaxial Modem GYDQW LHOGEXV 8VHU V XLGH TC630 Advant Fieldbus 100 Coaxial Optical Modem GYDQW LHOGEXV 8VHU V XLGH TKxxx Cables Depending on application S100 S800 MasterNet Advant Fieldbus 100 etc TK560 Interconnector near side 6 2 DUGZDUH 5HIHUHQFH 0DQXDO TU8xx Modules ...

Page 446: ...esignation See Table A 2 below Two RS 232 C communication interface Modem support HVFULSWLRQ CI531 is a submodule destined to the Submodule Carrier SC510 and SC520 The two RS 232 C communication interfaces are generally used in the following applications Printer EXCOM MasterView 320 See the controller documentation The communication channels support communication speeds up to 19 2 kbaud which is t...

Page 447: ... 0HFKDQLFDO DWD Module size Occupying one submodule slot H 95 mm L 140 mm connector not included Weight 0 13 kg 0 29 lbs 7DEOH 3LQ HVLJQDWLRQ IRU KDQQHO DQG RQQHFWRU DQG 3LQ 6KRUW HVFULSWLRQ 1 DCD Data Carrier Detect 2 RD Receive Data 3 TD Transmit Data 4 DTR Data Terminal Ready 5 GND Ground 6 DSR Data Set Ready 7 RTS Request To Send 8 CTS Clear To Send 9 RI Ring Indicator ...

Page 448: ...irst I O subrack require one energy reservoir Additional I O subracks need a second unit The following description refers to the block diagram next page The capacitor charging current is limited with a low resistance power resistor The energy stored in the capacitors is discharged via a resistor when the unit is disconnected from the mains power supply and the load Unregulated d c supply is connec...

Page 449: ...Width 482 mm 19 Height 177 mm 7 4 U Depth 75 mm 3 Weight 2 8 kg 6 2 lbs ORFN LDJUDP 7DEOH 66 2SHUDWLQJ DWD WHP 9DOXH Voltage rating input 24 V d c Output voltage 24 V d c Backup time in the range 18 5 16 V with 25 A load 5 ms Voltage derivative with power failure with 25 A load 0 3 V ms 66 X1 X2 1 2 3 4 1 2 3 4 ...

Page 450: ...ipped with flash PROM for different use For example to store and backup the system program of the controller An optional use is to store and backup the application program separate program card The flash PROM content is loaded into the processor module RAM during the primary initialization of the controller The diagnostics are mainly based on cyclic check sum calculation A red LED on the module fr...

Page 451: ...N green Module running normally 3RZHU 6XSSO 5 V d c typical 10 mA max 170 mA when reading Power loss heat typical 0 05 W 0HFKDQLFDO DWD Module size occupying one submodule slot Module weight 0 12 kg 0 26 lbs ORFN LDJUDP Fault Run Program card PCMCIA 2 0 Control Control Address Data Address Data Buffers Interface logic Contact to carrier module Contact 0 ...

Page 452: ...on is used Arbitration messages are supported To support a configuration with two redundant processor modules with one running in backup mode PM511V is equipped with logic that transfers a copy of all writes in the primary processor to the backup processor thereby keeping a complete updated copy of the primary processor s memory in the backup pro cessor This makes it possible for the backup proces...

Page 453: ...LFDWRUV LEDs on module front F red Module error RUN green Module running normally HLT red CPU halted TO yellow Bus time out BC green Backup voltage for RAM connected DUAL green Redundant processor ready 3RZHU 6XSSO 5 V d c typical 4900 mA max 6000 mA 24 V d c typical 200 mA max 280 mA Power loss heat typical 25 W 0HFKDQLFDO DWD Module size 12 SU 6 mp Module weight 0 8 kg 1 8 lbs ...

Page 454: ... Available module types are 7 SH HQRPLQDWLRQ SSOLFDWLRQ LPHQVLRQ RB510 Dummy Module full height 12 SU 6 mp 300 mm 30 mm Substituting for example Carrier Module Processor Module RB520 Dummy Module for submodule slot Substituting for example Communication Interface RB530 Dummy Module half height 6 SU 6 mp 150 mm 30 mm RB540 Dummy Module half height double width6 SU 12 mp 150 mm 60 mm Substituting fo...

Page 455: ...all three fans must work The unit is intended to be located beneath a controller subrack aimed at lowering the operating temperature of the electronic modules Operation is supervised by a speed sensor on each fan Indication FANFAIL is given when one or more fans fail Dust filter should be replaced at regular interval with respect to actual environment An integrated cable duct is used to support ca...

Page 456: ...KDQLFDO DWD Dimension 482 mm x 330 mm x 100 mm 19 x 13 x 4 excl cable duct 482 mm x 425 mm x 100 mm 19 x 16 7 x 4 incl cable duct Weight 3 kg 6 6 lbs 0DLQWHQDQFH 3DUWV Miniature Fuse Link 5 x 20mm 0 8AF fast ABB part no 3BSC 770 001 R43 Filter Carpet dust filter ABB part no 3BSC 930 057 R0001 Fan spare part ABB part no 6480 096 9 ORFN LDJUDP Fan 1 Fan 2 Fan 3 Power Supply Power Supply Power Supply...

Page 457: ...inet Admittance to the rear side of the subrack is not necessary after the installation A number of slots for modules of different sizes are included See figure below Each module is individually locked by snap on handle and screws The back plane is raised 35 mm and provides test and connection facilities for the power supply and battery supply A fan unit RC527 is mounted beneath the subrack This u...

Page 458: ...ges 5 V Test of 5 V power supply of the controller subrack 5VBACK Test of the RAM backup voltage 5 V 24 V A resp 24 V B Connection of system power supply 24 V B used at redundancy VBAT B resp VBAT A Connection of NiCd battery A used to double the battery capacity AUXx y PFAIL x Connections not applied 0HFKDQLFDO DWD Dimension See dimension drawing below Weight 8 5 kg 18 7 lbs ...

