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148

Rockwell Automation Publication ICSTT-RM448J-EN-P - April 2018

Chapter 7

Functional Acceptance Testing

Testing must be done on a known version of the controller. Record the type,
serial number and physical location of each module so that the system can be
dismantled, shipped and built with the modules in the same locations.

Review and finalize the technical manuals which have been prepared for the
maintenance and operation of the system.

Summary of Contents for AADvance

Page 1: ...AADvance Controller Catalog Numbers T9110 T9300 T9310 T9401 2 T9431 2 T9451 T9481 2 System Build Manual OriginalInstructions...

Page 2: ...ith any particular installation Rockwell Automation Inc cannot assume responsibility or liability for actual use based on the examples and diagrams No patent liability is assumed by Rockwell Automatio...

Page 3: ...tage may be present BURNHAZARD Labelsmaybeonorinsidetheequipment forexample adriveormotor toalertpeoplethatsurfacesmay reach dangerous temperatures ARC FLASH HAZARD Labels may be on or inside the equi...

Page 4: ...4 Rockwell Automation PublicationICSTT RM448J EN P April 2018...

Page 5: ...4 11 May 2015 Correct Documentation Feedback URL and Issue Record J April 2018 Update for AADvance Release 1 40 Topic Page Update hypertext link in Download section of Preface 7 Update AADvance Releas...

Page 6: ...6 Rockwell Automation PublicationICSTT RM448J EN P April 2018 Summary of Changes...

Page 7: ...ut the construction operation or maintenance of a control system installation You should also refer to your own local or supplied system safety manual installation and operator maintenance manuals REV...

Page 8: ...he Knowledge Base require a TechConnect Support Contract For more information about TechConnect Support Contract Access Level and Features please click on the following link https rockwellautomation c...

Page 9: ...ety System Applications in Hazardous Environments 26 ATEX Certificate 26 IECEx UL Certificate 29 Module Label 34 KCC EMC Registration 34 The AADvance Workbench and Software Development Environment 35...

Page 10: ...uired Tools Standard AADvance 67 Specifying an Enclosure 67 Maximum Enclosure Air temperature 68 Enclosure Requirements for a Non hazardous Environment 68 Enclosure Requirements for a Hazardous Enviro...

Page 11: ...al Input Field Loop Circuits 104 Analogue Input Field loop Circuits 108 Recommended Field Circuit for Digital Outputs 113 Recommended Circuit for Analogue Outputs 116 Install Modules 119 Install a 911...

Page 12: ...Acceptance Testing Devising tests for Functional Acceptance 147 Test Environment for Functional Acceptance 147 Managing Functional Acceptance Testing 147 Chapter8 Dismantling the AADvance System Abou...

Page 13: ...ctions power sources and external network connections The flexibility of the design means that a system can meet a wide variety of business needs An AADvance system is assembled to a scale and configu...

Page 14: ...14 Rockwell Automation PublicationICSTT RM448J EN P April 2018 Chapter 1 The AADvance System...

Page 15: ...ng applications Emergency shutdown system Fire and gas installation protection system Critical process control Burner management Boiler and furnace control Distributed process monitoring and control T...

Page 16: ...n operate as a stand alone system or as a distributed node of a larger control system A Key benefit of the AADvance system is its flexibility All of the configurations are readily achieved by combinin...

Page 17: ...on to other AADvance controllers or external third party equipment Communications internally between the processors and I O modules uses a proprietary communications protocol over a custom wired harne...

Page 18: ...that provide the safety architecture are the processor and I O modules the remaining components provide secure external interfaces and connectivity between the field elements and the main components...

Page 19: ...r is certified by independent certifying bodies Refer to the certificate for details of the standards included in the certification Performance and Electrical Specifications Table 1 Controller Perform...

Page 20: ...own above Where Sync time is a function of the total number of modules defined according to the following table IMPORTANT Overall system power consumption heat dissipation and weight can be estimated...

Page 21: ...3 ms 32 ms 48 x 0 04 ms 30 x 1 170 ms 18 x 1 174 ms 129 5 ms Minimum throughput time 129 5 ms 7 ms 136 5 ms Maximum throughput time 2 x 129 5 ms 13 ms 272 0 ms System Installation Environment The ins...

