Ac450 Guide
Ac450 Guide
Ac450 Guide
User’s Guide
3BSE 002 415R701 Rev A
Use of'$1*(5,:$51,1*,&$87,21, and127(
This publication includes, '$1*(5, :$51,1*, &$87,21, and 127( information where appropriate to point out safety
related or other important information.
'$1*(5 Hazards which could result in severe personal injury or death
:$51,1* Hazards which could result in personal injury
&$87,21 Hazards which could result in equipment or property damage
127( Alerts user to pertinent facts and conditions.
Although '$1*(5 and :$51,1* hazards are related to personal injury, and &$87,21 hazards are associated with
equipment or property damage, it should be understood that operation of damaged equipment could, under certain operational
conditions, result in degraded process performance leading to personal injury or death. Therefore, comply fully with all
'$1*(5, :$51,1*, and &$87,21 notices.
75$'(0$5.6
Advant, AdvaBuild, Advant Controller, Advant Fieldbus, Advant Station, MasterBatch, MasterGate, MasterBus,
MasterFieldbus, ABB Master, ABB MasterNet, ABB MasterPiece and ABB MasterView registered trademarks of ABB Asea
Brown Boveri Ltd. Switzerland.
Allan-Bradley is a trademark of Allan-Bradley Inc.
CardTalk is a trademark of Microsoft Corporation.
Epson is a registered trademark of Epson Corporation.
HART is a trademark of Rosemount Inc.
Master Safeguard is a trademark of ABB Industri AS, Norway.
Mannesmann Tally is a trademark of Mannesmann Tally Limited.
MC 68040 is 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 AS, Norway.
VT100 is a trademark of Digital Equipment Corporation.
127,&(
The information in this document is subject to change without notice and should not be construed as a commitment by ABB
Automation Products AB. ABB Automation Products AB assumes no responsibility for any errors that may appear in this
document.
In no event shall ABB Automation Products AB be liable for direct, indirect, special, incidental or consequential damages of
any nature or kind arising from the use of this document, nor shall ABB Automation Products AB be liable for incidental or
consequential damages arising from use of any software or hardware described in this document.
This document and parts thereof must not be reproduced or copied without ABB Automation Products AB’s written permission,
and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose.
The software described in this document is furnished under a license and may be used, copied, or disclosed only in accordance
with the terms of such license.
&(0$5.,1*
This product meets the requirements specified in EMC Directive 89/336/EEC and in Low Voltage Directive 73/23/EEC.
3BSE001264/E
Template: 3BSE001286/E
TABLE OF CONTENTS
Chapter 1 - Introduction
1.1 General Information................................................................................................. 1-1
1.2 Manual Organization ............................................................................................... 1-2
1.3 Conventions ............................................................................................................. 1-5
1.4 Related Documentation............................................................................................ 1-5
1.5 Release History ........................................................................................................ 1-9
1.6 Terminology........................................................................................................... 1-12
1.7 Product Overview .................................................................................................. 1-16
1.7.1 Product Versions ................................................................................... 1-18
1.7.1.1 Version Designation ....................................................... 1-19
1.7.2 Product Structure .................................................................................. 1-19
1.7.3 General System Utilities ....................................................................... 1-24
1.7.3.1 CPU ................................................................................ 1-24
1.7.3.2 Memory .......................................................................... 1-25
1.7.3.3 Program Module Contents ............................................. 1-27
1.7.3.4 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
1.7.8.1 Application Language .................................................... 1-92
1.7.8.2 Principles of Application Building ................................ 1-95
1.7.8.3 Control Functions........................................................... 1-97
1.7.9 Operator’s Interface ............................................................................ 1-103
1.7.9.1 Maintenance Personnel ................................................ 1-103
1.7.9.2 Local Operator ............................................................. 1-104
1.7.9.3 Central Operator........................................................... 1-105
1.7.9.4 Printer........................................................................... 1-106
1.7.10 Availability and Security .................................................................... 1-106
Chapter 2 - Installation
2.1 Site Planning Environment ...................................................................................... 2-1
2.1.1 Site Selection and Building Requirements.............................................. 2-1
2.1.2 Environmental Considerations ................................................................ 2-2
2.1.3 Electromagnetic Compatibility ............................................................... 2-3
2.1.3.1 Summary of CE-marking Aspects.................................... 2-4
2.1.4 Standard Layout and Disposition of Cabinets......................................... 2-5
2.1.5 Grounding ............................................................................................... 2-8
2.1.6 Cables ...................................................................................................... 2-9
2.1.7 Power 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 Process Safety ......................................... 2-16
2.2.1.2 Machine Safety............................................................... 2-17
2.2.2 Unpacking and Storing.......................................................................... 2-18
2.2.3 Location................................................................................................. 2-18
2.2.4 Arrange the Cabinets............................................................................. 2-18
2.2.5 Grounding ............................................................................................. 2-19
2.2.5.1 General ........................................................................... 2-19
2.2.5.2 Protective Earth .............................................................. 2-19
2.2.5.3 Earth Line ....................................................................... 2-19
2.2.5.4 Grounding of Process Cable Shields .............................. 2-19
2.2.5.5 Grounding of Communication Cable Shields ................ 2-21
2.2.5.6 Grounding of “Internal” System Cable Shields,
Connection Unit -- I/O Board......................................... 2-24
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
5.2.1.1 Personnel and Process Safety........................................... 5-2
5.2.1.2 Machine Safety ................................................................ 5-3
5.2.2 Visual Inspection..................................................................................... 5-4
5.2.3 Safety ...................................................................................................... 5-4
5.2.4 Cleanliness .............................................................................................. 5-4
5.2.5 Air Filter ................................................................................................. 5-4
5.2.6 Backup Batteries ..................................................................................... 5-4
5.2.7 Forced Cooling ....................................................................................... 5-4
5.3 Hardware Indicators................................................................................................. 5-4
5.4 Error Messages ........................................................................................................ 5-5
5.4.1 Halt Codes............................................................................................... 5-5
5.4.1.1 Reading of Halt Codes ..................................................... 5-5
5.4.2 System Messages .................................................................................... 5-5
5.4.2.1 Reading of System Messages........................................... 5-6
ILLUSTRATIONS
Figure 1-1. Example of Advanced Control System with Advant Controller 450 ........... 1-1
Figure 1-2. Basic Documentation Structure .................................................................... 1-2
Figure 1-3. Cabinet for Advant Controller 400 Series, RM500, in a Front View ......... 1-16
Figure 1-4. Advant Controller 450 in RM500 Cabinet (doors opened) -
Example of Physical Appearance ............................................................... 1-17
Figure 1-5. Example of PC Element (AND, TON, SHIFT) .......................................... 1-18
TABLES
Table 1-1. Related Documentation - Configuration/Application Building ................... 1-6
Table 1-2. Related Documentation - Installation........................................................... 1-7
Table 1-3. Related Documentation - Optional Functions .............................................. 1-7
Table 1-4. Related Documentation - Tools .................................................................... 1-9
Table 1-5. PC Elements in the Basic System Program Module QC07-BAS41........... 1-28
Table 1-6. Functional Units in Program Module QC07-BAS41 ................................. 1-30
Table 1-7. Additional PC Elements in Program Module QC07-LIB41....................... 1-31
Table 1-8. Additional PC Elements in Program Module QC07-LIB42....................... 1-33
Table 1-9. Functional Units in Program Module QC07-LIB42................................... 1-33
Table 1-10. PC Elements in Optional Program Module QC07-COM41 ....................... 1-35
Table 1-11. Modules Used in different Power Supply alternatives ............................... 1-40
Table 1-12. Selection Guide of Power Supply Modules................................................ 1-41
Table 1-13. Digital Input Boards ................................................................................... 1-54
Table 1-14. Digital Output Boards................................................................................. 1-57
ILLUSTRATIONS
Figure 1-1. Example of Advanced Control System with Advant Controller 450 ........... 1-1
Figure 1-2. Basic Documentation Structure.................................................................... 1-2
Figure 1-3. Cabinet for Advant Controller 400 Series, RM500, in a Front View......... 1-16
Figure 1-4. Advant Controller 450 in RM500 Cabinet (doors opened) -
Example of Physical Appearance............................................................... 1-17
Figure 1-5. Example of PC Element (AND, TON, SHIFT) .......................................... 1-18
Figure 1-6. Example of Version Designation with Compatibility Codes for
Basic Software............................................................................................ 1-19
Figure 1-7. Example of Advant Controller 450 Hardware Configuration incl.
a Variant of Process I/O.............................................................................. 1-21
Figure 1-8. Advant Controller 450 Block Diagram ...................................................... 1-22
Figure 1-9. Advant Controller 450 Functional Interfaces ............................................. 1-23
Figure 1-10. Location of System Program Card (PCMCIA) .......................................... 1-25
Figure 1-11. Location of Additional Program Cards ...................................................... 1-26
Figure 1-12. Principle of Power Supply of an Advant Controller 450
(a.c. mains supply)...................................................................................... 1-38
Figure 1-13. Principle of Redundant Power Supply of an Advant Controller 450
(a.c. mains supply)...................................................................................... 1-39
Figure 1-14. Voltage 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 1-21. 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 Input Signal DSDP 110, Block Diagram ............................ 1-66
Figure 1-28. Pulse Counter Input Signal DSDP 150, Block Diagram ............................ 1-66
Figure 1-29. Example of basic I/O Unit, DSDX 452 - 20 Inputs and 12 Outputs .......... 1-68
Figure 1-30. S800 I/O. Field Communication Interface with an I/O module on a
Compact or Extended MTU. ...................................................................... 1-70
Figure 1-31. Example of Electrical Redundant Bus Extension....................................... 1-81
Figure 1-32. Example including Non-redundant Optical Bus Extension........................ 1-82
Figure 1-33. Example of Physical Configuration of Non-redundant MasterFieldbus
TABLES
Table 1-1. Related Documentation - Configuration/Application Building ................... 1-6
Table 1-2. Related Documentation - Installation........................................................... 1-7
Table 1-3. Related Documentation - Optional Functions .............................................. 1-7
Table 1-4. Related Documentation - Tools .................................................................... 1-9
Table 1-5. PC Elements in the Basic System Program Module QC07-BAS41........... 1-28
Table 1-6. Functional Units in Program Module QC07-BAS41 ................................. 1-30
Table 1-7. Additional PC Elements in Program Module QC07-LIB41....................... 1-31
Table 1-8. Additional PC Elements in Program Module QC07-LIB42....................... 1-33
Table 1-9. Functional Units in Program Module QC07-LIB42................................... 1-33
Table 1-10. PC Elements in Optional Program Module QC07-COM41 ....................... 1-35
Table 1-11. Modules Used in different Power Supply alternatives ............................... 1-40
Table 1-12. Selection Guide of Power Supply Modules................................................ 1-41
Table 1-13. Digital Input Boards ................................................................................... 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 ................................................................................ 1-75
Table 1-24. Pulse Counting / Frequency Measurement Modules.................................. 1-76
Table 1-25. S800 Module Termination Units ................................................................ 1-77
Table 1-26. Power Supplies ........................................................................................... 1-79
Table 1-27. Modulebus Items ........................................................................................ 1-79
Table 1-28. Communication Survey .............................................................................. 1-90
Table 2-1. Methods of Handling Communication Cable Shields ................................ 2-23
Table 2-2. Cable Categories in a Cabinet .................................................................... 2-27
Table 2-3. Functional Jumpering ................................................................................. 2-37
Table 2-4. Printer Settings ........................................................................................... 2-42
Table 2-5. Grounding Philosophy, Earthing Line System ........................................... 2-43
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 A-2. Pin Designation for Channel 1 and 2. Connector X4 and X5 ......................A-7
Table A-3. DSSB 170, Operating Data...........................................................................A-9
Table A-4. SA1xx, Individual Technical Data .............................................................A-23
Table A-5. Fuses in SA1xx...........................................................................................A-24
Table A-6. SD150, Operating Data ..............................................................................A-35
Table A-7. Individual Technical Data...........................................................................A-39
Table A-8. Electrical Data, Front connected Input/Output Signals..............................A-47
Table B-1. RM500 Cabinet Measurements ....................................................................B-2
Table B-2. Distances in Figure B-4 ................................................................................B-4
Table B-3. RM500 cabinet protection classes ................................................................B-5
Table B-4. Available Degree of Protection Ratings for RM500 ....................................B-5
Table B-5. Permitted Power Dissipation for RM500 .....................................................B-6
Table D-1. Designation of Items in Figure D-17..........................................................D-11
Table E-1. Current Consumption and Power Dissipation, Controller Modules............. E-2
Table E-2. Current Consumption and Power 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. System Message Coding................................................................................ I-1
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
Table I-13. Type 29, Code 1, 2, 3 and 4 ......................................................................... I-22
Table I-14. Type 30, Code 21, 23................................................................................... I-23
Table I-15. Type 39 ........................................................................................................ I-25
Table I-16. Type 134, Code............................................................................................ I-27
Table J-1. Conversion of up to Four Figure Hexadecimal Numbers .............................J-2
&KDSWHU ,QWURGXFWLRQ
*HQHUDO,QIRUPDWLRQ
Advant OCS is a system for industrial automation. It consists of a family of computer-based
units and a local area network for communication.
