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System Build Manual (AADvance Controller)

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Summary of Contents for ics triplex AADvance

Page 1: ...oller System Build Manual System Build Manual System Build Manual System Build Manual Issue 08 Issue 08 Issue 08 Issue 08 DOCUMENT 553632 DOCUMENT 553632 DOCUMENT 553632 DOCUMENT 553632 ICSTT ICSTT ICSTT ICSTT RM448_EN_P RM448_EN_P RM448_EN_P RM448_EN_P ...

Page 2: ...ii Document 553632 ICSTT RM448_EN_P Issue 08 System Build Manual AADvance Controller This page intentionally left blank ...

Page 3: ...construction operation or maintenance of a control system installation You should refer to your own or supplied system safety manual installation instructions and operator maintenance manuals Revision and Updating Policy Revision and Updating Policy Revision and Updating Policy Revision and Updating Policy This document is based on information available at the time of its publication however the d...

Page 4: ... Record Issue Date Comments 01 April 2008 First Issue 02 Feb 2009 Update for Product Titles 03 Nov 2009 Update for Release 1 1 04 July 2010 Update for Release 1 1 1 05 Oct 2010 Updates for UL Certification 06 March 2011 Updated for Release 1 2 07 Aug 2011 Updated for UL Requirements 08 July 2012 Updates for release 1 3 and 1 3 1 ...

Page 5: ...e instructions may result in personal injury WARNING MAINTENANCE Maintenance must be carried out by people who are experienced in working on electronic equipment and in particular safety related systems They should have knowledge and experience of local operating and safety standards Failure to follow these recommendations may result in situations that can lead system damage and even personal inju...

Page 6: ...l Who Should Use this Manual Who Should Use this Manual This manual is intended primarily for System Integrators The information contained in this manual is aimed at engineers experienced in building and setting up safety related systems It is expected that the users have been trained and have a thorough understanding of the intended application Note Note System Integrators are responsible for com...

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Page 8: ...3 way 1 16 T9310 Expansion Cable Assembly 1 18 Backplane Electrical Ratings 1 19 Chapter 2 Chapter 2 Chapter 2 Chapter 2 Before You Begin 2 1 Required Tools Standard AADvance 2 1 Test Equipment 2 2 System Installation Environment 2 2 Specifying an Enclosure 2 2 Free Space Around the Controller 2 4 DIN Rails Fitting 2 5 Base Units DIN Rail installations and Expansion Cables 2 6 Adding Cable Managem...

Page 9: ...ontroller to an Ethernet Network 3 23 Install Modules 3 24 Install a T9110 Processor Module 3 24 Upgrade a Processor Module Firmware 3 25 Install a Processor Back up Battery 3 25 Set the Processor clock 3 26 Install I O Modules 3 27 Install Blanking Covers 3 28 Fit EMC Static Protection Covers 3 28 Install T9310 Expansion Cable 3 29 Fault Reporting Reference Information 3 32 Status Indicators on t...

Page 10: ...ility 4 24 About Discover Communications 4 25 Discover Communications Fault Finding 4 25 Configure the Controller Resource Number 4 26 Configure the IP Address in the Controller 4 27 Chapter 5 Chapter 5 Chapter 5 Chapter 5 Functional Acceptance Testing 5 1 Recommendations for Functional Acceptance 5 1 Chapter 6 Chapter 6 Chapter 6 Chapter 6 Dismantling the AADvance System 6 1 About Dismantling a S...

Page 11: ...evice that consists of processor modules I O modules and field termination assemblies that can easily be assembled and configured A system is built up from one or more controllers a combination of I O modules power sources communications networks and user workstations How you configure the system determines the type of application it can be used for An AADvance controller is particularly well suit...

Page 12: ...d onto a wall in a control room They do not require forced air cooling or special environmental control equipment However certain consideration to the cabinet type must be applied when used in hazardous environments A secure network communications protocol developed by Rockwell Automation for the AADvance system permits distributed control using new or existing network infrastructure while ensurin...

Page 13: ... reprogramming and downloading again maximizing system uptime Controller TUV Ce Controller TUV Ce Controller TUV Ce Controller TUV Certification rtification rtification rtification TÜV Certification TÜV Certification TÜV Certification TÜV Certification TÜV is the safety certifying authority for an AADvance controller The AADvance system is certified to the following standard The Euro Controller is...

Page 14: ...nts The AADvance controller has been investigated and approved by UL UL508 for use as Industrial Control Equipment in a general industrial environment and for use in hazardous locations Class I Division 2 Groups A B C and D The UL file numbers are E341697 and E251761 Certificate Certificate Certificate Certificate The AADvance controller modules have been evaluated to the requirements of EN 60079 ...

Page 15: ...Document 553632 ICSTT RM448_EN_P Issue 08 1 5 ...

Page 16: ...CEx Certified tool accessible IP54 enclosure The enclosure is to be marked with the following Warning Do not open when energized After installation of the modules into the enclosure access to termination compartments shall be dimensioned so that conductors can be readily connected The modules and assemblies are for use in an area of not more than pollution degree 2 in accordance with IEC 60664 1 M...

Page 17: ...into the KEY connector on the processor base unit and either no application is loaded or an application is loaded but not running The status will be locked if the controller reports that one or more of these criteria has not been met If the AADvanceDiscover utility reports a status of no response for a controller either the controller has been turned off or the communications between the computer ...