Page 22: ...No is DEMKO 11 ATEX 1129711X Rev 2 UL report number is 4786144521 The ATEX marking is Ex nA IIC T4 Gc Additionally the AADvance controller is approved under the IECEx certification scheme The certific...

Page 23: ...y Dual Non HazardousInstallationRequirements Environmental In a non hazardous environment a system can be installed in an enclosure or on a support wall however the enclosure or the area where it is i...

Page 24: ...s the essential requirements of EN 60079 0 2012 A11 2013 EN 60079 15 2010 and IEC 60079 0 Ed 6 and IEC 60079 15 Ed 4 WARNING Special conditions for safe use Model 9110 The ambient temperature range is...

Page 25: ...Canada Class I Division 2 Groups A B C and D The products have been investigated using requirements contained in the following standards CSA C22 2 No 213 M1987 Nonincendive Control Equipment for Use i...

Page 26: ...ntial Health and Safety Requirements are given in Annex II to the European Union Directive 94 9 EC of 23 March 1994 The examination and test results are recorded in confidential report no 4786831849 9...

Page 27: ...on Assembly 16 Channel TMR Digital Input 151561 130782 9831 Termination Assembly 16 Channel Simplex Analog Input 151721 130812 9832 Termination Assembly 16 Channel Dual Analog Input 151701 130802 9833...

Page 28: ...qC to 60 qC x All other Models The ambient temperature range is 25 qC to 70 qC x Devices are to be installed in an ATEX Certified IP54 tool accessible enclosure that has been evaluated to the requirem...

Page 29: ...n Sparking nA Marking Ex nA IIC T4 Gc Approved for issue on behalf of the IECEx Certification Body Paul T Kelly Position Principal Engineer Global Hazardous Locations Signature for printed version Dat...

Page 30: ...2 and Operational Documents as amended STANDARDS The electrical apparatus and any acceptable variations to it specified in the schedule of this certificate and the identified documents was found to co...

Page 31: ...re range is 25 C to 60 C All other Models The ambient temperature range is 25 C to 70 C Subject devices are to be installed in an IECEx Certified IP54 tool accessible enclosure that has been evaluated...

Page 32: ...nnexe for IECEx UL 12 0032 Issue 2 pdf IECEx Certificate of Conformity Certificate No IECEx UL 12 0032X Date of Issue 2014 05 28 Issue No 2 Page 4 of 4 DETAILS OF CERTIFICATE CHANGES for issues 1 and...

Page 33: ...t Module 18 32 165 Output 18 32Vdc 0 5A Pilot Duty 16VA 1 5A Inrush 9801 Termination Assembly 16 Channel Simplex Digital Input 0 32 6 5 9802 Termination Assembly 16 Channel Dual Digital Input 0 32 6 5...

Page 34: ...34 Rockwell Automation PublicationICSTT RM448J EN P April 2018 Chapter 2 The AADvanceSafety Controller Module Label The following label information must be attached to each module KCC EMC Registration...

Page 35: ...ot supported by AADvance Workbench 2 x Engineers can use one language or a combination that best suits their knowledge and programming style and the type of application The Workbench is a secure devel...

Page 36: ...ommunications with the controller It is recommended that the PC has a 2 2 GHz or higher CPU 1 024 MB or more RAM a 1 280 x 1 024 display and a 7 200 RPM or higher hard disk It is also recommended that...

Page 37: ...on and entering the code into the software When you use the demo license the AADvance Workbench displays a Demo License window each time you try to open a project The window includes the contact detai...

Page 38: ...ect together easily without the need for inter module wiring Environmental Specification An AADvance system can be installed in a non hazardous or a hazardous environment In a non hazardous environmen...

Page 39: ...ture during usual operation 43 C 109 F 2 C Humidity Operating 10 to 95 RH non condensing Storage and Transport 10 to 95 RH non condensing Vibration Functional Stress 5 Hz to 9 Hz Continuous 1 7 mm amp...