A controller is a computer-based unit in which control applications are running.
Advant Station 500 Advant Station 500 Advant Station 500 Master Batch 200/1
Control Network
(MasterBus 300/300E)
Advant Controller 410 $GYDQW&RQWUROOHU Advant Station 120
Field Communication
S100 Process I/O
RCOM
Advant Controller 110
Remote Process I/O
S400 I/O Controller
S800 I/O
Advant Controller 55
Process I/O
Advant Controller 450 is a large controller for mixed binary, regulatory and supervisory control.
It can be used standing alone, or as an integrated controller in a distributed control system,
communicating with other Advant OCS equipment (see Figure 1-1).
This manual is intended primarily 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.
0DQXDO2UJDQL]DWLRQ
%DVLF6WUXFWXUH
Figure 1-2 shows the basic structure of the Advant System’s various documentation.
Each document, whether it is describing and referencing hardware or software, is built around
this one structure to make it easy for you to locate related information in any of the documents.
Since this one structure is not completely applicable to both hardware and software, certain
sections contain only very brief statements in some documents. Small divergences from the
standard structure are given in italics in Figure 1-2.
&KDSWHU
Configuration/ Runtime
Introduction Installation Application Maintenance Appendices Index
Building Operation
The substructure followed in the product description in Section 1.7, Product Overview is also
followed in other sections describing, for example, Design Considerations and Capacity &
Performance. This is done to make it easy for you to find the information you need about
different activities.
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.
&KDSWHU,QWURGXFWLRQ
(this chapter) provides introductory and background information, including:
• Guidelines on how you can find information in this manual.
• This manual’s relationship to other Advant Controller 450 documents.
• A glossary defining terms frequently used in this manual.
• A product and functional overview. Read this to get an idea of what
the Advant Controller 450 can do and how it works.
&KDSWHU,QVWDOODWLRQ
guides you through various installation activities:
• Section 2.1, Site Planning Environment. This section contains guidelines for planning
installation of the product, outlining what you need to think about when you plan an
installation. It does not, however, provide the complete list of measures to take. You can
find descriptions of alternative solutions, design considerations elsewhere in this manual.
• Section 2.2, Setup. This section gives you concrete information on how to set up the
product. It includes safety regulations, handling and unpacking instructions, inspection
and assembly procedures, cable routing 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 there is a problem with initial power-up.
• Section 2.4, Start-up Procedures. In Section 2.2, Setup, the conditions and the preparation
necessary to begin are discussed. In Section 2.4, Start-up Procedures, you can find basic
power-up procedures, that is how to apply power to and initialize the system. Information
is also given on how you can verify a correct start. You can find information on activities
up to “ready for application program loading” in this section.
• Section 2.5, Product Verification. This section tells you how to make an initial
determination that the product is functional. This includes application program loading as
well as commissioning information.
• Section 2.6, Implementation of Functions in Systems Already Operating. This section
gives you the information you need to determine when, for example, to add an I/O board to
a running system. Important on-line, off-line aspects are discussed.
&KDSWHU&RQILJXUDWLRQ$SSOLFDWLRQ%XLOGLQJ
gives you detailed information about how to obtain a desired function. The main information is
structured as follows:
• Section 3.1, Design Considerations. You can find design guidelines, including design
rules, in this section. Keywords include the following.
– Limitations
– Combinations of options
– Module assortment supported by the system product
– Location
– Necessary extra HW and SW needed with respect to desired functionality
– CPU load calculation
– Memory calculation.
• Section 3.2, Technical Data Including Capacity & Performance.
In this section, technical data of the following types, for example, are discussed:
– Maximum number of instances
– Dimensions
– CPU-load data
– Memory capacity.
• Section 3.4, Tutorial. This section 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.
&KDSWHU5XQWLPH2SHUDWLRQ
addresses the controller’s different start modes and operating modes. The operator interface on
the processor module front is described.
In this chapter, you can also find a survey of the system software. Some important facilities that
you need to know during application work are described in greater detail.
&KDSWHU0DLQWHQDQFH
The preventive maintenance required for electronic equipment is not significant. This chapter
focuses on fault finding supported by built-in diagnostics. Various methods of fault
announcement are presented, including the use of system status in the central operator station
and LEDs on controller hardware units.
$SSHQGLFHV
A variety of information which does not fall into other categories within this manual’s structure
are included in the appendices. Examples are:
• Controller hardware descriptions
• Item designations in cabinets
• Description of delivery documentation
• Blanks for use during design work, for example calculation of heat dissipation.
,QGH[
The Index offers you an easy and quick way to find answers to specific questions.
&RQYHQWLRQV
Different versions of the processor module exist. In this User’s Guide the generic name PM511
is used all through the manual.
Advant OCS is used for Advant Open Control System, with Master software, throughout this
manual.
5HODWHG'RFXPHQWDWLRQ
This manual is the main document of the system product Advant Controller 450. Many of the
available options are briefly described in this manual. For additional detailed information about
options, see the appropriate individual manuals. Special subjects are also thoroughly treated in
separate documentation.
127(
The delivery binder, described in Appendix C, Delivery Documentation, includes
a document, 5HOHDVH1RWHVwhich comprise the latest product information not
covered by the standard user documentation listed below. You may find, for
example, additionals, changes, limitations, alerts and so on.
The extensive list of related documentation is structured into four subject areas:
• Configuration/Application Building
• Installation
• Optional functions
• Tools.
7DEOH 5HODWHG'RFXPHQWDWLRQ&RQILJXUDWLRQ$SSOLFDWLRQ%XLOGLQJ
'RFXPHQW 'HVFULSWLRQ
PC Elements Data for all PC elements in AC 410/450.
AC 400 Series
Data Base Elements Data for all data base elements in AC 410/450.
AC 400 Series
AMPL Application Building Basic manual covering the use of the application
program language AMPL.
AMPL Configuration Instructions for the configuration and application
AC 400 Series programming of AC 410/450 systems using
Advant Station 100 Series ES. Commands for
diskette handling are described in the User’s Manual
on the tool concerned.
User Defined PC Elements Describes how to define your own library of PC
elements.
Object Support via Advant Describes how to operate objects in Advant
Fieldbus 100 Controller 110/160 from a Advant Station 500 Series
AC 400 Series Operator Station.
Functional Units Part 1 An introduction to the concept of Functional Units in
Summary and Common Advant OCS with Master software.
Properties
Functional Units Part 2 Describes the functional units AI, AO, DI and DO.
AI, AO, DI, DO
Functional Units Part 3 Describes the functional units SEQ and GROUP.
SEQ, GROUP
Functional Units Part 4 Describes the functional units PIDCON, RATIOSTN
PIDCON, RATIOSTN, and MANSTN.
MANSTN
Functional Units Part 5 Describes the functional units GENCON, GENBIN
GENCON, GENBIN, GENUSD and GENUSD.
Functional Units Part 6 Describes the functional units MOTCON
MOTCON, VALVECON and VALVECON.
Functional Units Part 7 Describes the functional unit PIDCONA
PIDCONA
Functional Units Part 8 Describes the functional unit DRICONS
DRICONS
Functional Units Part 9 Describes the functional unit DRICONE
DRICONE
Functional Units Part 10 Describes the functional unit MOTCONI
MOTCONI
Application Notes Application notes on measurement and control.
'RFXPHQW 'HVFULSWLRQ
Environmental Immunity for Description of the environmental immunity for ABB
ABB Advant OCS Products Advant OCS products.
Elektroniska Apparater Minimum requirements on electronic equipment used
in power industry within EC and EFTA (in Swedish).
Interference-free Electronics This book teaches how to design circuit boards,
Design and applications electronic devices and systems with high immunity to
interference. It also deals with process adaptation,
communication and power supply with immunity to
interference.
Terminal Diagram Forms Complete set of diagrams on AC 450 covering all the
different I/O sets (boards, cables and terminals) as
well as the central unit and the power supply.
'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 User’s Guide describing how to include and use the
S100 I/O Intrinsic Safety System with S100 I/O.
S800 I/O User’s Guide This is a complete manual on the S800 I/O system.
Contains technical descriptions, instructions for
installation, commissioning, fault tracing and
technical data.
EXCOM Contains a description of EXCOM, necessary
hardware and installation instruction.
EXCOM This manual describes how to install and use the
Programmer’s Reference EXCOM communication package in an external
Manual computer. It describes all available services and their
parameters. It also covers the subject of declaration
of necessary variables and data types.
MasterView 320 Complete manual for MV 320 containing
descriptions, operating instructions, linkages to PC
programs, descriptions of error messages and a table
of ASCII codes.
'RFXPHQW 'HVFULSWLRQ
MasterFieldbus and S400 I/O This is a complete manual on the S400 I/O system
and MasterFieldbus. Contains technical descriptions,
instructions for installation, commissioning, fault
tracing and technical data. This manual also
describes MasterPiece 51 as a distributed unit, that is
the engineering required in AC 410/450 and the
programming.
MasterNet Manual describing how to configure, install and
maintain MasterNet communication networks,
MasterBus 300, MasterBus 300E and GCOM.
For information about ABB MasterGate
communication stations, see the manuals concerned.
RCOM Contains technical descriptions, instructions for
AC 400 Series configuration, installation, start-up and fault tracing of
AC 410/450.
MultiVendor Interface Contains technical descriptions, instructions for
Modbus with CI532V02 configuration, installation, start-up and fault tracing of
AC 400 Series Modbus in AC 410/450.
MultiVendor Interface Contains technical descriptions, instructions for
Modbus with MVB + CI534V02 configuration, installation, start-up and fault tracing of
AC 400 Series Modbus in AC 410/450.
MultiVendor Interface Contains technical descriptions, instructions for
Siemens 3964(R) configuration, installation, start-up and fault tracing of
AC 400 Series Siemens 3964(R) in AC 410/450.
Advant Fieldbus 100 Describes how to configure, install and maintain
communication using Advant Fieldbus 100.
Positioning System Complete manual on positioning in MasterPiece 200
User’s Manual (applicable to AC 410/450) containing technical
descriptions, instructions for engineering, installation,
programming, commissioning and maintenance.
This manual also takes up basic positioning theory,
information about pulse transmitters and technical
data on the function.
PROFIBUS-DP Advant Con- Describes the equipment and contains information
troller 400 Series User’s Guide required to install and commission the system.
Advant Interface to LON- Describes the equipment and contains information
WORKS User’s Guide. required to install and commission the system.
7DEOH 5HODWHG'RFXPHQWDWLRQ7RROV
'RFXPHQW 'HVFULSWLRQ
Advant Station 100 Series Contains a description of the basic functions,
Engineering Station connection and start-up and how to work with the
main functions.
AdvaBuild On-Line Builder This reference manual describes all common
commands used in AS 100ES, AS 500ES and
AS 500OS.
AdvaBuild Function Chart Describes how to program an Advant Controller via
Builder Function Chart Builder.
Source Code Handling This manual contains descriptions of and instructions
for source code handling of PC programs and data
bases. It contains instructions for designing source
code, editing, loading and dumping and correcting
defective programs.
5HOHDVH+LVWRU\
Advant Controller 400 Series is an evolutionary development of the process station
MasterPiece 200/1. New features have been added.
Two controller models are available:
• Advant Controller 410
$GYDQW&RQWUROOHU
From a system viewpoint, the new controllers are fully compatible to their forerunners.
This means that you can include new controllers in an available control network, as well as
operate them from MasterView 800/1 and Advant Station 500 Series Operator Stations.
An Advant Controller can run old application programs (if the functional libraries coincide).
The version history from the very first version ∗1.0 is given below:
New highlights in the $GYDQW&RQWUROOHU∗, include:
• More powerful 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.
• New functional unit PIDCONA. A self-tuning PID controller with adaptation facilities
• Communication including event handling with Advant Controller 110 on:
– Advant Fieldbus 100
– RCOM.