Page 459: ...for cables and y 300 11 8 7 U 35 330 13 37 7 57 2 88 9 222 25 445 17 5 482 19 Back plane 5 cable duct All measurements in mm in 7HVW DQG FRQQHFWLRQ IDFLOLWLHV SURYLGHG E WKH UDLVHG EDFNSODQH 0V 2 1V 3 3V 5V 5VBACK Test AUX1 A AUX2 A VBAT A AUX1 B AUX2 B VBAT B PFAIL A PFAIL A 24V A 24V B Connections 100 3 9 8 8 1 5 2 3 3 5 1 4 ...

Page 460: ...fers in width and number of units only A maximum of nine modems for example type TC625 or TC630 for Advant Fieldbus 100 can be fixed by two screws included in the modem design RF540 12 modems As an alternative a top hat rail is available for flexible application The subrack provides two contact groups which simplify 24 V distribution from the cabinet supply to the units The pluggable connection of...

Page 461: ...or the two variants are given below Otherwise see dimension drawing on previous page RF541 RF540 Total width 482 mm 19 609 mm 24 Hole pattern 465 mm 18 592 mm 23 Weight RF541 3 kg 6 6 lbs RF540 3 5 kg 7 7lbs ORFN LDJUDP SSOLFDWLRQ RI FRQWDFW JURXSV 24V 0V to first unit to second unit and so on from cabinet supply 13 RF540 14 RF540 As above 5 ...

Page 462: ...er supply units converting single phase a c to smooth but unstabilized 24 V or 48 V d c A unit includes a transformer giving galvanic isolation between the mains voltage and the d c output It also includes a full wave rectifier and a filtering capacitor The power supply unit is internally loaded to reduce the voltage at d c load switch off and to discharge the capacitor at mains switch off Electri...

Page 463: ...oltage a c nominal 120 V 230 V 120 V 230 V 120 V 230 V Mains voltage variation 85 110 Mains voltage a c max f 47 65Hz 142 V 285 V 142 V 285 V 142 V 285 V Mains load VA 450 VA 900 VA 450 VA Mains load W 320 W 705 W 320 W cos φ 0 7 min 0 75 min 0 7 min Efficiency factor 85 typ Output voltage at max current 26 V 10 A 25 V 25 A 50 V 5 A Ripple 100 Hz peak to peak r m s at max current 2 V max 1 V max 4...

Page 464: ...ht SA161 162 15 kg 33 lbs SA167 168 24 kg 53 lbs SA171 172 15 kg 33 lbs 0DLQWHQDQFH 3DUWV Midget Fuse 10 38 mm 6 AF fast ABB part no 5672 827 6 10AF 5672 827 10 15AF 5672 827 15 ORFN LDJUDP 7DEOH XVHV LQ 6 XVH 6 6 6 6 6 6 F1 a c Midget Fuse Fast 10AF 6AF 15AF 10AF 10AF 6AF F2 d c with reset button Time Lag 15AT 15AT 30AT 30AT 8AT 8AT d c output a c mains PE L1 L L2 N GND SA167 168 only 6 X1 X2 1 2...

Page 465: ... works together with one single battery package for example SB522 Use these two modules for current supply of processor module RAM in the event of mains supply drop out The capacity expressed in time of backup depends on the application Please refer to the actual Advant Controller documentation Use two sets SB510 and SB522 to double the backup time The mains supply input provides fusing and other ...

Page 466: ...ned to NiCd battery 12 V 4 Ah for example SB522 Charging current QGLFDWRUV LEDs on module front F Fault red Low charging current low 5 V supply IP is supposed to indicate converter in operation IP Input Power green Mains supply available converter in operation BP Battery Powered ylw Mains supply not available discharging of battery BF Battery Fault red Discharged unconnected battery short circuit ...

Page 467: ...15R701 Rev A A 27 Block Diagram 2AF SB522 6 RAM Processor Module Normal 5V supply Mains Supply a c or d c 2AF SB522 6 RAM Processor Module Normal 5V supply Mains Supply a c or d c Normal Operation Charging of Battery Backup Operation Discharging of Battery L N X11 PE PE L N X11 ...

Page 468: ... which works together with one single battery package for example SB522 Use these two modules for current supply of processor module RAM in the event of mains supply drop out The capacity expressed in time of backup depends on the application Please refer to the actual Advant Controller documentation Use two sets SB511 and SB522 to double the backup time The mains supply input provides fusing and ...

Page 469: ...ndicate converter in operation IP Input Power green Mains supply available converter in operation BP Battery Powered ylw Mains supply not available discharging of battery BF Battery Fault red Discharged unconnected battery short circuit or interruption in battery cold battery at start FC Fast Charging ylw Indicates recharging after power up or battery replacement 10 hours 0DLQWHQDQFH 3DUWV Miniatu...

Page 470: ...SB522 includes 10 NiCd cells size D organized in two lines The battery package as well as the connecting device are semi protected There is a built in non replaceable fuse to protect against shorts and results such as fire Store SB522 in a charged or discharged condition without considerable influence to useful life To be installed vertically in a well ventilated place max 40 1 6 max 341 13 4 325 ...

Page 471: ...eable fuse 20 A quick action 0HFKDQLFDO DWD Dimension width max 71 mm 2 8 height max 350 mm 13 8 depth max 40 mm 1 6 Weight 1 4 kg 3 1 lbs 5HOLDELOLW LJXUHV Useful life 3 years 0DLQWHQDQFH Replace the battery after three years of normal operation The battery includes cadmium and is to be treated as KD DUGRXV ZDVWH 0DLQWHQDQFH 3DUWV Battery Unit SB522 Block Diagram 12V 0V 20AF X1 4 X1 1 6 ...

Page 472: ...or HVFULSWLRQ Three variants of submodule carriers are available to fit into RF533 Series controller subrack A submodule carrier has no complete function but two slots for submodules of different kinds to define the desired function Communication interfaces are the most common category of submodules The actual application determines which submodule carrier to use Design considerations are given in...

Page 473: ...cates module running normally LED F Fault red on module front 3RZHU 6XSSO 6 6 5 V d c typical 1 3 A1 5 A excl submodules max 2 0 A2 0 A excl submodules 24 V d c typical 6 mA6 mA excl submodules Power loss heat typical 0 7 W0 8 W excl submodules 0HFKDQLFDO DWD Module size 12 SU 6 mp12 SU 6 mp Weight 0 55 kg 1 2 lbs 0 8 kg 1 8 lbs excl submodules ...