Page 18: ...cation Environmental Specification Environmental Specification Environmental Specification Attribute Value Operating Temperature Range For use in a Hazardous Environments see UL508 certification Processor Modules I O Modules and Assemblies For use in Non hazardous environments see TUV Certification Processor Modules I O modules and Assemblies 25 C to 60 C 13 F to 140 F 25 C to 70 C 13 F to 158 F 2...

Page 19: ... EN 62061 2005 Hazardous Location Capability Suitable for Class I Div 2 Groups A B C and D Note Casing Standard AADvance modules also have a plastic casing and are rated IP20 Protected against solid objects over 12mm 1 2in for example fingers There is no specific protection against liquids Product Dimensions Product Dimensions Product Dimensions Product Dimensions Ov Ov Ov Overall Dimensions of Mo...

Page 20: ...h of the controller assembly which is 136mm Module Dimensions Module Dimensions Module Dimensions Module Dimensions All modules have the same dimensions Compact Module Design Compact Module Design Compact Module Design Compact Module Design Each processor and I O module is enclosed in a flame retardant and impact resistant plastic cover The cover is designed to assist ventilation and heat dissipat...

Page 21: ...Keying Module Polarization Keying Module Polarization Keying For each I O Module there is a matched termination assembly set The controller incorporates module polarization keying to ensure they are matched when installed Modules have polarized sockets that align and mate with coding pegs located on the termination assembly The alignment of the sockets and pegs ensure only the matched I O module t...

Page 22: ...mblies to connect field wiring to the I O modules A termination assembly is a printed circuit equipped with screw terminal blocks for the field wiring in some cases fuses and connectors for the plug in I O modules Termination assemblies are matched to their relevant I O modules by the coding pegs and sockets and come in three types simplex dual or triple Therefore they can accommodate one two or t...

Page 23: ...NING FUSE REMOVAL or REPLACEMENT When the controller is installed in a Hazardous environment do not remove or replace a fuse when energized Field Wiring Connections Field Wiring Connections Field Wiring Connections Field Wiring Connections Field connections are made using industry standard screw terminal blocks Terminals are readily accessible for future wiring modifications without needing to dis...

Page 24: ...oller T9100 Processor Base Unit T9100 Processor Base Unit T9100 Processor Base Unit T9100 Processor Base Unit Every AADvance controller has one T9100 processor base unit A processor base unit supports one two or three modules depending on the architecture chosen for the application ...

Page 25: ...ing manufacture This means that you can remove a defective processor module and install a new one without needing to set up the IP address of the new module Ethernet Serial Data and Power Connections Ethernet Serial Data and Power Connections Ethernet Serial Data and Power Connections Ethernet Serial Data and Power Connections The external connections for Earthing Ethernet E1 1 to E3 2 serial data...

Page 26: ...four wire full duplex connection with tri state outputs on the transmit connections This should be used when the controller is acting as a Modbus slave on a four wire bus RS485hdmux A two wire half duplex connection appropriate for or master slave or slave use This is shown in the Modbus over serial standard T9300 I O Base Unit 3 way T9300 I O Base Unit 3 way T9300 I O Base Unit 3 way T9300 I O Ba...

Page 27: ...le connectors The backplane provides a connector at the right for the next I O backplane The connection to the left of the backplane can connect to a processor base unit or another I O base unit Adjacent base units clip together and are held in position by a plastic retaining clip Alternatively rows of I O base units can be connected together using a T9310 expansion cable assembly ...

Page 28: ...of a cable terminated by multi way plugs and a pair of adaptors One end has a cable socket assembly and the other end a cable plug assembly that connects to the right hand bus connector of an I O base unit or to IO Bus2 the left hand connector of a processor base unit The socket connects to the left hand bus connector of an I O base unit The expansion cable offers the following features Two meter ...

Page 29: ...2 10 4A 400mA per slot 9101 18 32 10 4A 400mA per slot 9300 18 32 9 6A 400mA per slot 9110 18 32 380 9111 18 32 380 9401 18 32 260 Input 18 32Vdc 24mA 9402 18 32 260 Input 0 32Vdc 6 5mA 9431 18 32 260 Input 0 32Vdc 6 5mA 9432 18 32 260 Input 18 32Vdc 24mA 9481 18 32 260 Output 18 32Vdc 0 20mA 9482 18 32 260 Output 18 32Vdc 0 20mA 9451 18 32 165 Output 18 32Vdc 0 5A Pilot duty 16VA 1 5A Inrush 9801...

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Page 31: ...ivities 2 12 Required Tools Standard AADvance Required Tools Standard AADvance Required Tools Standard AADvance Required Tools Standard AADvance The installation and maintenance of the AADvance controller requires the following tools Stand Stand Stand Standard Tools ard Tools ard Tools ard Tools Screwdriver flat 0 8 x 9 0mm 1 25 c 3 8 inch for the module clamp screws and blanking covers Screwdrive...

Page 32: ...tant to know the environment for each location Specifying an Enclosure Specifying an Enclosure Specifying an Enclosure Specifying an Enclosure An enclosure for a controller must be designed for the environmental conditions where the controller is installed It needs to support the weight of the controller modules provide mechanical protection and remove the heat that the controller generates The en...