Page 40: ...y Controller Product Dimensions A typical controller arrangement is shown with processor modules installed on the processor base unit and an I O base unit mated with the processor base unit I O module...

Page 41: ...that mate inside the module connectors Adding the depth of a module 118 mm to the depth of the base unit gives the overall depth of the controller assembly at 136 mm Module Dimensions All modules have...

Page 42: ...sisted cooling Processor and I O modules fit onto standardized base units Base units plug together by side connectors and are securely held in position by specially designed plastic clips which cannot...

Page 43: ...mination assembly The controller incorporates module polarization keying to make sure that they are correctly mated when installed Sockets on the rear end plate align and mate with coding pins found o...

Page 44: ...r The module senses the locking mechanism position and notifies the controller accordingly This acts as an interlock device and prevents the module from going on line when it is not in the locked posi...

Page 45: ...Automation PublicationICSTT RM448J EN P April 2018 45 The AADvance Safety Controller Chapter 2 Figure 5 Field Wiring Connections NOTE The recommended torque for termination assembly screw connectors...

Page 46: ...46 Rockwell Automation PublicationICSTT RM448J EN P April 2018 Chapter 2 The AADvanceSafety Controller Processor Base Unit A processor base unit holds up to three processor modules...

Page 47: ...cessor modules and prevents access to the application unless the Program Enable key is inserted Serial Communications Ports The serial ports S1 1 and S1 2 S2 1 and S2 2 S3 1 and S3 2 support the follo...

Page 48: ...nostic logs The processor diagnostic logs are stored in the portion of RAM backed by the battery The battery has a design life of 10 years when the processor module is continually powered for processo...

Page 49: ...he front panel of the processor module The battery position is shown in the illustration Battery Specification A Polycarbon monofluoride Lithium Coin Battery with a nominal voltage of 3V Nominal capac...

Page 50: ...ly CAUTION K1 is for maintenance only When AADvance is installed in a hazardouslocationpowermustbedisconnectedortheareaknowntobefree of ignitable concentrations of flammable gases or vapours when usin...

Page 51: ...Rockwell Automation PublicationICSTT RM448J EN P April 2018 51 The AADvance Safety Controller Chapter 2 I O Base Unit An I O base unit holds up to three I O modules...

Page 52: ...give the system designer flexibility when configuring redundant and fault tolerant systems Termination assemblies come in three types simplex dual or triple to accommodate one two or three I O modules...

Page 53: ...Rockwell Automation PublicationICSTT RM448J EN P April 2018 53 The AADvance Safety Controller Chapter 2 Figure 8 Top View...

Page 54: ...provides 8 dual configuration output channels It shares the same pin out as the standard AADvance T9852 Digital Output Terminal Assembly and has the same coding peg configuration The difference is tha...

Page 55: ...or heat dissipation values Refer to the separate topics on estimating Heat Dissipation and Power Consumption Module Back plane Electrical Ratings Input Output Electrical Ratings Voltage Range Vdc Maxi...

Page 56: ...dules and I O modules is supported by command and response busses that are routed across the processor and I O base units The processor modules acts like a communications master sending commands to it...

Page 57: ...e system for faults related to the controller and field faults related to field I O circuits Serious problems are reported immediately but faults that are not on non critical items are filtered to pre...

Page 58: ...inaccessible locations Refer to the AADvance Configuration Guide Doc No ICSTT RM405 ICSTT RM458 for Workbench 2 x for instructions on how to set up the variable On line updates I O Configuration Chang...

Page 59: ...ith the following ControlFLASH files 9110 ControlFLASH 9110 Recovery ControlFLASH The files are available from the Product Compatibility and Download Center website If the Recovery Mode firmware in th...

Page 60: ...firmware will be downloaded and stored on the module this will take approximately 5 minutes The modules will be rebooted to confirm the firmware has been updated successfully Refer to document 1756 UM...

Page 61: ...mation PublicationICSTT RM448J EN P April 2018 61 The AADvance Safety Controller Chapter 2 UDP 2222 CIP Produce Consume I O UDP 5000 Trusted peer to peer UDP 44818 CIP Produce Consume Protocol Port Nu...