• Routing of Advant Station 100 Series Engineering Station via Advant Controller 400
Series and Advant Fieldbus 100 to Advant Controller 110
• MultiVendor Interface for user-defined protocols
• Versions of MasterBus 300 and MasterBus 300E
– Executed in slave CPU
– Executed in main CPU.
• Free-programmable module with C (new series of PC elements)
• Maximum of 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 STATUS replaced by COM-STAT
• MasterBus 200 is removed
• MasterBus 100 is removed.
New highlights in the $GYDQW&RQWUROOHU∗, include:
• Object oriented connection units
• 8 or 16 Mbyte memory in Advant Controller 450
• Optical S100 I/O bus extension for distributing I/O boards up to 500 m from the controller
• Ex-barriers adapted to the S100 I/O System by certain manufacturer
• HART Interface adapted to the S100 I/O System.
7HUPLQRORJ\
$03/
The $BB 0aster 3rogramming /anguage is used for application programming.
$SSOLFDWLRQ3URJUDP
An application program is a general concept of an assembly of program functions aimed at
realizing and automating an addressed process control function.
$SSOLFDWLRQ(user-built)
An application is a user-implemented configuration of standard hardware and software units.
It is the solution to the user’s problem.
%DFNSODQH
A backplane is part of a subrack which interconnects inserted electronics PRGXOHV with the help
of a communication bus.
%DVLF6\VWHP
Basic system is the abstract name of a minimal composition of functional units forming a
system.
%DVLF8QLW
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 alternatives and options.
%RDUG
A board is usually a hardware component of a PRGXOH.
%RRW
Boot refers to the (re)start of nodes. Phases of the boot process include, for example power-up
diagnostics, software download, data base download and node initialization.
During the initialization phase of booting, control applications directly interfacing to process
outputs perform a FROGVWDUW or ZDUPVWDUW.
&DELQHW
The cabinet is the outer case of a piece of equipment (a packaging option), for example
Controller cabinet, I/O cabinet.
&38&entral 3rocessing 8nit
A CPU is a functional unit consisting primarily of a microprocessor and memory.
&LUFXLW%UHDNHU
In the context of a process control system, a circuit breaker is a device designed to open and
close a circuit by nonautomatic means and to open the circuit automatically on a predetermined
overload of current, without injury to itself.
&ROG6WDUW
Cold start is a kind of booting of a FRQWUROOHU (or SURFHVVVWDWLRQ). This means:
– Erasing the user-built DSSOLFDWLRQSURJUDP
– Transition to working mode CONFIGURATION.
&RQWUROOHU
Controller is a descriptive name for Advant Controller products.
A controller is an entity in which control applications are running.
From the product viewpoint, a controller consists of &38, communication and certain auxiliary
equipment such as power supply. It also includes the functionality of process I/O (the process
data communication software). It does QRW include process I/O hardware (and firmware as
applicable).
&RQWURO1HWZRUN
The structure of QRGHV (for example controllers and operator stations) linked together via
MasterNet is called a control network (DCN). It provides real time communication.
(6'
(6'stands for(lectro6tatic 'ischarge.
)XQFWLRQDO8QLW
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.
+$57
A protocol for connection of intelligent transducers (+ighway$ddressable5emote
7ransducer). For example, measuring range, calibration and other maintenance data can be
transferred.
+RWVWDQGE\5HGXQGDQF\
Hot stand-by redundancy is redundancy where a system component is backed up by identical
hardware and software in the event of any failure. The backup components do not load-share
with primary components.
,2
I/O is process ,nput or 2utput. From the functional and geographical distribution viewpoint,
process I/O is distinguished into two main categories:
– Central (located close to the controller)
– Distributed (in the process environment).
,06,nformation 0anagement 6WDWLRQ
An IMS is a station executing information management applications such as statistical control,
production control, and so on.
,QLWLDOL]DWLRQ
Initialization sets a starting position.
,1680
,Qtegrated 6ystem for 8ser optimized 0otor control. An ABB proprietary, LONWORKS based
system for switchgear and motor control systems.
,QWULQVLFDOO\6DIH(TXLSPHQW
Intrinsically safe equipment and wiring is equipment and wiring which is incapable of releasing
sufficient electrical energy under normal or abnormal conditions to cause ignition of a specific
hazardous atmosphere mixture.
/('/ight (mitting 'iode
/RFDO&RQWUROlocal operator
Local control is a mode of operation where responsibility is assigned to an operator/equipment
located in the process environment close to the process object.
/21:25.6
A fieldbus developed and owned by Echelon Corporation, and with a public protocol.
0RGXOH
A module is a hardware unit, with or without accommodated software, or a software unit.
There are modules of various sizes and functionality. Examples of hardware modules:
6XEUDFNVXEPRGXOHFDUULHU, communication module, I/O module.
Examples of software modules:
Basic system program module in a controller, a PC element.
0XOWLGURS&RQQHFWLRQ
A multi-drop connection is a means 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 FRQWUROQHWZRUN.
Examples are controller, process station, operator station.
• Any logically addressable unit connected via RCOM.
2EMHFW2ULHQWHG&RQQHFWLRQ
Object oriented connection means a way of organizing the connection of field intermediate
cables from process objects which utilize different categories of signals, for example, DI and
DO. The purpose is to eliminate the need of marshalling and cable split-up.
2IIOLQH
With off-line configuration, configuration data is created outside the application for later
installation, or the internal configuration data is directly affected, but the application is inactive.
2QOLQH
With on-line configuration, the internal configuration data of a system application is directly
affected, while the application is active.
3URFHVV2EMHFW
A process object is process concept/equipment, for example, valve, motor, conveyor, tank.
3URFHVV6WDWLRQ
Process station is a descriptive name for MasterPiece products.
A process station is an entity in which control applications are running. It includes the process
I/O.
3URGXFW2YHUYLHZ
Advant Controller 450 is a programmable system for control and supervision of processes and
equipment in industrial environments.
The system can handle thousands of inputs and outputs, connected directly or remotely to the
controller. Distributed I/O units, PLC-type controllers (Programmable Logic Controller) and
converters for d.c. motor drives can be connected via a field bus. Interface is available to other
vendors’ systems.
Measured values can be logged and/or tied to alarm and event registration.
Depending on the number of input and output channels, several equipment frames (subracks)
may be required to accommodate an Advant Controller 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 engineering stations. From a compatibility
viewpoint, you can also include MasterPiece 200/1 products, MasterView 800/1 products,
SuperView 900 products and external computers in the network (see Figure 1-1).
You can connect a local operator station and a printer to an Advant Controller 450 via standard
serial channels.
The programmability of Advant Controller 450 covers a wide range of functions, such as logic
and sequence control, data and text handling, arithmetic, reporting, positioning and regulatory
control, including advanced PID and self-tuning adaptive control.
A function-block language with graphic representation, you can use AMPL (ABB Master
Programming Language), for configuration and application building. It is especially oriented
toward process control.
The smallest units in the language are standardized functions, represented by graphic symbols
(PC elements). Each PC element represents a complete function such as an AND-gate, a time
delay, a shift register, a PID controller, and so on. (See Figure 1-5). The language offers a simple
method to link PC elements and describe the data exchange between the functions selected to
control the process.
1 & 20 SHIFT
(C1,C2)
2
2 F/B-N
C1 3 >C
4 R
T
1 1 O 5 11 IF OB 12
2 TD TE 6 13 IB OF 14
3URGXFW9HUVLRQV
This manual describes the Advant Controller 450 as a product.
The complete standard product including software, hardware and documentation is designated
Advant Controller 450 ∗X.Y/Z.
The software included, which is of modular character, is selected in accordance with the scope
of the function and consists of a basic system program module and applicable function library
program modules. All program modules are designated in principle in the same way, for
example, QC07-BAS41 ∗2.0/0.
9HUVLRQ'HVLJQDWLRQ
The designation of a complete standard product or a program module is divided into two parts
by an asterisk.
The first part consists of a product name. The second part consists of 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 the program modules.
Asterisk
Basic software
3URGXFW6WUXFWXUH
Headings in this section are:
*HQHUDO0RGXODUL]DWLRQ+DUGZDUH%ORFN'LDJUDP
,QWHUIDFH)XQFWLRQDO0RGXODUL]DWLRQ3URGXFW9DULDQWV
*HQHUDO0RGXODUL]DWLRQ
ABB Master is a totally modularized system at all levels. The high level consists of a family of
system products. An example of an advanced control system applying system products is
illustrated in Figure 1-1.
The system product is divided into HW modules and SW modules. In this way, the system
shows:
• High reliability
• High maintainability
• High integrity.
Hardware modules are replaceable units of the types power supply units, battery charger, and so
on, and printed circuit boards to be located in subracks.
The assembled program modules defining the product’s overall functionality are examples of
software modules. The different PC elements represent the lowest level of software
modularization exposed to you.
Further modularization exists to simplify different situations, for example sales, design,
application building and so on. Composite units are made by basic modules. Primarily, you can
find such packages in the 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 of supported I/O systems and I/O boards. For more in-depth
information, see separate I/O documentation.
The Advant Controller 450 includes:
• CPU with memory residing the fixed internal program (the system software) and the
application program
• Communication submodules
• System software backup submodule
• A backup power supply including a battery charger
• 5 V regulators.
• A supervision module
• Submodule carriers.
You use submodule carriers and submodules to equip a subrack, which provides great flexibility
in combining communication submodules of different kinds.
For a physical view of a medium hardware configuration, including an I/O subrack, see
Figure 1-7. The denominations of communication link types and system functions used are
made clear in the following subsections, beginning with Section 1.7.2, Product Structure.
The process I/O dedicated to an Advant Controller 450 is available as one or several I/O
subracks (for central location close to the controller) or I/O units (for distributed location).
Also available are different distributed, autonomous units including I/O, for example PLC-type
controllers.
MasterBus 300/300E
&RQWUROOHUVXEUDFN
30 30 65 65
6
\ 9ROWDJH 9ROWDJH
5HJ$ 5HJ%
V (op-
W tion)
H (option)
P
6:
6XSSO\ 6XSSO\ X
S
$ %
H
Engineering (option) U
tool Y
MasterFieldbus
,2VXEUDFN
I/O
%ORFN'LDJUDP
Figure 1-8 indicates broadly the functional relationship between main system utilities and how
the hardware is structured. This is an example of a version of the Advant Controller 450.
Processor module
Bus
interface
Voltage Backup Superv. Processor RAM System
regulator power module 68040 clock
supply
24 V/5 V
Eng. S100 I/O
“Run” tool PCMCIA
relay comm. interface interface
Battery
unit
Power
supply
unit
)LJXUH $GYDQW&RQWUROOHU%ORFN'LDJUDP
,QWHUIDFH
Besides the more “internal” I/O communication, a controller also communicates with a wide
range of peripherals. Figure 1-9 is scheduling the main functional interfaces.
Information
Management Operator
Station Station
LAN X
LAN Y
Other External
control system computer
MVI
EXCOM GCOM MasterBus 300
AS 100 Series ES
Terminal for LONWORKS
MasterView 320 LONWORKS
CPU PROFIBUS-DP Network Interface
PROFIBUS
Printer Interface
Advant Fieldbus 100
AC 110
Bus extension to S100 I/O Advant MasterFieldbus AC 70
Fieldbus 100
Fieldbus
Interface
Process
)LJXUH $GYDQW&RQWUROOHU)XQFWLRQDO,QWHUIDFHV
)XQFWLRQDO0RGXODUL]DWLRQ
The concepts of basic function and optional function are sometimes used in the documentation
of the Advant Controller 450 system. A system can be provided with a number of optional
functions which enable you to adapt each system for specific control tasks. Certain functions
require extra software while others require both extra 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.
When you order an Advant Controller 450, you select the desired function repertoire from a
library of program modules. These modules are factory assembled into a program card.
Available standard program modules with function library follow.
• Basic functions (always included):
– QC07-BAS41 Basic system
– (QC07-BOB41 Boot block).
• Additional functions:
– QC07-LIB41 Additional PC elements 1
– QC07-LIB42 Additional PC elements 2
– QC07-FUZ41 Fuzzy control
– QC07-LOS41 MasterView 320
– QC07-OPF41 Operator functions support
– QC07-BAT41 MasterBatch 200/1 support
– QC07-UDP41 User defined PC Elements
– QC07-COM41 Object support via Advant Fieldbus 100.
Examples of other optional functions requiring extra hardware are redundant CPU,
communication between controllers, positioning, digital input, and so on.
3URGXFW9DULDQWV
The Advant Controller 450 is a flexible system offered in several variants with respect to,
for example, 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.