Page 33: ...ncorrect handling You should label the exterior surfaces of the enclosure to caution personnel to observe antistatic precautions when handling modules Enclosure Requirements for a Hazardous Environment Enclosure Requirements for a Hazardous Environment Enclosure Requirements for a Hazardous Environment Enclosure Requirements for a Hazardous Environment For a system that is located in a Zone 2 Haza...

Page 34: ...y the additional depth of the DIN rails You must allow sufficient free space around the base units Every application needs space on at least three sides as follows Space above to manipulate and install field wiring Space below to enable modules to fit and to be able to grasp a module during removal Space to the right to move an I O base unit during assembly or in the event of installing a new base...

Page 35: ...arallel DIN rails The DIN rails must be TS35 rail which is 35mm 7 5mm standard symmetric rail Alternatively you can install the controller onto a flat panel The fixing dimensions are given below for both methods A typical DIN rail arrangement is shown below An application using DIN rails must provide the DIN rail free space to the left to fit an end stop on the upper DIN rail ...

Page 36: ...pansion Cables Using Expansion Cables Using Expansion Cables A further eight I O base units can be connected through an expansion cable to the left hand edge of the processor base unit The expansion bus accessed from the right hand edge of the 9100 processor base unit is designated bus 1 while the bus accessed from the left hand edge is designated bus 2 The module positions slots within the I O ba...

Page 37: ...t within a range of 25 C to 40 C for normal operation and and to maintain predictable reliability for the equipment Note Component failure rate of the controller doubles with every 10 C rise in temperature System Power Requirements System Power Requirements System Power Requirements System Power Requirements A controller s system power AADvance standard or Eurocard controller should be supplied fr...

Page 38: ...on requirements together with the protective philosophy for each distribution for example current limited at source or protective devices Where protective devices are used it is important to establish that sufficient current be available to ensure their protective action and that the protective device can break the maximum prospective fault current Ensure that the power supplies are sufficient to ...

Page 39: ...is dissipated as heat Use these tables to estimate the supply voltage and field power heat dissipation of your system Table 2 Table 2 Table 2 Table 2 Estimating Module Supply Power Dissipation Estimating Module Supply Power Dissipation Estimating Module Supply Power Dissipation Estimating Module Supply Power Dissipation Item Number of Modules Power Dissipation Subtotal W BTU hr T9110 Processor Mod...

Page 40: ...nel 340g 12oz T9431 Analogue input module 8 channel 280g 10oz T9432 Analogue input module 16 channel 340g 12oz T9451 Digital output module 24V dc 8 channel 340g 12oz T9482 Analogue output module 8 channel 290g 10 5oz T9300 I O base unit 3 way 133g 5 oz T98x1 Simplex Termination assembly 133g 5 oz T98x2 Dual Termination Assembly 260g 10oz T98x3 Triple Termination Assembly 360g 13oz T9310 Expansion ...

Page 41: ...ns will be more important than the goodness of the ground connection provided The controller input and output modules incorporate galvanic isolation Nevertheless it is possible that a particular application will require the provision of barrier strips with galvanic isolation for example to provide consistency with an existing installation In these cases there may be a separate intrinsic safety gro...

Page 42: ...ns for Maintenance Activities es es es Maintenance Activities Maintenance Activities Maintenance Activities Maintenance Activities The design of the installation must allow preventive and corrective maintenance activities to take place Corrective maintenance tasks will embrace the identification and renewal of defective modules and other assemblies and when exhausted renewal of the back up battery...

Page 43: ...ase units and security dongle Program Enable key Repair of controller modules will be by module replacement A way for plant operations personnel to inspect the status LEDs on each module The status LEDs report faults Clear access to examine remove and install fuses located on the termination assemblies Clear access to terminals and connectors for field power and network wiring and access to the wi...

Page 44: ...sue 08 System Build Manual AADvance Controller In addition it may be appropriate to make the following provisions A lock on the door of the enclosure to deter unauthorized access and possible unofficial modifications Lighting Utility sockets ...

Page 45: ...ll I O Modules 3 27 Install Blanking Covers 3 28 Fit EMC Static Protection Covers 3 28 Install T9310 Expansion Cable 3 29 Fault Reporting Reference Information 3 32 Status Indicators on the T9110 Processor Module 3 33 Unpacking and Pre Unpacking and Pre Unpacking and Pre Unpacking and Pre assembly Checks assembly Checks assembly Checks assembly Checks The components are packed to make sure they ar...

Page 46: ...ails The AADvance controller will be mounted onto one or more pairs of parallel DIN rails For each pair of rails mount the lower rail with its centre line 101 0mm below the centre line of the upper rail M5 thread rolling screws are suitable 2 Mount power supply units To install the power supply units refer to the instructions supplied with the units 3 Mount the T9100 processor base unit Place the ...

Page 47: ...e printed circuit board to secure the termination assembly in position 7 Check coding pegs Observe the legend on the 9100 processor base unit and repeated on some termination assemblies which defines the six possible positions for a coding peg The positions are numbered from 1 to 6 Examine a coding peg fitted and identify the index recess on the hexagonal flange Refer to the following table and ve...

Page 48: ...s for digital output modules 3 1 1 9842 1 analogue output module 3 1 2 This example shows pins set to positions 2 1 1 for a 9401 digital input module Install Base Units and Ter Install Base Units and Ter Install Base Units and Ter Install Base Units and Termination Assemblies Flat Panel Assembly mination Assemblies Flat Panel Assembly mination Assemblies Flat Panel Assembly mination Assemblies Fla...