Page 62: ...62 Rockwell Automation PublicationICSTT RM448J EN P April 2018 Chapter 2 The AADvanceSafety Controller...

Page 63: ...e Workbench has powerful intuitive features and functionality to enhance simplicity This chapter introduces the AADvance Workbench and describes basic software features Programming Language Support Th...

Page 64: ...n the computer before downloading to the controller hardware Support for Variable Types For each controller you can declare variables using all types identified in IEC 61131 3 including Boolean 16 bit...

Page 65: ...tructural and functional tests of each module and of the full application Application Resource Program Security The AADvance controller includes a Program Enable key that protects the application from...

Page 66: ...66 Rockwell Automation PublicationICSTT RM448J EN P April 2018 Chapter 3 Application Resource Development...

Page 67: ...odule Screwdriver flat 0 8 mm x 4 0 mm 1 25 inch x 5 32 inch for screws on extension cables Torque screwdriver flat 0 6 mm x 3 0 mm 1 40 inch x 1 8 inch for dc power wiring terminals Torque screwdrive...

Page 68: ...uced reliability ATTENTION DISSIPATION THERMIQUE ET EMPLACEMENT DE L ENCEINTE La temp rature ambiante nominale maximum dans une enceinte o un processeur AADvance et des modules d E S standard sont ins...

Page 69: ...A B C and D The enclosure must comply with the following UL requirements WARNING Special Conditions for Safe Use Models9110 Theambienttemperaturerangeis 25 Cto 60 C 13 F to 140 F AllotherModels theam...

Page 70: ...ent des conducteurs Le conducteur de mise la terre devra avoir une section minimale de 3 31 mm2 Les dispositifs concern s sont utilisables dans un environnement pr sentant un degr de pollution 2 au ma...

Page 71: ...wiring Space below to let modules fit and to be able to hold a module during removal Space to the right of the last base unit in the row to move an I O base unit during assembly or if you are install...

Page 72: ...below Figure 11 Flat Panel Mounting With reference to Figure 11 Flat Panel Mounting three mounting units are illustrated above Drill three holes per base unit to suit M5 screws 233mm Each base unit 2...

Page 73: ...or processor modules System and field power consumption by modules and termination assemblies is dissipated as heat You should consider the effect of heat dissipation on the design and positioning of...

Page 74: ...to the slots on each base unit Figure 12 Connecting Base Units with Expansion Cables The expansion bus accessed from the right hand edge of the 9100 processor base unit is designated I O Bus 1 while t...

Page 75: ...nterface limit the maximum possible length of either of the two I O buses the combination of I O base units and expansion cables to 8 meters 26 24 ft Adding Field Cable Management The field power and...

Page 76: ...ibution Requirements The power supplies and power distribution if incorrectly designed are a possible electrical or fire safety hazard and can contribute to common cause failure It is therefore necess...

Page 77: ...e of each power source The controller is designed to be resistant to a reverse polarity connection without permanent damage The power sources must come from a commercially available industrial un inte...

Page 78: ...ary to include the field power component dissipated within the controller Refer to the table Field Loop Power Heat Dissipation The field power requirements should be calculated separately and is depen...

Page 79: ...e Heat Dissipation The heat in the enclosure is generated from several sources such as the power supplies the AADvance modules and some of the field loop power Use the following calculation and the da...

Page 80: ...ogue Inputs Input current A x 135 Digital Outputs x Output current A x 0 57 Analogue outputs x Field voltage V x Output Current A load Resistance x Output current A 1 Total Item Number Used Weight All...

Page 81: ...al return will be referenced to the instrument ground The instrument ground will be isolated from the AC safety ground The AC safety ground and the instrument ground will usually be made available thr...

Page 82: ...ations with the controller It is recommended that the PC has a 2 2 GHz or higher CPU 1 024 MB or more RAM a 1 280 x 1 024 display and a 7 200 RPM or higher hard disk It is also recommended that the ha...

Page 83: ...in the T9110 processor module Fuses on the termination assemblies can be replaced so access to the fuses is required There are no user serviceable parts inside modules therefore repair is by replaceme...