*HQHUDO6\VWHP8WLOLWLHV
&38
The central processing unit of the Advant Controller 450 comes in two versions with 8 or 16
Mbyte dynamic RAM. The versions are both designated Processor Module PM511V. A label on
module side states the RAM size (PM511V or PM511V). A Processor Module is built up
around a microprocessor, Motorola 68040, running at 25 MHz.
In this User’s Guide the generic name PM511 is used all through.
On the module front, you can see indicators and a character display for high level system
diagnostics. The main operable equipment is a four-position rotary switch for start and
operating mode selection and a restart push button. See Chapter 4, Runtime Operation for more
information on these functions.
The module front also includes a program card interface and a connection for S100 I/O bus
communication.
You can connect a configuration and maintenance tool on the module front.
0HPRU\
The Processor Module PM511 contains the total amount of RAM (Random Access Memory),
which is an 8 or 16 Mbyte dynamic RAM with error correction code. This memory holds the
system program which is in use as well as the controller system configuration and application
program, that is all memory executed in run time.
The system program is described from the organizational viewpoint in Section 1.7.2, Product
Structure, under the heading Functional Modularization. The functional content is treated in the
next section, Section 1.7.3.3, Program Module Contents.
6\VWHP3URJUDP%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 located in the CPU as illustrated in
Figure 1-10 below. Normally the program card should be in place during operation.
The program card must be in place in order to start-up the backup CPU of a redundant pair.
3URFHVVRU0RGXOH
30
6\VWHP3URJUDP&DUG
1
2 3
4
3&0&,$
Additional program cards are located in program card interface MB510 as illustrated in
Figure 1-11.
Submodule Carrier
Program card interface SC510 or SC520
(Submodule)
Program card
(PCMCIA)
MB510
)LJXUH /RFDWLRQRI$GGLWLRQDO3URJUDP&DUGV
$SSOLFDWLRQ3URJUDP%DFNXS
The controller system configuration and the application program is normally created in an off-
line or sometimes an on-line configuration session supported by an engineering station. The work
is basically backed up in the engineering station environment (hard disc, flexible disc or likely).
To restore a RAM which has been cleared by an accident or a fatal error some measures have to
be taken, automatically and manually. In addition to the automatic loading of the system
program, described above under the heading System Program Backup, somebody has to
manually load the application program backup (including the controller system configuration)
using an engineering station. In some applications this is a too time consuming procedure and it
needs assistance of qualified maintenance people.
As an alternative the Advant Controller 450 can be equipped with an optional flash card of
similar type as the one used for 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 the interruption.
Flash cards are available in different memory-sizes. Select a type that take the actual application
program.
The system program backup and the application program backup can not be mixed in one single
program card.
3RZHU6XSSO\%DFNXSRI0HPRU\
The RAM is secured against loss of power for a minimum of four hours (two hours when
redundant processor modules) by a backup power supply and battery. This is important for the
configured application program, which is basically not otherwise backed up.
If a longer backup time is desirable, you can use:
• Additional backup power supply unit SB510 and battery package (doubled backup time)
• Alternative backup power supply unit SB511 connected to a 24 V or 48 V external battery
system
• An application program backup (see heading above).
3URJUDP0RGXOH&RQWHQWV
The program function library, among others, contains PC elements and functional units.
A functional unit is a package of different program functions such as PC elements and
operator’s functions. This simplifies the realization of combined functions with both the control
function and associated operator’s handling via a display screen and keyboard.
Please find below a survey of the functional contents and the concrete PC elements and
functional units in the different program modules.
%DVLF6\VWHP4&%$6
The basic system program is sufficient when you need digital signal processing, arithmetic,
queue and shift functions. It works with both analog and digital input and output signals.
)XQFWLRQDO6HUYH
• 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 RCOM
• Support for MultiVendor Interface
• Support for connection to Advant Fieldbus 100
• Support for PROFIBUS-DP
• Support for LONWORKS Network
• Support for connection to ACV 700 and DCV 700 thyristor converters
• Support for connection to TYRAK and SAMI thyristor converters
• Support for connection to strain gauge scales
• Free-programmable module.
1. Only the PC and data base element parts of the functional units are included in the basic program module.
For presentation and dialog support, QC07-OPF41 must be added. Special dedicated interface boards are QRW
included in the basic unit.
7DEOH 3&(OHPHQWVLQWKH%DVLF6\VWHP3URJUDP0RGXOH4&%$6
)XQFWLRQDOXQLW 'HVFULSWLRQ
AI Analog input signal, including AI, Temp (Pt100), TC (thermo-
couple), AIC (calculated AI) and pulse counter (DSDP 110)
AO Analog output signal, including AO and AOC (calculated AO)
DI Digital input signal, including DI and DIC (calculated DI)
DO Digital output signal, including DO and DOC (calculated DO)
DAT General data base value
)XQFWLRQDOXQLW 'HVFULSWLRQ
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
$GGLWLRQDO3&(OHPHQWV4&/,%
QC07-LIB41 extends the PC element library that is included in the basic system program
module with PC elements to support the functions listed below.
The optional program module QC07-LIB41 is selected, for example, for control operations with
few demands for operator intervention from panels or when, for example, a local operator
station like the MasterView 320 is adequate.
)XQFWLRQDO6XUYH\
• Feedback control
• Connection to analog thyristor converters.
7DEOH $GGLWLRQDO3&(OHPHQWVLQ3URJUDP0RGXOH4&/,%
$GGLWLRQDO3&(OHPHQWV4&/,%
QC07-LIB42 extends the PC element library that is included in the basic system program
module with PC elements and functional units for supporting the functions listed below.
The optional program module QC7-LIB42 is selected for advanced controlling which requires
powerful operator’s functions from an Advant Station 500 Series Operator Station or a
MasterView 800/1.
Advanced process control requires, in addition to QC07-LIB42, the program module for
operator functions support, QC07-OPF41.
)XQFWLRQDO6XUYH\
• Feedback control
• Self-tuning adaptive control, NOVATUNE
• Functional units, PID loop control, PIDCON, PIDCONA.
7DEOH $GGLWLRQDO3&(OHPHQWVLQ3URJUDP0RGXOH4&/,%
)XQFWLRQDOXQLW 'HVFULSWLRQ
PIDCON Regulatory controller
PIDCONA Adaptive self-tuning regulatory controller
RATIOSTN Ratio station
MANSTN Manual station
)X]]\&RQWURO4&)8=
QC07-FUZ41 contains the PC element FUZZYCON for fuzzy control. The control algorithm is
defined via a compiler for Fuzzy Control Language (IEC 1131-7).
0DVWHU9LHZ4&/26
The optional program module QC07-LOS41 extends the functionality given by the basic system
program module with functions listed below.
QC07-LOS41 adapts the Advant Controller 450 to a MasterView 320, a local operator station
built up on a VT100 terminal. This provides dialog texts in the following languages:
English, Swedish, Danish, Norwegian, Finnish, Dutch, German, French, Italian, Spanish and
Portuguese.
)XQFWLRQDO6XUYH\
• MasterView 320
• Reports for MasterView 320.
2SHUDWRU)XQFWLRQV6XSSRUW4&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.
)XQFWLRQDO6XUYH\
• Reports for Adva Command or MasterView 800/1
• Functional units, binary 1
• Functional units, analog 1
• Functional units, adaptive self-tuning PID loop control, PIDCONA 1
• Functional units, motor and valve control, group start 1
• Trend data storage
• Status list
• Group alarm
• Adva Command or MasterView 800/1 support.
0DVWHU%DWFK6XSSRUW4&%$7
The optional program module QC07-BAT41 extends the functionality given by the basic system
program module with functions listed below.
QC07-BAT41 adapts the Advant Controller 450 to the advanced batch functionality offered by a
MasterBatch 200/1.
)XQFWLRQDO6XUYH\
• MasterBatch 200/1 support.
8VHU'HILQHG3&(OHPHQWV4&8'3
The optional program module QC07-UDP41 extends the functionality given by the basic
system program module with the possibility to define your own library of user defined PC
elements. The user defined PC element is created in the Advant Station 100 Series Engineering
Station and built-up of a combination of normal PC elements found in the standard PC elements
libraries of the Advant Controller 450. After the user defined PC element is installed in the
Advant Controller 450 it can be used freely in all PC programs as a normal PC element.
These elements will appear in every sense as standard PC elements.
2EMHFW6XSSRUWYLD$GYDQW)LHOGEXV4&&20
The optional program module QC07-COM41 can provide AIS, DIS, MB, MI, MIL and MR
objects in Advant Controller 110/160 to be operated from the operator station
(Advant Station 500 Series or AdvaSoft for Windows).
Following functions are supported:
• Acknowledgment of events
• Blocking of events and alarms
• Blocking of process data update
• Blocking of process data value.
1. Only the presentation and dialog support are included in QC07-OPF41. The PC elements and corresponding data
base are included in QC07-BAS41 and QC07-LIB42.
7DEOH 3&(OHPHQWVLQ2SWLRQDO3URJUDP0RGXOH4&&20
7\SH 3&(OHPHQW
Advant Fieldbus 100 COM-AIS, COM-DIS, COM-M
communication elements
6\VWHP&ORFN([WHUQDO&ORFN6\QFKURQL]DWLRQ
The Processor Module PM511 is provided with a calendar clock which is backed up by the same
battery used for memory backup. You can set the date and time from the programming unit or
from a local operator station, for example MasterView 320. A slow, smaller adjustment in the
interval ±100 s can also be performed with the programming unit.
With Advant Controller 450 connected to MasterNet, as a part in a distributed control system,
the synchronization occurs automatically with other stations via a network with an accuracy
better than 3 ms.
If extreme synchronization accuracy is required between controllers (in the order of 2 ms) and
synchronization to an external clock, an external minute pulse signal can be connected to all
systems concerned.
The supervision module TC520 has a special input for 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 activation of the data base and
program areas.
Configuration/application building is introduced in Section 1.7.8.2, Principles of Application
Building.
([HFXWLRQ
The execution units in a PC program are normally given cycle times of 10 ms - 2 s (5 ms - 32 s
after reconfiguration). The internal program system (operating system and PC interpreter)
organizes the execution of the units with the periodicity selected, simultaneously performing
other tasks such as communication with a MasterView 320 and programming units.
Ordinarily, you can select the same cycle times for reading in values from digital and
analog boards.
6WDUWXS
The CPU front panel has a rotary switch which you use to select start and working mode.
The normal position of the switch is 1 (AUTO). This means an automatic start when voltage is
switched on or when voltage is recovered after a power failure. At an interruption of voltage,
the system stores all the information necessary for restarting. Whether the system is to continue
operations from its status at the interruption of the voltage or if it is to be reset to zero before
restart is selected with parameters.
The different ways to start are CLEAR, STOP, AUTO or OFF LINE. The way to start is selected
on the basis of the duration of the voltage failure.
You can connect a control module which is activated when the voltage returns and which
executes one cycle to each start alternative. All start modules must belong to the same PC
program. You can define how the process is to start with these control modules. Alarm can also
be blocked at initialization of the I/O boards. Start-up features and their application are
described in $03/&RQILJXUDWLRQ$GYDQW&RQWUROOHU 6HULHV5HIHUHQFH0DQXDO
)UHH3URJUDPPDEOH0RGXOH
The Free-Programmable Module PU535 works as 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
between the PC program and PU535.
For programming of the PU535, you can use an HP 9000/700 workstation to write and test the
application programs and to download them into the PU535 using the built-in SLIP protocol.
The PU535 also contains a simple User Test Interface for execution control and diagnostics,
available through the service port (V24/RS-232-C).
3RZHU6XSSO\
6\VWHP3RZHU6XSSO\
An Advant Controller 450 is normally delivered in one or several cabinets. Process I/O subracks
are included as applicable. The equipment is designed, as standard, for connection to a
120/230 V single-phase or two-phase a.c. mains supply, 50/60 Hz or for connection to a
24-48 V d.c. mains supply. Several alternatives are available. The main alternatives are:
• Supply from an a.c. mains supply A
• Supply from a d.c. mains supply A
• Direct supply (without d.c./d.c. converter) from d.c. mains supply A
• Supply from one or two a.c. mains supplies, A/B with redundant supply units
and regulators
• Supply from a d.c. mains supply A with redundant d.c./d.c. converters and regulators.
Mains
A LIVE Test DSSR 122
F
24V
24V A 2V
F1
24V B 5V Battery
x2
24V distr. I/O subrack 3
SB522
$GYDQW&RQWUROOHU8VHU¶V*XLGH
x2
DSTC 452/454 Fan unit
MFb modem 24V A RC527 24V
Power distr.