Page 49: ...uctions supplied with the units 5 Fit termination assemblies Insert the retaining clip on the back of the termination assembly into the slot on the I O base unit Press the termination assembly onto the base unit and then slide the assembly upwards as far as it will go Make sure the retaining tab clips over the printed circuit board to secure the termination assembly in position 6 Check coding pegs...

Page 50: ...e following table 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 digital input modules 2 1 1 9831 2 3 analogue input termination assemblies for analogue input modules 2 1 3 9851 2 digital output termination assemblies for digital output modules 3 1 1 9842 1 analogue output module 3 1 2 This example shows pins...

Page 51: ...ud between two washers and use two 10mm wrenches to tighten the nuts to a torque of 1 2Nm 0 74Ib ft n to 2Nm 1 48lb ft Refer to the illustration for an example Connect the 24V dc System Power to an AADvance Controller Connect the 24V dc System Power to an AADvance Controller Connect the 24V dc System Power to an AADvance Controller Connect the 24V dc System Power to an AADvance Controller The dual...

Page 52: ...om the power supply typically labelled 0V to the left hand terminal Connect the positive line from the power supply typically labelled 24V to the right hand terminal Apply a minimum tightening torque of 0 5 Nm 0 37 ft lb to the terminal screws Note Make sure that PWR 1 and PWR 2 are supplied from independent 24V dc sources Refer to the illustration for an example ...

Page 53: ...ase unit S1 1 S1 2 S2 1 S2 2 S3 1 S3 2 Six 5 way connectors Conductor cross section maximum 1 31mm 16 AWG Stripping length 7mm 9 32 in Wire to screw terminals on free connectors supplied with processor base unit Ethernet ports T9100 processor base unit E1 1 E1 2 E2 1 E2 2 E3 1 E3 2 RJ45 socket Use network patch cords not supplied Field wiring sensors actuators and field power sources I O Terminati...

Page 54: ...ng illustration Apply a minimum tightening torque of 0 22Nm 0 16ft lb to the terminal screws Make sure the length of the cable does not exceed 1 200m 3 900ft Note The line functions shown in this table receive and transmit are with respect to the processor base unit Terminal Function Description 4 wire Function Description 2 wire TRX_A Receive data A inverting Transmit receive data A inverting TRX...

Page 55: ...is is a 4 wire point to point connection The receive end should always be terminated a resistor and capacitor as shown in the diagram or similar termination The recommended values are 120R 100nf RS485 Full Duplex Multiplexed RS485 Full Duplex Multiplexed RS485 Full Duplex Multiplexed RS485 Full Duplex Multiplexed This is a 4 wire multi drop connection Circuits with multiple transmitters should be ...

Page 56: ...stem to accidental or malicious infection or attack There are some simple steps that can be taken to help prevent such issues Network and workstation security should be considered for example AADvance should not be on a network with open unsecured access to the Internet The Firewall must be active on the Workstation preventing access to the relevant Ethernet ports on each communication interface A...

Page 57: ...o a Euro Controller This provides read only access to controllers during normal operation Connecting Field Wiring Connecting Field Wiring Connecting Field Wiring Connecting Field Wiring Connect the field wiring to the screw terminal blocks on the termination assemblies Note Use conductor wire with a cross section of 16AWG The stripping length should be 6mm 1 4 in and a conductor temperature rating...

Page 58: ...op circuits for line monitoring digital inputs used in Emergency Shutdown or Fire Gas applications Field Loop Circuit for Digital Input Field Loop Circuit for Digital Input Field Loop Circuit for Digital Input Field Loop Circuit for Digital Input Field Loop Circuit for Line Monitored Digital Input for Emergency Shutdown Systems Field Loop Circuit for Line Monitored Digital Input for Emergency Shut...

Page 59: ...imum Isolation is 0 75M Ω between 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 input which is neither ON or OFF The values ensure that a line fault will be declared before it becomes possible for a false declaration of On and Off states due to a combin...

Page 60: ...l Dual TMR 16 Channel Dual TMR 16 Channel Dual TMR 16 Channel Dual TMR Apply a minimum tightening torque of 0 5 Nm 0 37 ft lb to the terminal screws Connections to 9801 Non Connections to 9801 Non Connections to 9801 Non Connections to 9801 Non isolated Digital Input TA isolated Digital Input TA isolated Digital Input TA isolated Digital Input TA 16 Channel Simplex 16 Channel Simplex 16 Channel Si...

Page 61: ... fuse as shown in each circuit to protect the field wiring Recommended Field Loop Circuits Recommended Field Loop Circuits Recommended Field Loop Circuits Recommended Field Loop Circuits Note A 150 ohm resistor is fitted only for the Euro Version of the Termination Assembly T9842 Euro Analogue Input TA 8 ch Simplex 2 2 2 2 Wire Analogue Input Wire Analogue Input Wire Analogue Input Wire Analogue I...

Page 62: ...e Input Connections to T9831 Non Connections to T9831 Non Connections to T9831 Non Connections to T9831 Non isolated Analogue Input TA isolated Analogue Input TA isolated Analogue Input TA isolated Analogue Input TA 16 Channel Simplex 16 Channel Simplex 16 Channel Simplex 16 Channel Simplex Apply a minimum tightening torque of 0 5 Nm 0 37 ft lb to the terminal screws ...