Page 474: ...ltage regulator units in a controller with 24 V d c unstabilized voltage It also provides galvanic isolation between the d c network and the d c output SD150 includes a mains filter circuits for limitation of power output protection of input against incorrect polarity and overvoltage protection of the output Adjustment controls for output voltage current limitation and overvoltage protection are l...

Page 475: ... 5DWLQJ Depth 337 mm 13 2 IP20 according to IEC 529 IEC 144 Height 132 mm 5 2 3 U QVXODWLRQ Weight 10 kg 22 lbs Rated insulation voltage 2000 V d c Input case or input output Block Diagram 7DEOH 6 2SHUDWLQJ DWD WHP 9DOXH Input voltage 24 48 V d c Input voltage variation 80 120 of nominal value Output voltage 24 V d c Maximum load 20 A Maximum input power 600 W Overcurrent protection output 25 A IN...

Page 476: ...ly Thus n regulators can share the load giving an arbitrary capacity of power and where adding an extra regulator to the stack the n 1 redundant power supply system is derived In an Advant Controller 450 use two SR511s to achieve redundancy You can exchange one regulator at a time in a redundant regulator live system without generating malfunction Two 24 V power supply networks with a common negat...

Page 477: ...Aexclusive 2 V load Current limit 43 A 3 A inclusive 2V Uin 24 V Overvoltage protection 6 3 V electronic 7 V typ 6 5 V min zener clamp 2XWSXW 9 G F Rated output voltage 2 1 V at 1 5 A load Voltage variation 2 2 V max 2 0 V min at 0 A and 6 A respectively Ripple voltage 10 mV typ at 8 A load Rated load current 1 3 A average Current limit 8 A min 9 5 A typ Temperature protection Linearly decreasing ...

Page 478: ...ed to the mains supply are equipped with a main power switch labeled S1 Expansion units lack the switch S1 PSD units are divided into two categories Main power supply for the Advant Controller for connection to mains A or the redundant mains B a c or d c Auxiliary power supply for for example modems battery charger etc for connection to mains C a c only These PSD units are referred to as main and ...

Page 479: ...0 Rated insulation voltage V 250 250 250 250 250 250 250 60 60 30 Dielectr test voltage a c V 3250 3250 3250 3250 3250 3250 2200 1000 1000 1000 Rated input voltage V 230 120 230 120 230 120 230 120 230 120 48 48 24 Rated input current A 1 6 3 2 1 6 3 2 35 35 25 80 80 100 Primary fuse external A 35 35 35 35 35 35 25 80 80 100 Primary fuse internal A Miniature Circuit Breaker see Block Diag Outlet f...

Page 480: ...8 202 mm 8 Height 177 mm 7 177 mm 7 corresponds to 4 U height modules in a cabinet Depth 95 mm 3 7 95 mm 3 7 130 mm 5 at the rear side of the apparatus plate Hole pattern is given in separate detailed dimension drawing Weight 2 5 kg 5 5 lbs 10 kg 22 lbs ORFN LDJUDP L N T1 F1 F3 X1 L1 L2 PE X2 PE L N PE L N PE L N PE X3 X4 X5 69 69 69 69 T1 F1 X1 X2 Isol transf K 10A K 10A X3 X5 Screw term 10A 10A ...

Page 481: ...PE L N PE L N PE X3 X4 X5 69 69 F2 1 3 X1PE K1 F2 69 69 T1 F1 F2 X1 Isol transf K 10A K 10A X3 X5 Screw term 10A 10 mm 2 10 mm2 MCB Outlet socket 10A 230 V 300 VA 120 V 300 VA F3 MCB K 1 6A K 3A F1 F2 Screw term 35 mm2 35 mm2 F1 X1 L N PE X2 PE L N PE L N PE L N PE X3 X4 X5 6 F1 X1 X2 K 10A X3 X5 Screw term 10 mm2 Outlet socket 10A 6 ...

Page 482: ...6 S1 F1 F2 X1 X2 Power switch K 16A K 25A X3 X5 Screw term 16A 25A 6 6 L1 L2 PE X2 F1 F2 16 mm 2 35 mm2 MCB Outlet socket L1 L2 Design as is L L X3 X4 X1 L1 L2 PE L1 L2 PE L1 L2 PE L1 L2 PE X3 X4 X5 6 6 F1 F2 X1 X2 K 16A K 25A X3 X5 Screw term 16A 25A 6 6 L1 L2 PE X2 F1 F2 16 mm 2 35 mm2 MCB Outlet socket L1 L2 Design as is L L ...

Page 483: ... 8VHU V XLGH 6HFWLRQ 3RZHU 6ZLWFK DQG LVWULEXWLRQ 8QLWV 3BSE 002 415R701 Rev A A 43 S1 S1 1 3 X1PE 1 3 F1 6 S1 F1 F2 X1PE Power switch K 50A S1 F1 F2 Screw term 35 mm2 6 F1 F2 35 mm 2 MCB Screw rerm L L L L 1 3 F2 L L ...

Page 484: ...the power inlet and one fast on tab connected to the steel frame for example used for grounding a cable shield Fast on tabs are utilized for the unfused power outlets to controller and I O subracks and for the five two pole male connectors fused 10A for connection to low power consumption units like modems backup battery chargers and field equipment The SX554 has an LED indicating a voltage at the...

Page 485: ...d protection with reset button 10AT time lag F2 Miniature Fuse Link 1AF fast 0HFKDQLFDO DWD Width 482 mm 19 Depth 240 mm 9 4 Height 43 mm 1 7 corresponds to 1 U height module in a cabinet Weight 1 kg 2 2 lbs 0DLQWHQDQFH 3DUWV Miniature Fuse Link 5 x 20 mm 1AF ABB part no 3BSC 770 001 R44 ORFN LDJUDP F1 F2 1AF 10AT X21 X22 X23 X10 X11 X12 X14 X15 X1 X5 X2 X4 1 2 1 2 a b a b R2 6 GND LIVE Terminal D...

Page 486: ...nk This serial link is available on the backplane to all main CPUs for listening only To achieve external synchronization of the Advant Controller system calendar clock the minute pulse is connected to TC520 The signal is separately distributed on the bus backplane to the processor module s The module also makes a RUN signal controlled relay contact externally available As long as the RUN signal i...