Page 84: ...r installation should make the following provisions Clear access to remove and install modules termination assemblies base units and security dongle Program Enable key Repair of controller modules wil...

Page 85: ...Rockwell Automation PublicationICSTT RM448J EN P April 2018 85 Before You Begin Chapter 4 Clear access to examine remove and install fuses located on the termination assemblies...

Page 86: ...licationICSTT RM448J EN P April 2018 Chapter 4 Before You Begin Clear access to terminals and connectors for field power and network wiring andaccess to the wiring itself Clear access to the Security...

Page 87: ...Ethernet cable These are two ports for each processor module If a direct connection is required from the controller to the workstation PC for example during setting up use a crossover cable This will...

Page 88: ...88 Rockwell Automation PublicationICSTT RM448J EN P April 2018 Chapter 4 Before You Begin Refer to the illustration for an example...

Page 89: ...shipping notify the carrier and Rockwell Automation immediately Damaged goods must be returned Rockwell Automation for repair or replacement see Warranty and Returns instructions with delivery documen...

Page 90: ...er to hold them in position Figure 15 Fit I O Base Unit onto DIN Rails For a system build that uses DIN rails do the following 1 Install the DIN rails The AADvance controller will be mounted onto one...

Page 91: ...e unit to the left 3 Mount each T9300 I O base unit Place a T9300 I O base unit onto the DIN rails to the right of the T9100 processor base unit Slide the I O base unit to the left until the joining c...

Page 92: ...ies 1 To fit termination assemblies do the following Insert the retaining clip on the back of the termination assembly into the slot on the I O base unit Press the termination assembly onto the base u...

Page 93: ...ase unit and repeated on some termination assemblies which defines the six possible positions for a coding peg The positions are numbered from 1 to 6 Examine a coding peg fitted and identify the index...

Page 94: ...ws pins set to positions 2 1 1 for a 9401 digital input module Application Key A Key B Key C 9100 processor base unit for 9110 processor module 1 1 1 9801 2 3 digital input termination assemblies for...

Page 95: ...mperature rating of 85 C Use a M6 lug on the end of the ground wire Place the lug below the second nut on the ground stud between two washers and use two 10mm wrenches to tighten the nuts to a torque...

Page 96: ...4 Vdc supply to further devices 24 Vdc Power Connectors For each power supply connection do the following Connect the negative line from the power supply typically labeled 0 V to the left hand termina...

Page 97: ...troller is acting as a MODBUS Slave on a four wire bus RS485hdmux A two wire half duplex connection applicable for master slave or slave use This is shown in the MODBUS over serial standard Each proce...

Page 98: ...serial port Terminal Function Description 4 wire 1 Function Description 2 wire 1 TRX_A Receive data A inverting Transmit receive data A inverting TRX_B Receive data B non inverting Transmit receive d...

Page 99: ...ect an applicable cable We recommend 3 pair overall shielded cable 2 Remove the serial port connector from the 9100 processor base unit 3 Make the connections shown in the illustration Terminate the t...

Page 100: ...g 1 Select an applicable cable We recommend 3 pair overall shielded cable 2 Remove the serial port connector from the 9100 processor base unit 3 Make the connections shown in the illustration Terminat...

Page 101: ...Select an applicable cable We recommend 3 pair overall shielded cable 2 Remove the serial port connector from the 9100 processor base unit 3 Make the connections shown in the illustration Terminate th...

Page 102: ...g 1 Select an applicable cable We recommend 3 pair overall shielded cable 2 Remove the serial port connector from the 9100 processor base unit 3 Make the connections shown in the illustration Terminat...

Page 103: ...rewall must be active on the Workstation preventing access to the relevant Ethernet ports on each communication interface Anti virus software must be installed and be kept updated The workstation must...

Page 104: ...al Input Field Loop Circuits RecommendedFieldLoopCircuits This section contains recommended field loop circuits for line monitoring digital inputs used in Emergency Shutdown or Fire Gas applications F...