Page 63: ...A Connections to T9832 T9833 Isolated Analogue Input TA Connections to T9832 T9833 Isolated Analogue Input TA Connections to T9832 T9833 Isolated Analogue Input TA 16 Channel TMR 16 Channel TMR 16 Channel TMR 16 Channel TMR Apply a minimum tightening torque of 0 5 Nm 0 37 ft lb to the terminal screws ...

Page 64: ...A fuses are fitted into the termination assembly and are T9902 SMF Omni Block Surface Mount Fuse Block 154 010 with a 10A 125V Fast Acting Fuse Littlefuse The field power input 5A fuses are No 396 TE5 5A time lag fuse UL 248 14 125 V T Leadfree manufactured by Littlefuse Note 1 Alternatively instead of fitting two 5A fuses you can use Class 2 power supplies for the 24V dc field voltage Class 2 is ...

Page 65: ...imum tightening torque of 0 5 Nm 0 37 ft lb to the terminal screws Recommended Circuit for Analogue Outputs Recommended Circuit for Analogue Outputs Recommended Circuit for Analogue Outputs Recommended Circuit for Analogue Outputs These circuits are suitable for simplex and dual configurations of analogue output modules All channels are isolated from each other but may be bridged at the terminal i...

Page 66: ...ered devices Field powered devices Field powered devices Field powered devices The above circuit is appropriate for devices that are powered locally and expect a current controlled signal loop Ensure that the loop is wired to pass current to the Loop Plus terminal and return it on the Loop Minus terminal Connections to T9881 T9882 Analogue Output TA Connections to T9881 T9882 Analogue Output TA Co...

Page 67: ...ion is required from the controller to the workstation PC for example during setting up it may be necessary to use a crossover cable This will depend on the characteristics of the network interface in the PC Wiring for 100BASE Wiring for 100BASE Wiring for 100BASE Wiring for 100BASE TX Ethernet Crossover Cable TX Ethernet Crossover Cable TX Ethernet Crossover Cable TX Ethernet Crossover Cable The ...

Page 68: ...s are delivered with the latest firmware and a base level Recovery Mode firmware build You can enter the Recovery Mode by pressing the Fault Reset button immediately after the module has booted up Inspect the module Before inserting a new I O module inspect it for damage The identification labels on the sides of the I O module will be hidden once the module is installed Therefore before installati...

Page 69: ...fer to the configuration Guide for detailed procedures on using the ControlFLASH utility Note If you need to downgrade the firmware to meet the requirements of your application and system contact Product support Install a Processor Back Install a Processor Back Install a Processor Back Install a Processor Back up Battery up Battery up Battery up Battery The T9110 processor module uses a battery to...

Page 70: ...led and the processor module is not under power the processor clock will need to be reset to the current time Correct the clock at the earliest opportunity If it is replaced when more than one processor module is installed then the clock will be updated through synchronization If you have previously set up SNTP when you set up your processor module then the clock will be reset to the current time ...

Page 71: ... the I O module will be hidden once the module is installed Therefore before installation record the location of the module and the details shown on the label Examine the coding pegs on the termination assembly and verify they complement the sockets on the rear of the new I O module To install each I O module do the following 1 Examine the coding pegs on the termination assembly and verify they co...

Page 72: ... units Place the blanking cover on the base unit and use a broad 9mm flat blade screwdriver to turn the clamp screw 90 to the lock position Fit EMC Static Protection Covers Fit EMC Static Protection Covers Fit EMC Static Protection Covers Fit EMC Static Protection Covers For EMC static protection you should fit the black plastic protection covers supplied with the base units over any exposed 48 pi...

Page 73: ...ferrites Connect Expansion Cable between T9100 Base Unit and T9300 I O Base unit IO Bus2 Connect Expansion Cable between T9100 Base Unit and T9300 I O Base unit IO Bus2 Connect Expansion Cable between T9100 Base Unit and T9300 I O Base unit IO Bus2 Connect Expansion Cable between T9100 Base Unit and T9300 I O Base unit IO Bus2 1 Connect the expansion cable to a T9100 processor base unit for an IO ...

Page 74: ...by inserting the two M3 socket cap screws Tighten the screws with a 2 5mm Allen key Install the cable to the plug assembly and tighten the retaining screws by hand Connect Between a T9300 I O Connect Between a T9300 I O Connect Between a T9300 I O Connect Between a T9300 I O Base Unit and a T9300 I O Base Unit Base Unit and a T9300 I O Base Unit Base Unit and a T9300 I O Base Unit Base Unit and a ...

Page 75: ...ee end of the expansion cable to the left hand plug of an I O base unit using a cable socket assembly Insert a cable socket assembly into the left hand connector of the T9300 processor base unit Secure the socket assembly by inserting the two M3 socket cap screws Tighten the screws with a 2 5mm Allen key Install the cable to the socket assembly and tighten the retaining screws by hand ...

Page 76: ...ut Module Status Indicators on the 94xx Series Input and Output Module Status Indicators on the 94xx Series Input and Output Module Indicator Status Description Healthy Provides an indication of the general status of the module OFF No power GREEN No module faults present RED One or more module faults are present Note 1 The Healthy indicator may turn RED immediately upon application of power to the...