Page 487: ...1 IO24VA or F1 50 to 2 V 12 to 60 V Opto 1ms 100ms 100ms Positive 2 A2 STATUSA2 IO24VB or F2 3 AG COMMONA ref to A1 A2 4 B1 STATUSB1 F3 5 B2 STATUSB2 F4 6 BG COMMONB ref to B1 B2 7 RA RUN A1 Relay contact Max 250 V a c or d c Max 8 A resistive load For processor module A Contact opening time max 8 ms 8 RA RUN A2 9 RB RUN B1 Relay contact As above For processor module B 10 RB RUN B2 11 FN FANFAIL 5...

Page 488: ... GYDQW RQWUROOHU 8VHU V XLGH SSHQGL DUGZDUH 0RGXOHV A 48 3BSE 002 415R701 Rev A ...

Page 489: ...ion class has no ventilation and complies with IEC 529 IP54 See Table B 3 and Table B 4 Figure B 1 RM500 Cabinet Front View The cabinets are delivered in a light grey RAL 7035 Structure color Two versions RM500V1 and RM500V2 with different dimensions are available see Table B 1 RM500V1 cabinets are provided with a single or a double door two doors each half the size of a single door See Figure B 3...

Page 490: ...inet add 2x20 mm at the cabinet width W but use D1 as cabinet depth 20x530 mm 0 8x20 9 inch 20x530 mm 0 8x20 9 inch 20x655 mm 0 8x25 8 inch Cable Entry W2xD2 660x311 mm 26 0x12 2 inch 660x311 mm 26 0x12 2 inch 560x436 mm 22 0x17 2 inch Weight 3 3 The weight does not include equipment to be installed within the cabinet 150 200 kg 330 440 lbs 150 200 kg 330 440 lbs 150 200 kg 330 440 lbs Doors Singl...

Page 491: ...roller 450 User s Guide Section B 2 Dimensions and Weight 3BSE 002 415R701 Rev A B 3 Figure B 2 Mounting Cabinets together Screw Position Figure B 3 Swing Radius for Door s and Hinged Frame Double door Single door ...

Page 492: ...binets and screw the following cabinets with two screws each at the right hand side The bottom angle hinges features holes 14 mm 0 6 in diameter These holes permit you to adjust the cabinet location after holes are drilled in the floor If drilling is necessary make sure that no dust or other foreign matter enters the equipment in the cabinet Please notice the minimum distances from cabinet to wall...

Page 493: ...lation grilles are covered with metallic net to prevent insects to enter the cabinet A heater is included to heat the cabinet when the controller is not in use IP 41 Sealed IP 54 Sealed with heat exchanger 4 4 Available as a standard sealed cabinet with heat exchanger as an option IP 54 Table B 4 Available Degree of Protection Ratings for RM500 RM500V1 H 1925 mm 75 8 inch RM500V1 H 2125 mm 83 7 in...

Page 494: ...gle RM500 cabinet is given in Table B 5 If required due to environmental conditions use Protection Class IP54 The CPU subrack is provided with a fan unit to equalize the temperature difference in the subrack Table B 5 Permitted Power Dissipation for RM500 Protection Class 15o C Temperature Rise 30o C Temperature Rise IP21 700 W 1 400 W IP41 500 W 1 000W IP54 300 W 600 W ...

Page 495: ... document specifies all parts of value which are included in the initial delivery the actual List of Apparatus When subsequent changes to the product occur the list of new parts is included here too License Certificate This certificate is the end user s evidence that he has purchased the right to use the specified software products The document contains the end user name and a list of the particul...

Page 496: ...Advant Controller 450 User s Guide Appendix C Delivery Documentation C 2 3BSE 002 415R701 Rev A ...

Page 497: ...r followed by a numerical combination The letter specifies the mounting plane and the numbers designate the level in the cabinet and the position in the cabinet This description applies to cabinet type RM500 and Advant Controller 400 Series D 2 Cabinet Mounting planes in cabinets are designated as shown in Figure D 1 A left hand side of cabinet B rear mounting plane 19 C right hand side of cabinet...

Page 498: ... height modules U 1U 44 45 mm see Figure D 1 Mounting planes B U and V are for 19 units and H is for 24 units The mounting planes A and C have a horizontal partition of 25 mm They are numbered 1 2 3 and so on from the rear and forward see Figure D 1 The levels specified are those of the upper left hand corners of the units installed The cabinet is designated with a letter combination followed by f...

Page 499: ...sposition of the subracks in terms of number of relevant modules are specified in the respective product documentation Location Oriented Item Designations The first module in a controller subrack is designated 102 the next 108 and so on Figure D 3 Item Designation in Controller Subrack 12 SU 1 56 85 102 108 156 1 6 7 12 756 Please note The given location oriented item designation should not be mix...

Page 500: ...Rev A Address Figure D 4 Item Designation in Controller Subrack 18SU Figure D 5 Addresses in Controller Subrack 12 SU 1 85 1 6 7 18 26 726 102 Address Position 1 2 3 4 5 6 7 8 B l i n d 1 2 Sub positions Voltage Reg Voltage Reg 1 2 Backup Power Supply Backup Power Supply 1 2 S u p e r v ...

Page 501: ...modules The first module in a subrack is designated 101 the next 105 the next 109 and so on See Figure D 6 The item designation of the modules gives their location in the subrack The module marked in the figure is at module location 25 The 1 in the designation refers to the uppermost level level 1 in the equipment frame Figure D 6 Item Designation in I O Subrack Item design 125 1 2 3 4 5 6 1 5 9 2...

Page 502: ...nd 24 inches The places in the subrack for modems have sequential numbers 1 9 and 1 12 Places 10 11 and 13 14 are contacts for power supply distribution 24 V Modems mounted on a bracket are numbered 1 and 2 as in Figure D 9 Figure D 7 Item Designation in Modem Subrack 19 inches Figure D 8 Item Designation in Modem Subrack 24 inches Figure D 9 Modem Mounted on a Bracket Item design 4 4 1 9 10 11 It...