Page 105: ...tween the field loop conductors These values will allow the input to detect more accurately different voltage levels that represent OPEN CCT OFF ON SHORT CCT and will also detect Over Voltage and an i...

Page 106: ...the Rockwell Automation Knowledgebase Support Center This also includes advice for fire detectors which are not simple volt free contacts DigitalInput Slew Tolerance It is possible during sustained p...

Page 107: ...PublicationICSTT RM448J EN P April 2018 107 Install the AADvance System Chapter 5 Connectionsto9801Non isolatedDigitalInputTA 16ChannelSimplex Apply a minimum tightening torque of 0 5 Nm 0 37 ft lb to...

Page 108: ...Dual TMR Apply a minimum tightening torque of 0 5 Nm 0 37 ft lb to the terminal screws Analogue Input Field loop Circuits These circuits can be used for simplex dual and triple configurations of analo...

Page 109: ...Rockwell Automation PublicationICSTT RM448J EN P April 2018 109 Install the AADvance System Chapter 5 FieldLoopCircuitfor2 WireAnalogueInput Figure 17 Wire Analogue Input Field Loop...

Page 110: ...110 Rockwell Automation PublicationICSTT RM448J EN P April 2018 Chapter 5 Install the AADvance System FieldLoopCircuitfor3 WireAnalogueInput Figure 18 Wire Analogue Input Field Loop...

Page 111: ...s can be declared faulted as a consequence of diagnostics otherwise designed to ensure the channels are operating within their designed safety accuracy To avoid spurious declaration of channel faults...

Page 112: ...on PublicationICSTT RM448J EN P April 2018 Chapter 5 Install the AADvance System ConnectionstoT9831Non isolatedAnalogueInputTA 16ChannelSimplex Apply a minimum tightening torque of 0 5 Nm 0 37 ft lb t...

Page 113: ...ghtening torque of 0 5 Nm 0 37 ft lb to the terminal screws Recommended Field Circuit for Digital Outputs This circuit is applicable for simplex and dual configurations of digital output modules The t...

Page 114: ...are T9902 SMF Omni Block Surface Mount Fuse Block 154 010 with a 10A 125V Fast Acting Fuse Littelfuse WARNING Forinductiveloads abackEMFprotectiondiodeshallbefittedat the load WARNING A fuse rated min...

Page 115: ...ed in the Solutions Handbook Accordingly it may be necessary to condition the field supply voltage or output signal such as by filtering or by appropriate choice of process safety time For further inf...

Page 116: ...sembly Wiring Apply a minimum tightening torque of 0 5 Nm 0 37 ft lb to the terminal screws Recommended Circuit for Analogue Outputs These circuits are suitable for simplex and dual configurations of...

Page 117: ...ircuit is appropriate for devices that are powered by the system The channel will pass a requested current between 0mA and 24mA The field device could also be connected between the 24V supply and the...

Page 118: ...Minus terminal AnalogueOutputSlewTolerance Analogue output channels voltage slew is unconstrained with the limits set by the module s compliance operating voltage range To avoid spurious declaration...

Page 119: ...the terminal screws Install Modules The modules of the AADvance controller mount onto the base units The processor module s mount onto the T9100 processor base unit while the various I O modules mount...

Page 120: ...f you are installing more than one processor module make sure they all have the same firmware build Installation 1 Examine the coding pegs on the 9100 processor base unit and make sure they complement...

Page 121: ...ears when the processor module is continually powered for processor modules that are un powered the design life is up to 6 months TIP Battery design life is based on operating at a constant 25 C and l...

Page 122: ...M448J EN P April 2018 Chapter 5 Install the AADvance System Procedure To replace a faulty battery do the following 1 Use a small cross head screwdriver to release and remove the battery cover 2 Remove...

Page 123: ...odule is installed and the processor module is not powered up and SNTP has not been set up you must set the clock to the current time as soon as practicable The battery does not do any function while...

Page 124: ...les RTC Program Year RTC Program Month RTC Program Day of Month RTC Program Hours RTC Program Minutes RTC Program Seconds RTC Program Milliseconds ProceduretoChecktheCurrentDateandTime 1 Wire the proc...