Page 77: ...fault RED Channel fault Status Indicators on the T9110 Processor Module Status Indicators on the T9110 Processor Module Status Indicators on the T9110 Processor Module Status Indicators on the T9110 Processor Module Table 7 Table 7 Table 7 Table 7 Status Indi Status Indi Status Indi Status Indicators on the 9110 Processor Module cators on the 9110 Processor Module cators on the 9110 Processor Modu...

Page 78: ... then Green Amber Module is in the Recovery Mode Run Provides an indication of the module s application status Should be the same for all educated and synchronised processors OFF No power and stays off while the module is booting up 10 to 20 seconds RED Module is not educated synchronised No application loaded The processor module is in the Recovery Mode and the base level firmware is running GREE...

Page 79: ...tion is stopped OFF No power and stays off while the module is booting up 10 to 20 seconds or under application control GREEN Under application control AMBER Module is in the Recovery Mode or under application control Serial 1 and 2 Provides an indication of serial port activity OFF No power and stays off while the module is booting up 10 to 20 seconds RED Pulse stretched Tx GREEN Pulse stretched ...

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Page 81: ... Workbench Communications 4 24 Recommendations to Manage Test Documentation Recommendations to Manage Test Documentation Recommendations to Manage Test Documentation Recommendations to Manage Test Documentation It is important that the system is documented when it is installed and this documentation is maintained throughout the testing process system 1 Obtain these items of documentation I O wirin...

Page 82: ...s or options called for on the drawings are present and correct Check nameplates and identification labels against the drawings Identify any non conformance found between the system and the drawings If appropriate correct the drawing Record each non conformance in the log book Procedure to Conduct the Mechanical Inspection Procedure to Conduct the Mechanical Inspection Procedure to Conduct the Mec...

Page 83: ...d first power up verifies that the power distribution circuits function as designed and as detailed in the drawings It shows the correct voltages are appearing and only in the correct places It also provides an opportunity to verify correct operation of any power indicators outside the controller itself Do the following 1 Make sure all modules are removed 2 Trip all circuit breakers and disengage ...

Page 84: ...system status indications show the system is on line and operating as expected Processor Module Start Up Process Processor Module Start Up Process Processor Module Start Up Process Processor Module Start Up Process Note When inserting more than one processor module they MUST be inserted one at a time and the module be allowed to educate in the case of a 2nd and 3rd processor Table 8 Table 8 Table ...

Page 85: ...t up the processor IP Address so that the workstation can communicate with the processor module and download the latest firmware build and configure the processor variables 3 Set the Controller IP Address for all the processor modules using the AADvance Discover Utility Refer to the Configuration Guide for detailed instructions on using the AADvance Discover Utility Doc No 553633 4 Install a Progr...

Page 86: ...dule in position All the Module LEDs are OFF until the module is installed As soon as the module receives power it will boot up then educate and display the following indications Healthy Flashes RED for a second then goes GREEN as the module boots up 10 to 20 seconds Ready Will remain OFF as the module boots up 10 20 seconds then goes RED for 10 secs then flashes GREEN as it educates and finally i...

Page 87: ... compared to installing the module into a system that is off line and has processor modules but no I O modules installed The first part of this procedure covers the initial start up of an off line system the second part covers a system that is on line and you are adding I O modules Table 10 Table 10 Table 10 Table 10 Single Single Single Single Module or First Module of a group Installation Proced...

Page 88: ...ion Procedure Second or third Module of a Group Installation Procedure Step Task 1 This procedure applies to a second or third module of a redundant group 2 Install the Input Output Module and turn the locking screw to the lock position 3 The input module will provide the following status indications Healthy GREEN Ready RED Run RED Channel 1 8 Off 4 The input module will enter its start up sequenc...

Page 89: ...Document 553632 ICSTT RM448_EN_P Issue 08 4 9 8 If the module fails to educate and go on line replace the module ...

Page 90: ...d with the Recovery Mode installed then this stage is not necessary Note Stage 1 must be done individually on each processor it does not matter if you download the Recovery Mode one at a time in a specific slot or in their own slots Stage 2 Reboot the processor and enter the Recovery Mode the run the latest version of 354400_xxxx_ControlFLASH msi program to install the ControlFLASH to upgrade your...

Page 91: ...t networks Before installing the ControlFLASH Firmware Kit RSLinx must be configured with the IP address of the controller you wish to upgrade Ensure that when you run the RSLinx software from the Communications menu click Configure Drivers Select a driver of type Ethernet Devices and add the required IP address to the list Stage 1 Installing the ControlFLASH Firmware Stage 1 Installing the Contro...

Page 92: ...N_P Issue 08 System Build Manual AADvance Controller 3 Read and agree to the license and click Next 4 Click Browse to select the location of the installation or Next to select the default location 5 Click Next to start the installation ...

Page 93: ...Document 553632 ICSTT RM448_EN_P Issue 08 4 13 ControlFLASH installs 6 To launch ControlFLASH select the Yes I want to launch controlFLASH option then click Close ...

Page 94: ...ASH Utility Note ControlFLASH can upgrade 3 processor modules at once when installed into a 9100 base unit and they are in the Recovery Mode To do this press and hold the Fault Reset button on all three processors when they are being powered up during a power on off cycle until the AUX LED goes Amber WARNING FIRMWARE UPGRADE DANGER TO A RUNNING SYSTEM Do not attempt to upgrade firmware on a runnin...