Page 503: ...22 X31 and so on Other plug in circuit boards in the front of the units have sequential numbers 1 2 3 and so on Connectors on the Rear Side Connectors are numbered X1 X2 and so on from the top downward Figure D 10 Numbering of Submodules and Connectors on the Front Figure D 11 Numbering of Connectors on the Rear Side X1 X2 1 2 Module front with contacts Module front with slots for submodules 1 X21...

Page 504: ...g bar the units are numbered as follows The mounting bar for connection units is divided in width modules à 20mm which is a multiple of the standard connection unit width 19 inch 24 width modules 24 inch 30 width modules The item designation specified for a connection unit is that module number covered by the upper left hand corner of the unit installed Figure D 14 shows a typical connection betwe...

Page 505: ...ion to pole 3 becomes B1 1 X90 3 D 7 Mains Units The mounting plates can carry two or three mains units The mains units are numbered 1 2 3 as in the figure The mounting plates are 3 U high Figure D 14 Typical Internal Connection Figure D 15 Terminal Block Numbering Figure D 16 Location of Mains Units X90 B1 1 X80 S2 S1 X1 X2 Flat Cable U4 125 Hinged frame Rear mounting plane X90 1 2 3 4 5 Etc X80 ...

Page 506: ...8 Examples of Item Designation in Cabinets A number of modules connection points and so on located in a double cabinet are illustrated in Figure D 17 An extract from a wiring table Table D 1 shows the corresponding item designations Figure D 17 Example of general Disposition of a Double Cabinet ...

Page 507: ... in Cabinets 3BSE 002 415R701 Rev A D 11 Table D 1 Designation of Items in Figure D 17 No Instar Connection point A Item designation Terminal 1 1B2 126 2 X1 2 1B2 780 X1 3 1B12 3 X2 4 1B12 11 X3 5 2U5 121 6 1C32 x 1 1 x stands for 1 2 3 and so on X1 7 2H15 13 X80 8 1H35 2 F1X3 ...

Page 508: ...Advant Controller 450 User s Guide Appendix D Item Designations D 12 3BSE 002 415R701 Rev A ...

Page 509: ...aneously Use the tables as forms in your own calculation E 2 Calculation Algorithms and Forms with Technical Data Current Consumption When calculating the current consumption focus on current per power supply unit Consider the available capacity given in Section 3 1 3 Power Supply Obtain the current consumption with 24 V Itot in the following way where I24V current consumption 24 V obtained from t...

Page 510: ...3 CI531 0 4 0 04 3 CI532Vxx 0 4 0 04 3 CI534Vxx 0 4 0 04 3 CI535 0 4 0 04 3 CI538 0 4 0 04 3 CI541V1 0 85 0 25 11 CI543 0 6 0 25 9 1 1 6 W dissipated in the transceiver connected to the module CI570 0 9 5 CI572 0 35 1 75 CI573 0 35 1 75 CS513 0 25 0 25 8 MB510 0 01 0 05 PM511 4 9 0 2 25 PU535 0 4 0 04 3 SB510 20 Approx SB511 20 Approx SC510 1 3 0 006 0 7 SC520 1 5 0 006 0 8 SR511 100 Approx 2 2 Do...

Page 511: ...I 155A 0 25 0 10 3 8 DSAO 110 0 30 0 53 14 0 DSAO 120 0 30 0 28 8 2 DSAO 120A 0 35 0 58 14 DSAO 130 0 30 0 22 8 6 DSAO 130A 0 25 0 54 11 DSAX 110 0 48 0 17 7 7 DSAX 110A 0 1 W ch on connection unit at 20 mA DSDC 111 1 40 0 10 12 0 DSDI 110A 0 46 5 5 With DSTD 150A DSTD 190 DSDI 110A 0 46 8 mA ch 12 0 With 4x DSTD 195 DSDI 110A 0 46 8 mA ch 18 5 With 4x DSTD 198 DSDI 110A 0 46 7 5 With 4x DSTD 196 ...

Page 512: ...f all channels activated DSTD 108LP 0 13 2 7 70 of all channels activated DSTD 109P 0 045 9 5 70 of all channels activated DSTD 145 0 36 8 3 70 of all channels activated DSTD 147 0 36 11 5 70 of all channels activated DSTD 148 0 36 13 70 of all channels activated DSTD 195 0 045 1 6 70 of all channels activated DSTD 196P 0 16 3 3 70 of all channels activated DSTD 197 0 045 2 9 70 of all channels ac...

Page 513: ...ent Consump A Tot Power Dissipation W Comments No of Units Total Itot Ptot 5 V 24 V SA1xx 100 Approx for all types of power supply units 1 1 Redundant power supply units should not be included in the calculation of number of boards units RC527 0 7 15 For three fans TC512V1 0 1 2 TC513V1 0 1 2 TC514V2 0 1 2 TC515V2 0 1 2 TC516 0 1 2 TC560V1 0 24 5 6 TC561V1 0 28 6 6 TC562 0 13 3 TC570 0 02 0 5 TC62...

Page 514: ...Advant Controller 450 User s Guide Appendix E Current Consumption and Heat Dissipation E 6 3BSE 002 415R701 Rev A ...

Page 515: ... ____ B 0 20 C _______ ms E 100 A B C E _______ F 0 15 G _______ H A G F 10 H _______ E H ________ AIC A ____ B 0 003 C _______ ms E 100 A B C E _______ F 0 08 G _______ H A G F 10 H _______ E H ________ DI cycl A ____ B 0 20 board D ___ch board C _______ ms E 100 A B C D E _______ F 0 05 G _______ H A G F 10 H _______ E H ________ DI interr A ____ F 0 60 G _______ H A G F 10 H _______ E H _______...

Page 516: ... Total load AO A ____ B 0 02 C _______ ms E 100 A B C E _______ F 0 18 G _______ H A G F 10 H _______ E H ________ AOC A ____ B 0 003 C _______ ms E 100 A B C E _______ F 0 03 G _______ H A G F 10 H _______ E H ________ DO A ____ B 0 003 C _______ ms E 100 A B C E _______ F 0 13 G _______ H A G F 10 H _______ E H ________ DOC A ____ B 0 003 C _______ ms E 100 A B C E _______ F 0 03 G _______ H A G...