DSTC 24V B A
SX542 452/454 x2
Mains
C Pw Modem subrack
Tw
Rw 24V A AF 100 and short distance modems
TC516
TC513 TC515V2
TC512 TC514V2
TC630 Alt. TC562
P Optical
Bus Ext.
Expansion Tx
24V B
24V A Rx
24V B
Alt. BF
SA1XX Field equipm. Power supply for I/O rack
SB510 BP
FC SA16X SX554
Heat exchanger
LIVE Test
A
x2
DSTC 452/454 Fan unit
24
MFb modem 24V A RC527 vA
Power distr. DSTC Diode Unit
24V B A
SX542 452/454 DSSS 170
Mains Fail x2
C Pw Modem subrack 24V A
Tw 24V B
AF 100 and short distance modems 24V A
Rw 24V A SA16X SX554
24V B 24V LIVE Test
TC516
TC513 TC515V2
TC512 TC514V2
SA1XX SX554
TC630 P TC562 LIVE Test 24
Power supply 24V distr. 24V B VB
Power switch Tx Alt.
and distribution SA16X SX554 24V A Optical
PRx Bus Ext. B
SX540 LIVE Test x2
Mains 24V B
Tx
B 24V A
24V Rx
B 24V B B
x2
x2
B
1-39
$GYDQW&RQWUROOHU8VHU¶V*XLGH
&KDSWHU ,QWURGXFWLRQ
0RGXOH8WLOL]DWLRQ
6LQJOH6XSSO\ 5HGXQGDQW6XSSO\
$SSOLFDWLRQ DF GF DF GF
9 9 9 9
9 9 9 9 9
0DLQV3RZHU6ZLWFKDQG
'LVWULEXWLRQ
Mains A and B SX540 SX540 SX555 SX555 SX550 2*SX540 2*SX540 2*SX555 2*SX550
Mains A and B SX541 SX541 SX555 SX555 SX551 2*SX541 2*SX541 2*SX555 2*SX551
(expansion)
(2)
Mains C, category II SX542 SX542 --- --- --- SV543 SV542 --- ---
(2) SV541 SV540 SV543 SV542
Mains C, category III --- --- --- --- ---
3RZHU6XSSO\
Controller + I/O subrack 1 SA167 SA168 SD150 DSSB SD150 2*SA167 2*SA168 2*SD150 2*SD150
170
9ROWDJH5HJXODWLRQ
Controller Subrack SR511 2*SR511
I/O Subrack DSSR 122 3*DSSR 170 + Voting unit DSSS 171
0DLQV1HW)LOWHU
The CE-marked design provides a mains net filter for each supply A, B and C. The filter is
installed between the enclosure port and the mains power switch. The purpose is to minimize
the risk of interference and the emission of conducted radio frequency field.
The filter is adapted to the estimated load from the installed equipment.
0DLQV3RZHU6ZLWFKDQG'LVWULEXWLRQ
You use the power switch and distribution unit to connect and disconnect the
Advant Controller 450 system to the mains and for distribution of voltage to different units in
the cabinet. The power switch unit contains terminal blocks, miniature circuit breakers and
power outlets for, for example, power supply units.
Normally, a common circuit breaker disconnects the mains from all cabinets housing the
controller and the I/O installation, that is the “hard” related cabinets. Variants can exist. Please
refer to the actual delivery documentation for further information.
3RZHU6XSSO\
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 certain restrictions on utilizing a common power supply for the system itself and
external equipment. Please refer to Section 3.1, Design Considerations.
Use duplicated power supply units to provide redundancy.
Varying requirements on power supply are met by a range of supply modules with different
technical data. You can select according to Table 1-12.
7DEOH 6HOHFWLRQ*XLGHRI3RZHU6XSSO\0RGXOHV
9ROWDJH5HJXODWLRQ
All modules in the subracks are powered by 24 V unstabilized voltage and 5 V stabilized
voltage. 24 V is converted to 5 V by voltage regulators. Each subrack has one or several
dedicated voltage regulators. Different types are available which are adapted to mechanical,
energy and special high-reliability/availability requirements.
Figure 1-14 shows the voltage regulator location 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).
&RQWUROOHUVXEUDFN
30 65 65
9ROWDJH 9ROWDJH
5HJ$ 5HJ%
(option)
6% 7&
%DFNXS 6
3RZHU X
6XSSO\ S
H
%
U
Y
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 (n+1 redundancy). Figure 1-15 illustrates the two alternatives.
These regulator modules are installed on the rear of the I/O subrack.
Fuse
X4
X9
Connections X1
X6
X2 DSSR
170
DSSR
X7 170 LF
DSSR IA
DSSS 170 LF VI
171 IA EL
LF LF VI
IA IA EL
VI VI
EL EL
A
B
PBC
)LJXUH 9ROWDJH5HJXODWLRQLQ,26XEUDFN
%DFNXS3RZHU6XSSO\
The power supply system for Advant Controller 450 includes a battery package intended for
current supply for RAM and the system clock in the event of a power failure in the controller
subrack.
The Ni-Ca battery included in Battery Unit SB522 is kept charged by a Backup Power Supply
SB510 or SB511.
SB510 is used at 110-230 V a.c./d.c. supply voltage.
SB511 is used at 24-48 V d.c. supply voltage.
The backup power supply is supervised. Status is available to the controller diagnostic system.
Status is also indicated by LEDs on the backup power supply module front.
Battery capacity is four hours in a single CPU system and two hours in a redundant CPU
system.
For further technical data, see Chapter 3, Configuration/Application Building and the respective
module descriptions in Appendix A, Hardware Modules.
Please note that you can use an optional network C, which maintains battery-charging and
supply of the RAM while the power supply is otherwise switched off.
If a longer backup time is desirable, you can also use the alternative backup power supply unit
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 the normal diagnostics of the SB511.
)XVLQJ
The fusing and electronic overload protection of the Advant Controller 450 and its main parts
are illustrated in Figure 1-12 and Figure 1-13.
(DUWKLQJ
The signal processing electronics in Advant OCS are normally earthed to chassis and all
interference suppression for external signals refers to chassis. If this rule is broken, the system is
sensitive to high-frequency interference, mainly interference from unsuppressed relays, to
contactors and to discharge of static electricity.
3RZHU6XSSO\IRU)LHOG(TXLSPHQW
Auxiliary equipment in the controlled system is normally powered separately. This means
separate power supply units and fusing. However, given a small current requirement, and if you
follow the rules given in Section 3.1, Design Considerations, you can also use the system power
supply unit for field equipment.
The series of power supply units listed in Table 1-12 is, of course, generally applicable.
3URFHVV,QWHUIDFH
An Advant Controller 450 communicates with the process through various types of sensors and
actuators connected to process interface units. Three variants of the I/O system are offered,
S100 I/O, S400 I/O and S800 I/O. The I/O systems are optimized for different use.
As the short presentation below illustrates, the S100 I/O is the most complete system with
respect to special functions.
Process events can be time-tagged. The time accuracy is determined by the applied I/O system
and the selected board type.
Cabling represents a large portion of the cost of installing a process control system. In order to
reduce this cost, a range of distributable I/O units (S400 I/O and S800 I/O) are available
covering the most common process signal types. The distributable I/O units communicate with
the controller through MasterFieldbus (S400 I/O) and Advant Fieldbus 100 (S800 I/O).
Large S100 I/O cluster can be distributed 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 in separate
documents as follows.
• S100 I/O: Hardware descriptions and technical data of I/O boards, connection units
and the S100 I/O bus extension.
-6,2+DUGZDUH5HIHUHQFH0DQXDO
• S400 I/O: System description, hardware description and technical data of I/O units and
MasterFieldbus.
-0DVWHU)LHOGEXVDQG6,28VHU¶V*XLGH
• S800 I/O: System description, hardware description and technical data of I/O modules and
Advant Fieldbus 100.
- $GYDQW)LHOGEXV8VHU¶V*XLGH
6,28VHU¶V*XLGH
Function descriptions, including configuration-application building information on I/O boards
and signals, which are applicable to the actual Advant Controller, are found in separate
documents as well. Please refer to either of these two documents:
'DWD%DVH(OHPHQWV$GYDQW&RQWUROOHU 6HULHV5HIHUHQFH0DQXDO
)XQFWLRQDO8QLWVSDUW5HIHUHQFH0DQXDO
*HQHUDO6LJQDO3DWKV
The input and output signals can be in digital or in analog form (current or voltage signals).
Figure 1-16 and Figure 1-17 shows, in principle, the layout of the signal paths for the input and
output signals for the different I/O systems. The signal paths are built up of the following 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:
• External signal cable
• Module Terminal Unit (MTU)
• I/O module
• Fieldbus Communication Interface (FCI)
• Advant Fieldbus 100
• Communication module for Advant Fieldbus 100
• Internal system bus.
6,2
,2VXEUDFN &RQWUROOHUVXEUDFN
Parallel
data Processor Internal
bus module
Bus extension system
Comm. (max 12 m (39 ft.) el. bus
module max 500 m (1640 ft.) opto)
DSBC 174/ S100 I/O FB+
DSBC176 interface
Connection I/O
unit board
6,2
&RQWUROOHUVXEUDFN
Processor
module
SDB Internal
Short distance bus system
I/O bus
unit
Modem Comm. FB+
Modem Modem module
I/O TC570 CI570
unit LDB
Long-distance bus
(max 750 m (2460 ft.) el.
SDB
I/O max 3000 m (9842 ft.) opto)
unit
6,2
&RQWUROOHUVXEUDFN
,2LQWHUIDFHVRQD',1UDLO
Processor
module
Internal
Modulebus system
bus
Advant Fieldbus 100
Modem Comm.
“FCI” module
CI810 TC512V1
CI522A
Twisted pair media
I/O (max bus length of the
module configuration 1700 m (5500 ft.))
Optical
Modulebus
Expansion
Modulebus
TB820
I/O
module
([WHUQDO6LJQDO&DEOH
The process cables are connected to screw terminals (terminal blocks) on the connection units
or directly to the I/O units.
&RQQHFWLRQ8QLW6,2
The connection unit consists of a circuit board which is to be located on a mounting bar in the
backplane of the cabinet. See example in Figure 1-18.
You can distribute the connection unit 3 - 15 m if you use shielded cables to join the I/O board.
Mounting bars are available in two models for 19-inch and 24-inch widths.
Connection units have different widths. For dimensions and other technical data, see the6
,2+DUGZDUH5HIHUHQFH0DQXDO.
A connection unit is provided with terminal blocks to connect external signal cables.
Normally, a connection unit has additional terminals for power distribution to sensors and
actuators. Generally, you can disconnect the terminals individually 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.
Connection to process
Connection cable
to S100 I/O board in subrack
“Internal Cable”
A connection unit relates to an I/O board in different ways. The basic arrangement is that one
connection unit corresponds to a specific I/O board. Sometimes two or more connection units
are used to adapt to a single I/O board application. For example, the need of different rated input
voltages to a digital input multi-channel board.
Two I/O boards of different categories (for example, DI and DO) are used to support an object
oriented type of connection unit. An object oriented connection unit facilitates the connection of
field cables without using any marshalling or process cable slit-up. Process objects like motors
and valves utilizing both ordering and indicating signals are joined with the control system in a
rational and uniform way. Figure 1-19 gives an example of application.
Motor object
M
DO Contactor
Mounting bar
Process cable
MCB DI Ready
DI Run
Fuses Plug-in Trip
Terminals DI
connector
I/O boards Connection unit
)
DSDI 110A
'6',
Up to 8 rows in a cabinet
)
DSDO 115
Connection
'6'2
cable
,QWHUQDO&DEOHLQ6,2
The connection units and I/O boards 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.
,2%RDUG6,2
I/O boards convert incoming electrical signals from the process controlled, so that they can be
further processed in the processor module. Outgoing signals are adapted to their functions in the
process. I/O boards are divided into the following groups:
• Digital input boards
• Digital output boards
• Analog input boards
• Analog output boards
• Pulse counter/frequency measurement boards
• Positioning boards
• Others.
Connection units and wiring which connects boards and connection units are associated with
each I/O board.
You can exchange I/O boards while the system is running. You can also insert new boards live,
provided they are predefined in the data base. A newly inserted board is taken into operation
within 10 seconds.
,28QLW6,2
An I/O unit in the S400 I/O system corresponds to an I/O board in S100 I/O.
I/O units 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.