Page 95: ...Document 553632 ICSTT RM448_EN_P Issue 08 4 15 2 Click Next 3 Select T9110 from the list 4 Browse to the device in the RSLinx window ...

Page 96: ...4 16 Document 553632 ICSTT RM448_EN_P Issue 08 System Build Manual AADvance Controller 5 Select the firmware revision for the latest Release 6 Check the summary details click Finish ...

Page 97: ... RM448_EN_P Issue 08 4 17 The continue message is displayed 7 Click Yes to continue with the update A progress bar is displayed When the progress bar reaches the end it may take several minutes for the next screen to appear ...

Page 98: ...e next message box appears You may get a Comms error message as AADvance processors do not automatically reboot as ControlFLASH expects them to but the firmware download should have completed correctly 8 Click OK Wait another couple of minutes and the same message will appear again 9 Click OK The following message now appears ...

Page 99: ...ing the ControlFLASH Firmware Kit for OS FPGA LSP and BUSP Stage 2 Installing the ControlFLASH Firmware Kit for OS FPGA LSP and BUSP Stage 2 Installing the ControlFLASH Firmware Kit for OS FPGA LSP and BUSP Stage 2 Installing the ControlFLASH Firmware Kit for OS FPGA LSP and BUSP This procedure describes how to upgrade the Processor Firmware for OS FPGA LSP and BUSP The procedure that follows is b...

Page 100: ...sor module firmware using ControlFLASH Note ControlFLASH can upgrade 3 processor modules at once when installed into a 9100 base unit WARNING FIRMWARE UPGRADE DANGER TO A RUNNING SYSTEM Do not attempt to upgrade firmware on a running system Control FLASH will not warn you that a system is running and you will lose control of the application when the system reboots 1 Run the ControlFLASH software b...

Page 101: ...Document 553632 ICSTT RM448_EN_P Issue 08 4 21 4 Browse to the device in the RSLinx window 5 Select the firmware revision for the latest Release ...

Page 102: ...4 22 Document 553632 ICSTT RM448_EN_P Issue 08 System Build Manual AADvance Controller 6 Check the summary details click Finish The continue message is displayed 7 Click Yes to continue with the update ...

Page 103: ...not in the Recovery Mode the following error is displayed Follow the procedure in Stage 1 to download the recovery Mode After the progress bar reaches the end it may take several minutes for the next screen to appear Use the View Module Firmware Versions procedure to verify that the upgrade has worked ...

Page 104: ...etting Controller IP Address Setting The AADvanceDiscover Utilility uses a discovery and configuration protocol proprietary to Rockwell Automation to set the controller IP address within the AADvance Workbench and to scan the broadcast domain for other AADvance controllers The utility locates each controller by its unique MAC Address Having located a particular controller to be configured the util...

Page 105: ...g feature About Discover Communications About Discover Communications About Discover Communications About Discover Communications AADvanceDiscover uses DCP Discovery Configuration Protocol not TCP This is a general purpose protocol which allows AADvance controllers without an IP address to be configured on a network without having to set switches or connect a serial cable to preset an IP address D...

Page 106: ... 109 will not discover with more than one network connection available Configure the Controller Resource Number Configure the Controller Resource Number Configure the Controller Resource Number Configure the Controller Resource Number When you build a new AADvance controller or install a new 9100 processor base unit you have to configure the resource number stored in the controller This is a kind ...

Page 107: ... the Resource Properties Configure the IP Address in the Controller Configure the IP Address in the Controller Configure the IP Address in the Controller Configure the IP Address in the Controller When you build a new AADvance controller or install a new 9100 processor base unit you have to configure the IP Address stored in the controller The procedure to configure the IP Address uses the AADvanc...

Page 108: ...AADvance AADvance Discover The AADvanceDiscover utility scans the network for controllers and creates a list 4 Locate the controller in the list and make sure that the status of the controller is Configurable 5 Double click on the MAC address in the Controller ID field The resource and IP address dialog box opens 6 Enter the IP Address and Subnet Mask into the fields for each Ethernet port 7 Enter...

Page 109: ...Document 553632 ICSTT RM448_EN_P Issue 08 4 29 Returning to the main window of the utility the controller status will show In Progress and then Configurable The controller uses the new settings ...

Page 110: ...4 30 Document 553632 ICSTT RM448_EN_P Issue 08 System Build Manual AADvance Controller This page intentionally left blank ...

Page 111: ...limits in the module specifications for the categories below Environmental tests including electromagnetic compatibility life and stress testing Testing in degraded modes fault modes and exception testing If technical manuals have been prepared for the maintenance and operation of the final safety instrumented system the content of these manuals should be reviewed as well Test Cases Descr Test Cas...

Page 112: ...troller Configuration Controller Configuration Controller Configuration Controller Configuration Testing should take place on a defined version of the controller Record the type serial number and physical location of module for shipping and later re installation in their original locations ...

Page 113: ...sal It will be necessary to arrange for the collection treatment recovery and environmentally sound disposal of the equipment at the end of its life Contact Rockwell Automation to discuss the most appropriate way to do this Re Re Re Re use use use use Before disposing of serviceable items contact Rockwell Automation It may be possible to return unwanted items to Rockwell Automation for possible fu...