Page 517: ...time ms Load Number Total load A B C A 100 B C D C D A B C A 100 B C D C D A B C A 100 B C D C D A B C A 100 B C D C D A B C A 100 B C D C D A B C A 100 B C D C D A B C A 100 B C D C D A B C A 100 B C D C D A B C A 100 B C D C D A B C A 100 B C D C D A B C A 100 B C D C D A B C A 100 B C D C D A B C A 100 B C D C D A B C A 100 B C D C D A B C A 100 B C D C D A B C A 100 B C D C D Total ________ ...

Page 518: ...Advant Controller 450 User s Guide Appendix F Load Calculation F 4 3BSE 002 415R701 Rev A ...

Page 519: ...s on AF 100 x 0 40 Calculated signals For presentation and event handling in AS 500 Series operator stations includ ing signals via Advant Fieldbus 100 x 0 30 PIDCON Excluding I O signals x 1 50 PIDCONA Excluding I O signals x 8 5 MANSTN Excluding I O signals x 0 80 RATIOSTN Excluding I O signals x 1 00 GENCON Excluding I O signals x 0 50 GENBIN Excluding I O signals x 0 50 GENUSD Excluding I O si...

Page 520: ...f LONWORKS Communication modules CI572 CI573 x 65 No of LONWORKS devices x 0 2 No of LONWORKS variables input and outputs x0 06 No of LONWORKS multiple network variable x 0 33 No of LONWORKS Event Treat x 0 14 No of MasterBus 300 300E RCOM RCOM GCOM and MultiVendor Interface x 8 00 User Defined PC elements Basic requirements for QC07 UDP41 1 x 132 00 Storage of user defined PC elements 7 1 x 150 0...

Page 521: ...dynamic values 4 The figures apply to 100 events per list 5 The figures are calculated for 1 log with 10 variables each with 240 stored values Each value takes approximately 5 byte 6 The figures are calculated for 50 storage vessels 4 sections and 20 operations with 6 recipe variables each 7 This is a recommended starting value Adjustment of this figure might be necessary to do when the real need ...

Page 522: ...Advant Controller 450 User s Guide Appendix G Memory Calculation G 4 3BSE 002 415R701 Rev A ...

Page 523: ...g and operating an Advant Controller system to minimize the risk of injury to personnel and damage to the equipment Figure H 1 Example of LSYSHI Printout LSYSHI QC02 BAS21 7 0 0 02 01 01 COPYRIGHT 1994 BY ABB INDUSTRIAL SYSTEMS AB CXNLIB7 0 0 CXKLIB 7 0 0 Network node 11 1 Time date 10 10 15 1994 12 24 Current task CXKK 340 H 00482360 SSP H 004800DA D0 H 00000069 D1 H 00000834 D2 H 004A00DC D3 H 0...

Page 524: ... CPU had when it was last restarted NOTE If position AUTO does not work then switch to CLEAR or vice versa 2 Check size of primary memory on primary and backup CPU boards 8 16 MByte Make sure they are equal and restart the backup or the system 00 Debug trap in system mode The halt codes 0 5 do not normally appear in a system after commissioning but if one should appear it is probably due to interf...

Page 525: ...place the processor module 0C Autotest error Instruction test failed Replace the processor module 0d Autotest error Interval timer test failed Replace the processor module 0E Autotest error Interrupt controller test failed Replace the processor module 0F Autotest error Bus error test failed Replace the processor module 10 Level 7 interrupt Power failure Power up after power fail in a system that h...

Page 526: ...y Indication on the backup module Internal error System program in backup and primary is not equal Restart with the same system program in both processor modules 40 System with redundant processor modules only Error when initializing the backup module Try again by depressing the ENTER button If the same error occurs replace the backup module 41 System with redundant processor modules only Indicati...

Page 527: ...means a serious shut down of a redundant system Further detailed information of the possible reason of the halt is stored in the system This information is accessible by ABB experts only 48 System with redundant processor modules only Indication on the new primary at changeover Error in changeover Status channel interrupt not pending during changeover This means a serious shut down of a redundant ...

Page 528: ...Advant Controller 450 User s Guide Appendix H Halt Codes H 6 3BSE 002 415R701 Rev A ...

Page 529: ...on Time The time at which the message was generated Type The type of message i e the error category in the Advant Controller Code Specifies the character of the change within the category that is the nature of the fault Task Specifies the software task affected by the message Interrupted Specifies if the task has been interrupted Address Specifies the address associated with the change of status D...

Page 530: ...ror in the controller data base MMC operator station 24 Data transmission fault MMC operator station 25 Fault in the operator station MMC operator station 26 Other faults MMC operator station 28 Process communication incl Data Set AF 100 PROFIBUS DP LONWORKS MasterFieldBus RCOM 29 Redundant processor modules operating system kernel 30 MasterBus Data Set Communication EXCOM Clock synchronization Se...

Page 531: ...ter 5 Maintenance when fault finding and operating an Advant Controller system to minimize the risk of injury to personnel and damage to the equipment NOTE In all situations when the controller has stopped you should carefully read all halt codes and system messages available before you proceed See Section 5 4 2 1 Reading of System Messages Table I 3 Type 2 Code 46 Type Code Significance Task Comm...

Page 532: ...701 Rev A Table I 5 Type 10 Code 19 Type Code Significance Data 1 Comments Actions 10 19 Task interrupted 61000 61001 61002 61700 Gap in Data Set Dat referred to missing No RAM at initialization No Data Set or Dat 11 1 12 23 44 10 19 CXAA 000 H 000FF333 Type 10 Task killed A 61000 ...

Page 533: ... that all network numbers are within the same decade 24 Network and node number MB 300 GCOM interface incompatible with system software 25 Network and node number Incorrect duplicate network number Change the network number to the correct number 50 H LRSNCPSP LR SN CP SP CS513 config error Logical Record in the data base Slave Number Carrier Position in the subrack Submodule Position on the carrie...

Page 534: ...r Too many nodes connected to the network MB 300 Reduce the number of nodes 19 0 main processor 0 slave processor Incorrect allocation of memory at start up 3 Disconnection 11 2 3 Data link level disconnected Faulty communication board or wiring Faulty communication board 13 H RRAANENO RR AA NE NO Connection with node broken Faulty communication board or wiring Disconnection cause 00 no contact wi...