,20RGXOH6,2
An I/O module in the S800 I/O system corresponds to an I/O board in S100 I/O.
I/O modules are divided into the following groups:
• Digital modules
• Analog modules.
• Pulse counter / frequency measurement module
• Digital and analog modules with Intrinsically safe interface
• Analog modules with Intrinsically safe interface and HART communication.
You can connect process cables directly to the I/O module’s terminal blocks.
You can exchange an I/O module while the system is running. You can also install new I/O
modules live, provided they are predefined in the data base and there is a free Module
Termination Unit of right type in the station. A newly inserted I/O module is taken into
operation within 10 seconds.
,QWULQVLF6DIHW\%DUULHUV6,2
Hazardous applications may use barriers between the standard electronics and the equipment
located in hazardous atmosphere. Certain barrier brands provide rational connection facilities
adapted to the Advant Controller 400 Series thus making these brands especially advisable.
The basic principle is to replace the connection units of the S100 I/O System with termination
boards housing the intrinsically safe isolator modules. The Advant Controller 400 and the
intrinsically safe equipment are always delivered in separate cabinets.
You are referred to the separate documentation,QWULQVLF6DIHW\6XSSRUWIRU6,26\VWHP
+$57,QWHUIDFH6,2
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
solution.
The principles of connection is illustrated in Figure 1-20. Otherwise you are referred to the
separate documentation +$573URWRFRO,QWHUIDFHWRWKH$GYDQW&RQWUROOHU 6HULHV
&RQWUROOHUV
Intelligent Connection
transducer Unit
1
16
Multiplexer
Man-Machine
16 channels Interface
Next 16 channels
RS485 RS-232-C
Next
Multiplexer
+$57,QWHUIDFH6,2
Intelligent transducer using the HART protocol may be applied in an Advant Controller 400
installation utilizing the S800 I/O System. S800 I/O modules supporting HART together with an
Advant Control Configurator tool version 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.
HART data
HART device
6,2
S100 I/O is the group of input and output boards located in the I/O subrack. The I/O subrack
communicates with the controller subrack using Bus Extension to S100 I/O. Single and
redundant Bus Extension to S100 I/O are available. Redundant S100 I/O Bus Extension requires
redundant processor module. Electrical and optical bus extensions are provided. See the outline
presentation of the bus extension in Section 1.7.7, Communication or to the separate
documentation mentioned.
Information in this section is divided according to the different categories of boards and
subdivided into 0DLQ3RLQWV,available%RDUG7\SHVand a signal %ORFN'LDJUDP.
Regarding connection units and internal cables used in the hazardous and HART applications
you are referred to the separate documentation.
'LJLWDO,QSXW0DLQ3RLQWV
• All 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 rapid scanning of push buttons.
• The input signals are filtered on the input board to suppress the effects of electrical
interference or bouncing contacts. The filter time is fixed to 5 ms or configurable
depending on board type selected.
• Board types offering interrupt-controlled scanning are most suitable to get time-tagged
events.
'LJLWDO,QSXW%RDUG7\SHV
Table 1-13 presents available digital input boards.
7DEOH 'LJLWDO,QSXW%RDUGV
'LJLWDO,QSXW%ORFN'LDJUDP
Digital
input Data base Program
board
Digital
connection
Transducer unit
)LJXUH 'LJLWDO,QSXW6LJQDO%ORFN'LDJUDP
'LJLWDO2XWSXW0DLQ3RLQWV
• All digital outputs are galvanically isolated from the system potential by means of relays
or opto-couplers.
Grouping of channels, with respect to isolation, can exist. Please refer to information given
with the actual board type and connection unit type.
• Transistor- and relay -type outputs are available.
• There are low-power relay outputs for currents < 100 mA.
'LJLWDO2XWSXW%RDUG7\SHV
Table 1-14 presents available digital output boards.
7DEOH 'LJLWDO2XWSXW%RDUGV
7DEOH 'LJLWDO2XWSXW%RDUGV
'LJLWDO2XWSXW%ORFN'LDJUDP
Digital Unit
output board Connection controlled:
Program Data base unit lamp,
contactor,
etc.
)LJXUH 'LJLWDO2XWSXW6LJQDO%ORFN'LDJUDP
$QDORJ,QSXWIRU6WDQGDUG6LJQDO0DLQ3RLQWV
• Input units are available for standard voltage or current signals, single-ended or
differential, with or without live zero.
• An isolation amplifier is available in the form of a connection unit. The isolation
voltage is 3 kV.
• Some board has reference channels for automatic calibration and testing.
• The data base is updated by scanning, with cycle times normally selected from the
range 100 ms to 600 s.
• Optional software filtering, square-root linearization and deadband limits for updating
can be selected.
• Optional redundancy. Two types of boards can be duplicated to achieve increased
availability.
• A board is offered which combines analog inputs and analog outputs (loop dedicated I/O).
$QDORJ,QSXWIRU3W0DLQ3RLQWV
• 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.
• Each board has built-in reference channels for automatic calibration and testing.
• The data base is updated by scanning, with cycle times normally selected from the range
100 ms to 600 s.
• The suppression frequency is selectable from 20, 30, 50 and 60 Hz.
• The current generators for sensors deliver 2.5 mA, in accordance with DIN 43760.
• Optional software filtering and deadband limits for updating can be selected.
$QDORJ,QSXWIRU7KHUPRFRXSOH0DLQ3RLQWV
• Thermocouple inputs are available for different sensor types.
• Each board has built-in reference channels for automatic calibration and testing.
• The data base is updated by scanning, with cycle times normally selected from the range
100 ms to 600 s.
• Optional software filtering and deadband limits for updating can be selected.
$QDORJ,QSXW%RDUG7\SHV
Table 1-15 presents available analog input boards.
7DEOH $QDORJ,QSXW%RDUGV
$QDORJ,QSXW%ORFN'LDJUDP
Process
transducer
Test
point (X3)
)LJXUH $QDORJ,QSXW6LJQDO%ORFN'LDJUDP
With redundancy, the pair of boards is treated as an individual in the data base.
A common connection unit connects the singular process object (transducer, actuator).
Figure 1-25 illustrates an application with redundancy.
6RIWZDUH
Inputs Board
2
Actuator
Outputs
)LJXUH $QDORJ,QSXW2XWSXW6LJQDOZLWK5HGXQGDQF\%ORFN'LDJUDP
$QDORJ2XWSXW0DLQ3RLQWV
• Analog outputs are available for standard voltage and current signals.
• There are both isolated and non-isolated outputs.
• Optional redundancy is featured, where one type of board can be duplicated to achieve
increased availability.
• A board is offered which combines analog inputs and analog outputs (loop dedicated I/O).
• An output is read out each time new values are entered into the data base.
• Optional software limitations can be selected.
$QDORJ2XWSXW%RDUG7\SHV
Table 1-16 presents available analog output boards.
7DEOH $QDORJ2XWSXW%RDUGV
$QDORJ2XWSXW%ORFN'LDJUDP
e.g.
Analog Connection
Program Data base output
board unit
Test
terminal (X3)
(not all types of units)
)LJXUH $QDORJ2XWSXW6LJQDO%ORFN'LDJUDP
3XOVH&RXQWLQJ)UHTXHQF\0HDVXUHPHQW0DLQ3RLQWV
• Pulse counter units are available for pulse counting and frequency measurement,
for 5, 12 or 24 V d.c. inputs and frequencies up to 2.5 MHz.
• Scaling (conversion to process-related units).
• Optional software limitations can be selected.
3XOVH&RXQWLQJ)UHTXHQF\0HDVXUHPHQW%RDUG7\SHV
Table 1-17 presents available boards.
7DEOH 3XOVH&RXQWLQJ)UHTXHQF\0HDVXUHPHQW%RDUGV
3XOVH&RXQWLQJ)UHTXHQF\PHDVXUHPHQW%ORFN'LDJUDP
Direction
)LJXUH 3XOVH&RXQWHU,QSXW6LJQDO'6'3%ORFN'LDJUDP
%RDUG'6'3 &RQWUROOHUVRIWZDUH
Discrimination
level
5, 12 or 24 V
,Q Signal
adaptation
Number of pulses
16 bits Reading
and
counter calculation Error
Error signal
supervision
Channel 2
3RVLWLRQLQJ0DLQ3RLQWV
For further information on positioning, see Section 1.7.8.3, Control Functions, under the
heading 3RVLWLRQLQJand see the3RVLWLRQLQJ6\VWHP8VHU¶V0DQXDO.
3RVLWLRQLQJ%RDUG7\SHV
Table 1-18 presents the available board.
7DEOH 3RVLWLRQLQJ%RDUG
&RQYHUWHU&RQQHFWLRQ0DLQ3RLQWV
For further information on converter connection, see
Section 1.7.8.3, Control Functions, under the heading &RQYHUWHU&RQQHFWLRQ.
&RQYHUWHU&RQQHFWLRQ%RDUG7\SHV
Table 1-19 presents the available board.
7DEOH &RQYHUWHU&RQQHFWLRQ%RDUG
6,2
S400 I/O units communicate with the Advant Controller 450 using MasterFieldbus.
See the outline presentation of MasterFieldbus in Section 1.7.7, Communication or the separate
documentation mentioned.
Process variables, connected via S400 I/O units and S100 I/O boards, are available in the
process data base in the same way. The high performance of MasterFieldbus makes the delay in
process scanning due to fieldbus communication negligible in most applications.
However, time-tagged events have comparatively reduced accuracy.
If an S400 I/O unit loses its contact with Advant Controller 450 for any reason, it enters “local
mode.” In this mode, it maintains its output signals at their most recent correct values or to a
predetermined value, as selected by the 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.
6,28QLWV2XWOLQH'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 units are connected to
the basic units by means of short ribbon cables.
The units are enclosed and equipped with a built-in power supply including a separate, isolated
supply for sensors. The enclosure is in accordance with IEC 529, IP20. All external connections
are made by plug detachable screw terminals. You can mount the units directly on a wall, or,
more commonly, in a protective enclosure on a mounting plate, or on DIN mounting rails.
All units have LED indicators for power supply and communication. Digital units also have
LEDs for indication of the status of each I/O channel.
$%$%$%$%$%$%$%
ABB Master
................... 1 17
............. ......... .........
DSDX 452
5 21
......... .........
9 25 192 mm (7.6”)
......... .........
13 29
......... .........
237 mm (9.3”)
)LJXUH ([DPSOHRIEDVLF,28QLW'6';,QSXWVDQG2XWSXWV
6,28QLWV
7DEOH 6,28QLWV
6,2XQLWV 'HVFULSWLRQ
'LJLWDOEDVLFXQLWV
DSDX 452 DI: 20 channels,
DSDX 452L 24 V d.c. for DSDX 452 and DSDX 452L
DSDX 454 48 V d.c. for DSDX 454 and DSDX 454L
DSDX 454L DO: 12 channels, relay output(1), expandable
Supply: 120/220 (230)/240 (230) V a.c., 50/60 Hz
6,2
The S800 I/O provides distributed I/O to the Advant Controller 450 controller using the Advant
Fieldbus 100 (AF 100). See the outline presentation of Advant Fieldbus 100 in Section 1.7.7,
Communication or the separate documentation mentioned for all details.
Process variables, connected via S800 I/O modules and S100 I/O boards, are available in the
process data base in the same way. The high performance of Advant Fieldbus 100 makes the
delay in process scanning due to fieldbus communication negligible in most applications.
However, time-tagged events have comparatively reduced accuracy for modules without
internal sequence of event handling.
If an S800 I/O module loses its contact with Advant Controller 450 for any reason, it enters
“local mode.” In this mode, it maintains its output signals at their most recent correct values or
to a predetermined value, as selected by the 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), Optical Modulebus modem, I/O modules and
field wiring termination Units (MTUs) (Module Termination Units) which act as I/O module
carriers. The communication interface modules, Optical Modulebus modem and MTUs are
mounted on standard DIN-mounting rails according to DIN EN50033-35*15.
• All modules have plastic injection moulded enclosures which provide safety protection
degree IP20 according to IEC 529.
• I/O modules are protected from destruction by a mechanical keying arrangement if an attempt
is made to insert a module type in a position with a different key code than the factory set
code of the I/O module. MTUs have keys which are set to key code of its I/O module’s key
code.
6,26WDWLRQ
A S800 I/O Station can consist of a base cluster and up to 7 additional I/O clusters. The base
cluster consists of a Fieldbus Communication Interface and up to 12 I/O modules.
I/O cluster 1 to 7 consist of an Optical Modulebus modem and up to 12 I/O modules.