Page 125: ...Therefore before installation write down the location of the module and the details shown on the label Installation 1 Examine the coding pegs on the termination assembly and make sure that they compl...

Page 126: ...rites Connect Expansion Cable between T9100 Base Unit and T9300 I O Base unit I O Bus2 1 Connect the expansion cable to a T9100 processor base unit for an I O Bus 2 connection Insert a cable socket as...

Page 127: ...two M3 socket cap screws Tighten the screws with a 2 5 mm Allen key Install the cable to the plug assembly and tighten the retaining screws by hand Connect Between a T9300 I O Base Unit and a T9300 I...

Page 128: ...module has a set of front panel status indicators The function and meaning of these indicators related to each module is as follows Status Indicators on the 94xx Series Input and Output Module Table...

Page 129: ...et button on any processor module to set the module to go on line RED Module is prepared to go on line but no application is running Channel 1 8 OFF Input module field switch is open Output module out...

Page 130: ...er being installed as the module is booting up Continuous RED means a Module has a fault GREEN As the module boots up it goes GREEN this lasts for 10 to 20 seconds When the module is operational the L...

Page 131: ...the module is booting up 10 to 20 seconds RED There is a fault on one or more modules or The application has stopped because the module has entered Recovery Mode GREEN No system or module faults prese...

Page 132: ...132 Rockwell Automation PublicationICSTT RM448J EN P April 2018 Chapter 5 Install the AADvance System...

Page 133: ...wiring database with checklist Complete set of drawings Bill of materials 2 Ensure that each item of documentation is the latest issue Mark each item as Test Copy 3 Create a system activity log book a...

Page 134: ...acceptable standard of workmanship has been achieved in the assembly and wiring and that the test arrangements are correct Do the following Visually inspect the controller and verify that base units...

Page 135: ...d fuses 3 Apply power to the incoming power terminals 4 It is good practice to switch on power supplies to field devices before supplies to the controller Devise a formal sequence in which to switch o...

Page 136: ...labeled KEY on the processor base unit 6 Install the first Processor module Refer to the Processor Module start up process 7 Install the second or the third processor module if required Refer to the...

Page 137: ...he Module boots up 10 to 20 seconds then goes GREEN Force Will stay OFF as the Module boots up 10 to 20 seconds then stays OFF until the module has educated Aux Will stay OFF as the Module boots up 10...

Page 138: ...ducates and lastly it goes to steady GREEN Run Will stay OFF as the module boots up 10 to 20 seconds then goes RED until educated and then it goes AMBER System Healthy Will stay OFF as the Module boot...

Page 139: ...althy GREEN Ready RED Run RED Channel 1 8 Off 4 The input module will follow its start up sequence and the module will educate 5 Afterapproximately 3 secondsthe module will now show the following stat...

Page 140: ...The normal and recovery firmware are updated with separate ControlFLASH files Before starting check that ControlFLASH and RSLinx Gateway has been installed and configured The PC is connected via Ether...

Page 141: ...ime Controller IP Address The AADvance controller stores its IP address data in non volatile memory in the 9100 processor base unit The data is independent of the 9110 processor modules in the control...

Page 142: ...top disable Wireless If you have more than one network connection disable the one you are not using The Discover tool installed with AADvance Workbench release 1 2 1 20 109 will not discover with more...

Page 143: ...RM448J EN P April 2018 143 System Start Up Chapter 6 The AADvance Discover utility scans the network for controllers and creates a list 4 Locate the controller in the list and make sure that the stat...

Page 144: ...Number field then click Apply Returning to the main window of the utility the controller status will show Pending Restart 7 To finish the update turn off the power to the controller 8 Start the contr...

Page 145: ...ress do the following 1 Write down the controller s MAC address the Controller ID displayed on a label on the processor base unit Install at least one 9110 processor module into the processor base uni...

Page 146: ...d The resource and IP address dialog box is displayed 6 Enter the IP Address and Subnet Mask into the fields for each Ethernet port 7 Enter the Gateway values for each processor module then click Appl...