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Page 115: ...t module 8 channel isolated T9432 Analogue input module 16 channel isolated T9481 Analogue output module 3 channel isolated T9482 Analogue output module 8 channel isolated Special Application Modules Part No Part Description T9441 Frequency Input Module Product not yet released Contact Sales for more information Termination Assemblies Part No Part Description T9801 Digital input TA 16 channel simp...

Page 116: ... Input Module TA TMR Active not yet released T9847 Frequency Input Module TA Simplex Passive not yet released T9848 Frequency Input Module TA Dual Passive not yet released T9849 Frequency Input Module TA TMR Passive not yet released Expansion Cable Assembly Expansion cable assembly comprising expansion cable and two adaptors Part No Part Description T9310 02 Backplane expansion cable 2 metre Blank...

Page 117: ...controller Part No Part Description T9083U IEC 61131 Workbench USB key multiple controllers T9083D IEC 61131 Workbench hard disk key multiple controllers Part No Part Description T9084U IEC 61131 Workbench 5 user USB key multiple controllers T9085 5 additional user licenses for use with T9084U Part No Part Description T9030 OPC portal server T9033 AADvance DTM for use with HART Passthru feature De...

Page 118: ... SMF Omni Block Surface Mount Fuse Block 154 010 with a 10A 125V Fast Acting Fuse Littlefuse T9905 Poly carbonmonofluride Lithium Coin Battery BR3032 20mm dia Nominal voltage 3V Nominal capacity mAh 190 Continuous standard load mA 0 03 Operating temperature 30 C to 80 C supplied by Panasonic ...

Page 119: ...evel components asynchronous asynchronous asynchronous asynchronous A data communications term describing a serial transmission protocol A start signal is sent before each byte or character and a stop signal is sent after each byte or character An example is ASCII over RS 232 C See also RS 232 C RS 422 RS 485 availability availability availability availability The probability that a system will be...

Page 120: ...on A mechanism for deciding which device has control of a bus C C C C CIP CIP CIP CIP Common Industrial Protocol A communications protocol formally known as CIP over Ethernet IP created by Rockwell Automation for the Logix controller family and which is also supported by the AADvance controller AADvance controllers use the protocol to exchange data with Logix controllers The data exchange uses a c...

Page 121: ...unction circuit where the devices are energized under normal operation Removal of power de activates the field devices dictionary dictionary dictionary dictionary The set of internal input and output variables and defined words used in a program discrepancy discrepancy discrepancy discrepancy A condition that exists if one or more of the elements disagree DITA DITA DITA DITA Digital input terminat...

Page 122: ...easures can be initiated at any time fire alarm routing equipment fire alarm routing equipment fire alarm routing equipment fire alarm routing equipment Intermediate equipment which routes an alarm signal from control and indicating equipment to a fire alarm receiving station function block diagram function block diagram function block diagram function block diagram An IEC 61131 language that desc...

Page 123: ...nch variable input Workbench variable input Workbench variable input Workbench variable In the context of an AADvance Workbench variable this term describes a quantity passed to the Workbench from a controller instruction list instruction list instruction list instruction list An IEC 61131 language similar to the simple textual language of PLCs See limited variability language integer integer inte...

Page 124: ...ication software OPC OPC OPC OPC A series of standards specifications which support open connectivity in industrial automation output Workbench variable output Workbench variable output Workbench variable output Workbench variable In the context of an AADvance Workbench variable this term describes a quantity passed from the Workbench to a controller P P P P peer to peer peer to peer peer to peer ...

Page 125: ... which may be represented For example 12 bits can distinguish between 4096 values RS RS RS RS 232 232 232 232 C RS C RS C RS C RS 422 RS 422 RS 422 RS 422 RS 485 485 485 485 Standard interfaces introduced by the Electronic Industries Alliance covering the electrical connection between data communication equipment RS 232 C is the most commonly used interface RS 422 and RS 485 allow for higher trans...

Page 126: ...not be expressed easily with graphical languages synchronous synchronous synchronous synchronous A data communications term describing a serial transmission protocol A pre arranged number of bits is expected to be sent across a line per second To synchronise the sending and receiving machines a clocking signal is sent by the transmitting computer There are no start or stop bits T T T T TA TA TA TA...

Page 127: ...ct does what the user requires verification verification verification verification In quality assurance confirmation that the product conforms to the specifications voting system voting system voting system voting system A redundant system m out of n which requires at least m of the n channels to be in agreement before the system can take action W W W W withstand voltage withstand voltage withstan...

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Page 129: ...roller and systems It sets out some guidelines on how to specify a system to meet your application requirements System Build Manual This technical manual describes how to assemble a system switch on and validate the operation of a your system Configuration Guide This manual defines how to configure an AADvance controller using the AADvance Workbench to meet your system and application requirements...

Page 130: ...uston Parkway North Suite 100 Houston Texas 77043 1219 USA Rockwell Automation Hall Road Maldon Essex CM9 4LA England UK Rockwell Automation Millenium House Campus 1 Aberdeen Science Tech Park Balgownie Road Bridge of Don Scotland UK Tel 1 713 353 2400 Fax 1 713 353 2401 Tel 44 1621 854444 Fax 44 1621 851531 44 1224 227 780 Rockwell Automation No 2 Corporation Road 04 01 to 03 Corporation Place Si...

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