A S800 I/O Station can have a maximum of 24 I/O modules. I/O cluster 1 to 7 are connected to
the FCI module through an optical expansion of the Modulebus.
0RGXOHEXV
The Fieldbus Communication Interface module communicates with its I/O modules over the
Modulebus. The Modulebus can support up to 8 clusters, one base cluster and up to 7 I/O clusters.
The base cluster consists of a communication interface module and I/O modules. An I/O cluster
consist of an Optical Modulebus modem and I/O modules. The Optical Modulebus modems are
connected via optical cables to a optional Modulebus Optical port module on the communication
interface module. The maximum length of the Optical Modulebus expansion is dependent of the
number of Optical Modulebus modems. The maximum length between two clusters is 15 m
(50 ft.) with plastic fibre and 200 m (667 ft.) with glass fibre. Factory made optical cables (plastic
fibre) are available in lengths of 1.5, 5 and 15 m (5, 16 or 49 ft.). The Optical Modulebus
expansion can be build up in two ways, a ring or a duplex communication.
Within a cluster the Modulebus is made up of increments integrated into each Module
Termination Unit (MTU). Each communication interface module and Optical Modulebus modem
has a Modulebus 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 assigned the unique position identity of
its MTU. Through the incremental bus design the physical size of an S800 I/O installation is
directly proportional to the number of installed MTUs.
MTUs and their associated I/O modules can within a cluster be set up in two or three physically
separated groups with extension cable adaptors which fit to the bus outlet and inlet connectors of
communication interface modules, Optical Modulebus modem and MTUs. The factory made
extensions cables which plug into the cable adaptors are available in lengths of 0.3, 0.6 and 1.2 m
(1, 2 or 4 ft.), allowing together with up to 12 I/O modules, for a total bus length of 2.5 meters
(8.2 ft.).
The S800 I/O modules can be inserted and removed from MTUs without disturbing system
operation. The physical lock which locks an I/O module to its MTU allows I/O module removal
only when the lock is in its unlock position. The locking mechanism also acts as a logic lock so
that an I/O module is operable only when the lock is in the locked position. If the lock is in its
unlocked position, output channels are de-energized and I/O modules can be inserted/removed
without need to remove system or field power.
The MTUs are totally passive units and all active circuitry is allocated to the I/O module.
)LHOGEXV&RPPXQLFDWLRQ,QWHUIDFH0RGXOHV
The Fieldbus Communication Interface (FCI) modules have an input for one 24 V d.c. power.
The FCI provides 24V d.c. (from the source) and an isolated 5V d.c. power to the base cluster’s
I/O modules (12 maximum) by way of the ModuleBus connections. There are three types of FCIs
one for single Advant Fieldbus 100 configurations, one for redundant Advant Fieldbus 100
configurations and one for single PROFIBUS configurations. The power source can be the
SD811/812 power supplies, battery, or other IEC664 Installation Category II power sources.
Power status inputs, 2 x 24 V, to monitor 1:1 redundant mains are also provided.
The single Advant Fieldbus 100 FCI module have two connectors and built-in modems, for
redundant AF 100 twisted pair cables, a connector for the Modulebus Optical port module and a
galvanically isolated RS-232 service port to allow trouble free tools connection.
The redundant Advant Fieldbus 100 FCI module have one connector and built-in modem, for one
AF 100 twisted pair cable and connectors to a connection unit. Two redundant FCI modules are
connecting to each other via an Interconnection Unit (TB815). Connectors for electrical
Modulebus, Modulebus Optical port module and two galvanically isolated RS-232 service ports
are placed on the Interconnection Unit TB815 one for each FCI.
The AF 100 connector plugs 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 status indications.
Two rotary switches are provided for setting of the station address. No other addresses are
required to be set within the I/O-station. Labels for optional user text and item number are also
provide.
7DEOH &RPPXQLFDWLRQ,QWHUIDFH0RGXOH
0RGXOHW\SH 'HVFULSWLRQ
CI810A AF 100 Fieldbus Communication Interface, 2 x AF 100 Modems for
twisted pair cable. Power supply 24 V.
Rated isolation voltage 50 V.
CI820 AF 100 Fieldbus Communication Interface for redundant configurations,
1x AF 100 Modems for twisted pair cable. Power supply 24 V.
Rated isolation voltage 50 V.
TB815 Interconnection Unit for redundant FCI (CI820).
CI830 PROFIBUS Fieldbus Communication Interface, one Modems for twisted
pair cable. Power supply 24 V. Rated isolation voltage 50 V.
,2,QWHUIDFHV
A range of I/O modules is available covering analog, pulse and digital signals of various types.
Interfaces for RTDs and TCs of various types and modules with intrinsically safe interface and
HART communication are available.
The S800 system provides I/O modules with typically 2, 4, 8 or 16 channels depending on type
and ratings of the individual module.
All I/O modules are supervised at system start-up as well as under normal operation. The status
of a module is indicated with front mounted LEDs; RUN (R), green, normal operation, FAULT
(F), red, when a fault is detected, WARNING (W), yellow, when a channel fault is detected and
OUTPUT SET AS PREDETERMINED (OSP), yellow, when the module has lost
communication. Detailed status and diagnostics are available on the System Status Displays of
the Operator Station.
All I/O modules can be replaced with both system power and field power connected.
'LJLWDO0RGXOHV
The digital I/O modules all have galvanic isolation relative to chassis ground. All modules have
LEDs to indicate channel status (on/off) and the standard set of module status indicators. Some
modules has also a LED per channel indicating fault.
24 V and 48V modules have two isolated groups with 8 channels.each Each group has a field
power status input to indicate presence of field power. Loss of field power is indicated on
Warning 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'LJLWDO0RGXOHV
0RGXOHW\SH 'HVFULSWLRQ
0RGXOHW\SH 'HVFULSWLRQ
$QDORJ0RGXOHV
The analog I/O modules all have galvanic isolation relative to chassis ground in a group of 4 or
8 channels. The modules have the standard set of module status indicators.
Open circuit detection is available for inputs and outputs configured for 4…20 mA and for the
RTD and TC inputs.
7DEOH 6$QDORJ0RGXOHV
0RGXOHW\SH 'HVFULSWLRQ
0RGXOHW\SH 'HVFULSWLRQ
3XOVH&RXQWLQJ)UHTXHQF\0HDVXUHPHQW0RGXOHV
The Pulse Counting / Frequency Measurement modules DP820 is a two-channel pulse counter
module in the S800 I/O series. Each channel can be used for independent pulse count/length
measurement and frequency/speed measurement. The module is placed in a S800 I/O station
connected to the Controller via Advant Fieldbus 100.
Configuration and signal handling of module DP820 is handled via the data base element
DP820 and PC-element DP820-I and DP820-O.
7DEOH 3XOVH&RXQWLQJ)UHTXHQF\0HDVXUHPHQW0RGXOHV
0RGXOHW\SH 'HVFULSWLRQ
0RGXOH7HUPLQDWLRQ8QLWV078
Termination Units are available as Compact MTUs or Extended MTUs. A compact MTU
normally offers termination of one wire per channel for a 16 channel module. With compact
MTUs power distribution of field circuits must be made with external terminal blocks and current
limiting components if required. Extended MTUs with group-wise isolated interfaces allows for
two or three wire termination of field circuits and provides group-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.
Compact MTUs are 58 mm (2.3”) wide and extended MTUs are 120 mm (4.72”) wide. The two
MTU types can be mixed and matched within an I/O-station to fit a user’s needs. Choice of
compact MTU or extended MTU can be made freely trading space versus termination needs.
Compact and extended MTUs are available with rated isolation voltages 50 V and 250 V.
The 50 V types can be used with all 24 V or 48 V discrete I/O and analog I/O modules.
The MTUs with 250 V rated isolation voltage are used with all 120 V and 250 V rated I/O
modules. There is also one compact MTU for modules with Intrinsically safe interface.
7DEOH 60RGXOH7HUPLQDWLRQ8QLWV
0RGXOHW\SH 'HVFULSWLRQ
TU830 Extended MTU, 120 mm wide. Two isolated groups each with 2
rows of 8 uncommitted terminals, 2 pcs L+ terminals and one row
of 10 pcs L-.
Rated isolation voltage 50V.
Conductor area: 0.2-2.5 mm2, AWG 24-12.
7DEOH 60RGXOH7HUPLQDWLRQ8QLWV
0RGXOHW\SH 'HVFULSWLRQ
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.
TU838 Extended MTU, 120 mm wide. Two isolated groups. Each group
8 I/O channels, 4 fused transducer power outlets, 4 return con-
nections and process power connection.
Rated isolation voltage 50 V.
Conductor area: 0.2-2.5 mm2, (Stranded) AWG 24-12.
3RZHU6XSSOLHV
The power supplies SD811 and SD812 (24 V output) can be used to power processor modules
and S800 I/O modules, through the processor unit and to power 24 V field circuits (optional).
The supplies have a wide input voltage range, nominally 110V-240 V without input voltage range
selection. The primary side can connect to industrial mains installation class III (IEC664).
The outputs are short circuit proof and can operate with resistive, capacitive and constant power
loads, for example, switched mode power converters.
The outputs of the supplies can be connected in parallel to increase power, 2 x SD811 or
2 x SD812, or be configured for redundant mains to increase availability, 2 x SD811 or
2 x SD812. Each supply has a power OK signal which can connect to the SA or SB inputs of the
communication interface modules or Optical Modulebus modem to monitor power status in 1:1
redundant mains configurations.
7DEOH 3RZHU6XSSOLHV
0RGXOH7\SH 'HVFULSWLRQ
2SWLFDO0RGXOHEXV([SDQVLRQ
The Modulebus can be expanded by using a Modulebus Optical port module on the Fieldbus
Communication Interface module and communicates via an optical cable with the Optical
Modulebus modem in the I/O cluster.
2SWLFDO0RGXOHEXV0RGHP
The Optical Modulebus modems have an input for one 24 V d.c. power. The FCI provides 24V
d.c. (from the source) and an isolated 5V d.c. power to the base cluster’s I/O modules (12
maximum) by way of the ModuleBus connections. The power source can be the SD811/812
power supplies, battery, or other IEC664 Installation Category II power sources. Power status
inputs, 2 x 24 V, to monitor 1:1 redundant mains are also provided
The front plate of the Optical Modulebus modem provides LEDs for diagnostic and status
indications. One rotary switches is used for setting of the cluster address. Labels for optional user
text and item number are also provided.
0RGXOHEXV2SWLFDO3RUW
The Modulebus Optical port have connectors for optical cables and connector for connection to
the communication interface module.
7DEOH 0RGXOHEXV,WHPV
0RGXOHW\SH 'HVFULSWLRQ
&RPPXQLFDWLRQ
System communication resources are primarily treated in Section 1.7.7.1, Provided Link Types.
You will find an enumeration of the main applications of these communication links in Advant
Controller 450 in this section.
3URYLGHG/LQN7\SHV
Information in this section is divided according to the different link types. An outline
description follows. All link types, besides the widely spread standard V.24/RS-232-C,
are described in separate users’ guides. For referrals to specific documents, see Section 1.4,
Related Documentation.
Provided link types in Advant Controller 450 are:
0DVWHU%XV0DVWHU%XV(*&20%XV([WHQVLRQWR6,20DVWHU)LHOGEXV
$GYDQW)LHOGEXV352),%86'3/21:25.61HWZRUN5&20(;&20
0XOWL9HQGRU,QWHUIDFHand956&
0DVWHU%XV0DVWHU%XV(2XWOLQH'HVFULSWLRQ
Use MasterBus 300 to interconnect Advant Controller 400 Series, Advant Station 500 Series,
MasterPiece 200/1, MasterView 800/1 Series and MasterBatch 200/1 stations in a control
network (network communication). It provides high-speed, high-performance communication
over medium distances.
MasterBus 300 is based on the IEEE 802.2 class 1 connection-less unconfirmed data link
service protocol and IEEE 802.3 CSMA/CD (Carrier Sense Multiple 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 networks. The communication bridges must conform
to the IEEE 802,3 standard. The characteristics of MasterBus 300E are the same as for
MasterBus 300 except that the communication parameters can be tuned to allow communication
over links, which introduces delays and limits the bandwidth.
The MasterBus 300/MasterBus 300E separates the communication function within a
station/controller. You can expand or reconfigure the control network without any changes to
the application in the controllers or operator’s stations. The network is self-configured, that is
no configuration of the data base is required. The configurator sets network and node identity on
hardware.