Page 147: ...and define the pass criteria for every test Make sure that the test cases allow for the associated systems and their interfaces which the system needs to communicate with If a requirement cannot be ph...

Page 148: ...done on a known version of the controller Record the type serial number and physical location of each module so that the system can be dismantled shipped and built with the modules in the same locati...

Page 149: ...procedure Disposal It is necessary to make a plan for the collection treatment recovery and environmentally sound disposal of the equipment at the end of its life Contact Rockwell Automation to discus...

Page 150: ...150 Rockwell Automation PublicationICSTT RM448J EN P April 2018 Chapter 8 Dismantling the AADvance System...

Page 151: ...ital input module 24 Vdc 8 channel isolated T9402 Digital input module 24 Vdc 16 channel isolated T9451 Digital output module 24 Vdc 8 channel isolated commoned T9431 Analogue input module 8 channel i...

Page 152: ...lex commoned T9852 Digital output TA 24Vdc 8 channel dual T9881 Analogue output TA 8 channel simplex commoned T9882 Analogue output TA 8 channel dual T9844 Frequency Input Module TA Simplex Active not...

Page 153: ...y BR2032 20 mm dia Nominal voltage 3 V Nominal capacity mAh 190 Continuous standard load mA 0 03 Operating temperature 30 C to 80 C supplied by Panasonic Part No Part Description T9901 Replacement inp...

Page 154: ...program enable key T9907 Installation tool kit T9908 Fuse Extractor Tool T9082U IEC 61131 Workbench USB key single user single controller T9082D IEC 61131 Workbench hard disk key single user single c...

Page 155: ...als shown in this document map Actual configuration guide applicable is dependent upon version of AADvance Workbench used Resource Document Number Safety Manual ICSTT RM446 System Build Manual ICSTT R...

Page 156: ...Maintenance Manual This technical manual describes how to maintain troubleshoot and repair an AADvance Controller OPC Portal Server User Manual This manual describes how to install configure and use t...

Page 157: ...ypically using logic sequences limits and expressions to read inputs make decisions and control outputs to suit the requirements of the system for functional safety architecture Organizational structu...

Page 158: ...and or hardware means to make sure the data retains its integrity blanking cover A plastic moulding to hide an unused slot in an AADvance base unit boolean A type of variable that can accept only the...

Page 159: ...cation compilation process This process in conjunction with the validated execution code produced by the AADvance Workbench ensures a high degree of confidence that there are no errors introduced by t...

Page 160: ...s if one or more of the elements disagree DITA Digital input termination assembly DOTA Digital output termination assembly E element A set of input conditioning application processing and output condi...

Page 161: ...ult warning receiving station field device Item of equipment connected to the field side of the I O terminals Such equipment includes field wiring sensors final control elements and those operator int...

Page 162: ...ted Function in the Safety System only performs its designed function on a demand and the frequency of demands is greater than one per year hot swap See live insertion I I O base unit A backplane asse...

Page 163: ...GRAF based components K key connector The receptacle on the AADvance controller for the program enable key A 9 way D type socket located on the 9100 processor base unit L ladder diagram An IEC 61131 l...

Page 164: ...and Combustion Systems Hazards Code Applies to certain boilers stokers fuel systems and steam generators The purpose of this code is to contribute to operating safety and to prevent uncontrolled fire...

Page 165: ...ds all of the processor modules in an AADvance controller Part number 9100 See also processor module processor module The application execution engine of the AADvance controller housed in a self conta...

Page 166: ...The MODBUS protocol supported by the AADvance controller for MODBUS communications over serial links with the ability to multi drop to multiple slave devices S safe state A state which enables the ex...

Page 167: ...with syntax similar to Pascal Used mainly to implement complex procedures that cannot be expressed easily with graphical languages synchronous A data communications term describing a serial transmiss...

Page 168: ...nit A unit of measure used to describe the height of equipment intended for mounting in a standard rack Equivalent to 44 45mm 1 inches V validation In quality assurance confirmation that the product d...

Page 169: ...odes Find the Direct Dial Code for your product Use the code to route your call directly to a technical support engineer http www rockwellautomation com global support direct dial page Literature Libr...

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