Page 535: ...r position in the subrack Type of error 01 Failed to initialize 03 Board has halted 04 Board missing or not accessible 04 H CCSSEE00 CC SS EE CI532 535 error Carrier position in subrack Submodule position on the carrier Type of error 01 Failed to initialize 03 Board has halted 04 Board missing or not accessible 05 H CCSSEE00 CC SS EE CI531 error Carrier position in subrack Submodule position on th...

Page 536: ...ault in the system 6 10 indicates fault in the engineering station 0 1 2 3 4 5 6 7 8 9 10 Status fault in system I O fault in the system Bus fault in the system Time tripping time out in the system Memory fault in the system Address fault in the system Internal fault Illegal instruction Faulty address Buffer overflow Jump table index without limit 18 11 Communication failure between Advant Control...

Page 537: ...r terminal and external computer CXBH260 CXBH261 CXBH262 CXBH263 CXBH264 Printer MasterView 320 no 1 MasterView 320 no 2 MasterView 320 no 3 MasterView 320 no 4 Connected unit has the voltage disconnected Cable not connected XON signal not generated from the unit connected Fault in signal transmission e g modem or cable 06 03 54 20 1 CXBH260 H 000000B8 Type 20 Error on V24 RS 232 C Channel H 00020...

Page 538: ...ement POS A are different The positioning board is inactive The I O address given on the PC element POS A is odd The address jumpering of the positioning board and the I O address given on the PC element POS O are different The positioning board is inactive The I O address given on the PC element POS O is odd The address jumpering of the positioning board and the I O address given on the PC elemen...

Page 539: ...er Incorrect address in PC element the address is too high or too low POS A POS L POS O FREQ SP FREQ MP COUNT DP Incorrect address in the PC element Incorrect address to MV 100 unit MV 100 controller out of order MV 100 controller in order MV 100 unit out of order MV 100 unit in order DSDC board out of order Fault on DSDC board Fault on DSDC board DSDC board reactivated DSXW board out of order DSX...

Page 540: ...I 10 Type 26 Code 12 Type Code Address Comments Actions 26 12 H 04900010 H 04900020 Text too long to be printed PC element PRINT with LAST missing Set LAST 1 in the last PRINT element 16 23 54 26 12 DCCA910 H 04900010 Type 26 Other Faults System Messages from Printer and operator station 1 2 11 1 ...

Page 541: ...LE If the logical file for a certain data base element is required search for it in the UCONCSTR column and follow the line out to LOGFILE An S has been added for channels for example DI channel is designated DIS DI channel has logical file 8 DI boards have logical file 4 Table I 11 List of Common Concept Numbers in System Messages Hex Dec DB Element Concerning 2 2 AI Analog input boards 3 3 AO An...

Page 542: ...as failed yyyy 2 Board 2 has failed H 015D 349 x H xxxxyyyy MasterFieldBus xxxx Bus number yyyy Not used H 00B5 181 x H xxxxyyyy MasterFieldBus nodes xxxx Bus number yyyy Node number H 014D 333 x H xxxxyyzz AF100 and PROFIBUS xxxx Bus number yy 0 No redundant CI52x yy 1 CI52x sub module 1 yy 2 CI52x sub module 2 zz Station number of CI52x or CI541 H 014E 334 x H xxxxyyyy AF100 stations and PROFIBU...

Page 543: ... error xxxx H 00D2 Checksum error xxxx H 00D3 Error in DPM xxxx H 00D4 Error in internal memory xxxx H 00D5 Error in external memory xxxx H 00D6 Watch dog error xxxx H 00D7 Interval clock error xxxx H 00D8 ADC reference error 0 V xxxx H 00D9 ADC reference error 10 V xxxx H 00DA ADC reference error 5 V xxxx H 00DB Gain error xxxx H 00DC AO supervision error yyyy 0 Board 1 and board 2 has failed yyy...

Page 544: ...t xxxx 0080 Runtime error H 0145 325 x H wwxxyyzz S800 I O modules ww Bus number xx Station number yy Cluster number zz Position number H 0167 359 x H xxxxyyyy Single DSBC176 or redundant DSBC174 bus extender xxxx Status from DSBC174 or DSBC176 yyyy 1 Left DSBC17x connected to left CPU yyyy 2 Right DSBC174 connected to right CPU 23 A measurement range not permitted for pulse counter 24 6 x An anal...

Page 545: ...er yyyy Node number 30 H xxxxyyyy MasterFieldbus cable A in operation xxxx Bus number yyyy Node number 31 H xxxxyyyy MasterFieldbus cable B fault xxxx Bus number yyyy Node number 32 H xxxxyyyy MasterFieldbus cable B in operation xxxx Bus number yyyy Node number 33 AO channel external fault 34 AI channel overflow Table I 12 Type 28 Continued Type Code Data 1 Data 2 Comments Actions ...

Page 546: ...ule 2 zz Station number of CI52x or CI541 H 014E 334 x H xxxxyyyy AF100 stations and PROFIBUS slaves xxxx Bus number yyyy Station number H 0145 325 x H wwxxyyzz S800 I O modules ww Bus number xx Station number yy Cluster number zz Position number H 0167 359 x H xxxxyyyy Single DSBC176 or redundant DSBC174 bus extender xxxx 400 Status word from DSBC17x yyyy 1 Left DSBC17x connected to left CPU yyyy...

Page 547: ...EV or is not active 76 Concept instance No H 015F 351 x H 0000000x EVS R has been removed Reconfiguration will be done x 0 Removed EVS R belonged to AF 100 x 1 9 Removed EVS R belonged to RCOM network x 1 Concept instance No H 014D 333 x H xxxxxxxx Process error diagnostics from remote device AF100 32 bit process error diagnostic xxxxxxxx H 20000000 More than 50 errors xxxxxxxx H 40000000 Simultan...

Page 548: ...signal addresses Bus master synchronization lost Simultaneous time masters Invalid bus length H 014D 333 x H 40000000 PROFIBUS address conflict H 014D 333 x H 00000002 H 00000008 H 00000010 H 00000020 H 00000040 H 00000080 H 00010000 LONWORKS channel error bits Parameter not correct Can not open LONWORKS driver Location mismatch Supervision timeout Runtime error Subnet node mismatch Error command ...

Page 549: ... x H xxxxyyzz AF100 and PROFIBUS Communication Error Reason No contact with device xxxx Bus number yy 0 No redundant CI52x yy 1 CI52x sub module 1 yy 2 CI52x sub module 2 zz Station number of CI52x or CI541V1 8 Concept instance No H 014D 333 x Bus controller CI52x halted 9 Diagnostics info Fatal bus error in CI52x modem or cable 10 H xxxxyyzz Redundant communication media error xxxx Bus number yy ...

Page 550: ...al number of corrected bit errors has exceeded a certain limit Data 1 processor module position Program card supervision H 10 H 11 H 12 H 13 Correct program card PCMCIA 2 0 replaced Program card memory checksum error Program card removed missing card Wrong program card For the addresses H 10 H 13 data 1 and data 2 give the position and subposition respectively 3 Incorrect backup voltage for RAM 1 ...

Page 551: ...XCOM 23 Fault in the data base element DS MS TS There are no data references DS or MS has been blocked H EB28 60200 4 DS MS TS number Routine CXAA000 DS MV 300 CXAM000 DS MVI RCOM CXAT000 TS MV 300 Incorrect polling time at receiving data base element DS or MS DS or MS blocked H ED1D 60701 4 DS MS number Routine CXAA000 DS MV 300 CXAM000 DS MVI RCOM Transmitting and receiving data base elements DS...

Page 552: ...or TS YYYY DS MS or TS number The receiving reference in the data base element DS MS or TS is not addressable H EEAD 61101 4 DS MS TS number Routine CXAA000 DS MV 300 CXAM000 DS MVI RCOM CXAT000 TS MV 300 The data base element DS MS or TS addressed does not exist H FICC 61900 3 H XXYYZZVV XX Destination network YY Destination node ZZ DS MS or TS number VV 1 transmitting type VV 2 receiving type Ta...

Page 553: ...DSPs concerned are updated with the basic cycle time The basic cycle time is changed with the APP command 5 Unconfigured DSPs exist No data 1 One or several unconfigured DSPs have been found after configuration at start up The DSPs might automatically be configured at reconfiguration 2 Previous configuration failed 6 Communication to the communication interface is lost See Comments See Comments Th...

Page 554: ...ta 1 DSP data base concept instance number Data 2 Logical bus number Otherwise Data 1 0 Data 2 Logical bus number 9 The DSP has badly defined references Concept instance of the DSP concerned No data The DSP references e g a non existing DAT 14 Illegal definition of DSP Internal error code The DSP is badly defined and by this not configured The bad definition concerns IDENT STATION or no DATs are r...

Page 555: ...r 1 error 2 Regulator 2 error 3 Regulator 3 error 4 Regulator 4 error AC410 101 Regulator missing 102 Regulator error 22 AC 410 450 battery error MSW Direction LSW Battery H EEEE Error coming H 2222 Equip in working order 1 Battery A Only AC 450 2 Battery B Only AC 450 23 AC 410 450 backup power supply error MSW Direction LSW Backup power supply H EEEE Error coming H 2222 Equip in working order 1 ...

Page 556: ...E Error coming H 2222 Equip in working order 28 AC 410 450 user defined error MSW Direction LSW Which error H EEEE Error coming H 2222 Equip in working order 1 F1 2 F2 Only AC 450 3 F3 Only AC 450 4 F4 Only AC 450 29 AC 450 TC520 communication error Status of operation 31 AC 450 TC520 communication error Status of operation 70 AC 450 S100 I O connection error MSW Direction LSW Not used H EEEE Erro...

Page 557: ... the structure of the notation systems Decimal notation 1090 1 103 0 102 9 101 0 100 1090 Binary notation 1010 1 23 0 22 1 21 0 20 10 dec Hexadecimal notation 1099 1 163 0 162 9 161 9 160 4249 dec A09B 10 163 0 162 9 161 11 160 41115 dec From the examples above it is seen that each position in a number corresponds to the value times the base 2 10 16 raised to the power corresponding to its positio...

Page 558: ...EC HEX DEC 0 1 2 3 4 5 6 7 8 9 A B C D E F 0 4096 8192 12288 16384 20480 24576 28672 32768 36864 40960 45056 49152 53248 57344 61440 0 1 2 3 4 5 6 7 8 9 A B C D E F 0 256 512 768 1024 1280 1536 1792 2048 2304 2560 2816 3072 3328 3584 3840 0 1 2 3 4 5 6 7 8 9 A B C D E F 0 16 32 48 64 80 96 112 128 144 160 176 192 208 224 240 0 1 2 3 4 5 6 7 8 9 A B C D E F 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 ...

Page 559: ...3 51 Logging 3 53 Masterview 320 3 52 Others 3 54 PC and Process I O 3 46 Performance General 3 44 Subscription Command Event 3 49 Creating 2 57 Current consumption 3 6 D Data and text handling 1 97 Data entry 2 57 Data Set 1 92 Delivered Version Specification C 1 Delivery Specification C 1 DI810 1 73 DI811 1 73 DI820 1 73 DI821 1 73 to 1 74 Dimensioning 2 57 Distributed connection units 2 36 DO81...

Page 560: ...1 92 Positioning 1 97 Primary processor module 4 1 Priority system 3 39 Product variants 1 24 Protective earth 2 8 Pulse counting 1 98 R Release Notes C 1 Reports 1 99 Run Alarm relay Description 1 108 Electrical data A 46 Installation 2 31 S Safety switch 2 10 Safety system aspects 1 108 SD811 1 78 to 1 79 SD812 1 78 to 1 79 Selection of primary backup processor module 4 3 Sequence control 1 97 S...

Page 561: ...Advant Controller 450 User s Guide Index 3BSE 002 415R701 Rev A iii V Valve control 1 102 VT100 terminal 1 105 ...

Page 562: ...Advant Controller 450 User s Guide Index iv 3BSE 002 415R701 Rev A ...

Page 563: ......

Page 564: ...3BSE 002 415R701 Rev A March 2000 ...

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