There is a low-load version of MasterBus 300/MasterBus 300E for the Advant Controller 450
which uses special hardware. The low-load version has dedicated CPU support, so it causes a
lower load in the main CPU of the controller.
The transmission rate is 10 Mbits/s.
To also ensure availability of data communication when a cable or a communication unit fails,
you can duplicate MasterBus 300/MasterBus 300E.
*&202XWOLQH'HVFULSWLRQ
GCOM is a data link protocol used for data exchange with the help of message passing between
external computers and Advant OCS stations/controllers. The protocol is available for VAX
computers. The following data link protocol alternatives are supported:
• IEEE 802.2 class 1 logical link control and IEEE 802.3 CSMA/CD medium access control
• CCITT recommendation X.25.2 LAPB with transmission rate 19.2 or 50 kbits/sec
• ADLP-10 (ABB Data Link Protocol), an asynchronous protocol based on ECMA 16 and
ECMA 24, with transmission rate of 9.6 kbits/sec.
You can duplicate GCOM to achieve full redundancy.
%XV([WHQVLRQWR6,2
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 cables.
Figure 1-31 illustrates a bus extension comprising two I/O subracks.
Controller subrack
P P
M M
5 5
1 1
1 1
D D I/O subrack 1
S S For redundant S100 I/O bus
B B
C C duplicate CPUs, bus extenders
1 1
7 7 and cables.
4 4
The I/O bus connected to the
left CPU should be connected
I/O subrack 2 to the left bus extender and
vice versa.
D D
S S
B B
C C
1 1
7 7
4 4
)LJXUH ([DPSOHRI(OHFWULFDO5HGXQGDQW%XV([WHQVLRQ
An optical bus extension is available which makes I/O subrack distributable. Figure 1-32
illustrates a configuration combining a central I/O subrack and two distributed I/O clusters.
Controller subrack
PM511
T
I/O subrack 1
Modem Modem
TC560V01 TC560V01
max 500 m
(1640 ft.) max 500 m (1640 ft.)
I/O cluster
Modem
I/O cluster TC561V1
Modem
I/O subrack 2 TC561V1 I/O subrack 4
max 12 m
DSBC DSBC (39 ft.)
176 176
I/O subrack 3 max 12 m
(39 ft.) T
DSBC
176
T T = Termination
The bus extension is part of the I/O system described in a separate manual, 6,2+DUGZDUH.
0DVWHU)LHOGEXV2XWOLQH'HVFULSWLRQ
MasterFieldbus is a high-speed communication link that connects S100 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.
You can disconnect remote units from the bus and replace them without disturbing other units or
their communication with Advant Controller 450. Communication with a reconnected unit is
resumed automatically.
MasterFieldbus operates at 2 Mbits/s.
For distances up to 25 m (82 ft.), use MasterFieldbus with twisted pair cable and without
modems. For longer distances, use modems. Both coaxial and optical types of cable are
available.
MasterFieldbus can also operate at 375 kbits/s. This 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.
‘Bus controller’
Comm. module
CI570
Conn. unit
TC570
SDB
SDB
Distr. Distr.
unit unit = Termination unit
)LJXUH ([DPSOHRI3K\VLFDO&RQILJXUDWLRQRI1RQUHGXQGDQW0DVWHU)LHOGEXVDQG6,28QLWV
$GYDQW)LHOGEXV2XWOLQH'HVFULSWLRQ
Advant Fieldbus 100 is a high-performance bus specially designed for real-time applications.
A number of different products are connectable to Advant Fieldbus 100, that is
Advant Controller 410/450, Advant Controller 110, distributed S800 I/O stations, ACV 700
Converter, and so on. It features reliable, cyclic data transfer as well as event-driven background
transfer of service data.
Advant Fieldbus 100 also features a distributed master scheme. If 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 modules.
An S800 I/O station has a built in modem and communication interface for the twisted pair
media.
AC 450
TC625 TC625
Advant Fieldbus 100
CT CT
External
CI626
CI626
Device
AC 110 AC 110
CT Grounded 75 Ohm BNC termination
CT 75 Ohm BNC termination
With modem TC515V2 you can extend the bus length up to 1400 m.
AC 450
CI522A
TC516
Advant Fieldbus 100
TT TT
TT TT
External
PM810V1 Device
I/O Modules
AC 70
TB815
CI820
CI820
TC515V2
TT TT
TT TT
Together with the opto-modem TC630 or TC514V2 and opto-fibre cable, you can extend the
bus length up to 1700 m.
AC 450
Optical media
TC630 TC630
TC512V1 TC513
CI626
CI626
AC 110 AC 110
TC514V2
PM810 CT Grounded 75 Ohm BNC termination
AC 70 CT 75 Ohm BNC termination
Optical media TT Grounded twisted pair termination
TT Twisted pair termination
TC514V2
Twisted pair media
TT TT
Network Configurations
AC 400 Series
or AC 110
DP to PA PROFIBUS-
segment coupler PA device
PROFIBUS-DP PROFIBUS-DP
device device
Up to 125 slave nodes can be connected to one bus. Up to eight buses can be configured in an
Advant Controller 450.
Network Configurations
AC 400 Series
LONWORKS LONWORKS
device device
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.
(;&202XWOLQH'HVFULSWLRQ
EXCOM (EXternal computer COMmunication) permits the external computer to read or write
in the Advant Controller 450 data base with the help of simple commands and an asynchronous
serial communication link V.24/RS-232-C. The communication is controlled by the external
computer. Figure 1-39 shows the possible alternative means of connection with an external
computer. This figure shows how you can connect an external computer directly to one or more
Advant Controller systems. The external computer can reach other nodes in the configuration
through communication via a MasterBus.
EXTERNAL
COMPUTER
5&202XWOLQH'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 series
• MasterPiece 200/1
• Older types of ABB Master process stations or alien computers
• Various equipment, for example, Essentor PC manager.
0XOWL9HQGRU,QWHUIDFH2XWOLQH'HVFULSWLRQ
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 Controller. The module used has two serial asynchronous channels
and is programmed in C language. The programming is done in a MVI Development
Environment based on a personal computer.
The module CI535 requires an older Development Environment based on a work station.
MVI uses a V24/RS-232-C asynchronous serial communication link. This link allows
communication at long distances.
$SSOLHG&RPPXQLFDWLRQ
Advant Controller 450 communicates with a wide range of products, as indicated in Table 1-28.
The links used are shown. RCOM is, in some cases, an alternative for long-distance or low-
cost/less-performance applications. The main functionality obtained is given. Additionally,
there are diagnostics generally included as a basic link function.
Diagnostics information on the communicating units is also commonly accessible via status
messages.
7DEOH &RPPXQLFDWLRQ6XUYH\
([SODQDWLRQV
Mainly recipe data and report data are sent.
Configuration data transfer.
The control of d.c. motors in a drive system is integrated in the converter, which involves a
considerable exchange of signals with Advant Controller 450. A special communication
package implemented in the converter makes this adaptation possible.
EXCOM also provides reading of object data of the type AI, AO, DI, DO (Analog
Input/Output, Digital Input/Output). This is utilized by the given product.
The main use of a printer for generating reports is described in Section 1.7.8.3, Control
Functions, under the heading Reports.
Read/write process I/O data.
5,%indicates Real, Integer and Boolean data, respectively. Bi-directional information flow is
possible.
(indicates handling of time-stamped events. Events are defined and time-stamped in the central
I/O of Advant Controller 450 or in distributed units of the type Advant Controller 110 and
Advant Controller 70. Advant Controller 450 sends the information to operator stations for
presentation in lists. High accuracy in time.
($ 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 Advant
Controller 450. Advant Controller sends the information to operator station for presentation in
lists. Less accuracy in time.
6indicates subscription of data from the Advant Controller 450 data base. It is requested by an
operator station or a similar station. A subscription is normally an object-oriented, complex
package of mixed data used for presentation purposes.
&indicates command signals, for example complex commands including several parameters or
increase/decrease, start/stop, and so on from an operator station or similar device.
'DWD6HW
Information is exchanged between separate controllers (and between a controller and other
equipment indicated in Table 1-28) by means of “Data Sets,” that is messages containing
aggregates of data base information. Data Sets are explicitly specified in the communicating
controllers, as part of the application programming.
With a Data Set, the communication normally transmits cyclically between the nodes.
The cyclic time is configurable.
In addition to Data Set, other variants exist, for example MVI Set, Data Set Peripheral.
A Text Set is a type of Data Set. With a Text Set, you can send text between controllers/process
stations of the type Advant Controller 410/450 and MasterPiece 200/1 using MasterBus 300.
Transmission of a Text Set is commanded from a PC program.
For a detailed description of Data Set and Text Set, see the reference manual $03/
&RQILJXUDWLRQ$GYDQW&RQWUROOHU 6HULHV.
3URFHVV&RQWURO
Advant Controller 450 offers powerful features covering all aspects of process control in most
application areas. For information on the application language used, the principles of
configuration/application building and the functional resources, see the following sections.
$SSOLFDWLRQ/DQJXDJH
*HQHUDO
Process control applications are programmed in the 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
written in AMPL is referred to as a PC (process control) program, and the building blocks are
called PC elements. The range of ready-to-use function blocks is wide and powerful.
You can program a controller in AMPL fully on-line with the programs running and controlling
the process. If required, you can block part of a PC program, a complete PC program or the
whole controller during programming. You can also develop programs off-line in an engineering
station and load them into the controller at a later stage.
In addition to functional PC elements, AMPL contains a number of structural elements for
division of a PC program into suitable modules which can be managed and executed
individually. You can give the modules different cycle times and priorities so that both fast and
slow control operations can be managed by the same PC program.
The inputs and outputs of an element are connected to the inputs and outputs of other elements
or to process I/O points. Picking these elements and making these connections constitutes the
programming work. The resulting PC program can then be documented graphically, which
Figure 1-40 illustrates.
When a dedicated station is used for programming, it can be connected, either directly to the
controller to be programmed, or indirectly via another controller in the communications
network. For remote access, the public telephone network can be used.
Signals are represented in engineering units throughout the whole application program.
This facilitates the configuration work, especially in connection to arithmetic operations. It also
simplifies reading and understanding of the graphical documentation of the application
program.
Scaling of an I/O signal from an electrical variable, for example, 4 - 20 mA, to a variable
expressed in engineering units is made in the data base for the point.
PC7
PCPGM(40,7)
=DI1.1/START 1 ON RUN 5 P =DO1.1/RUNNING
D=0 2 R
1
CONTRM(250,3,0)
D=1 1 5
D=0 2 ON RUN 6
D=0 3 >SINGLE MODP
1
=DI1.6/MOTOR_STOP C 1
& 60 P =DO1.5
2
IND_MOTOR-START
=DI1.6/MOTOR_START C 11 ≥1
12
2
=AI1.3/MOTOR_CURRENT C 1 + 20 P =AO1.4/
D=5.000Amp 2 R IND_MOTOR_CURREN
3
COMP-R(2,1)
1 I
D=0.00 1 HHYS I<H1 20
CURRENT_WARNING D=95.000Amp 1 H1 I>=H1 21 P =DO1.6
CURRENT_LIMIT D=100.000Amp
D=100.000Am 1 H2 I>=H2 22 IND_CURRENT_WARNING
D=0.000 3 LHYS I>L1 40
D=0.000 3 L1 I<=L1 41
4
S P =DO1.18
=DI1.7/ALARM_ACKNOWLEDGE C 4 R ALARM_CURRENT LIMIT
5
F=1 F1 PRINT(1,1,72)
F=1 F1 <
F=1 F1 FIRST BUSY 5
1 LAST REPNO 6
2 FF ERR 7
3 NODE
3 BUS
PRID
>ACT
D=’HIGH MOTOR 1
EXECUTION ORDER; 1 2 3 4
1
PC7
7\SH&LUFXLWV
To boost application programming productivity even further, the engineering stations support
the use of type circuits, 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.
8VHU'HILQHG3&(OHPHQWV
Another way to implement your frequently used control solution and ensure a fully integrated
engineering environment is to make use of the option User Defined PC Elements.
A user defined PC element appears in every sense as a standard PC element. Actually the
control solution of a user defined PC element is defined by other PC elements. See illustration
in Figure 1-41.
Library of
Control solution user defined
PC elements
AND
VALVEC
USER
ELEMENT
OR LUBE
COUNT OIL
SR
Reuse
Application PC program
USER
ELEMENT
Signal in 4
SEAL
OIL
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.
3ULQFLSOHVRI$SSOLFDWLRQ%XLOGLQJ
Figure 1-42 illustrates how process signals available in the data base are linked to the AMPL
application program.
DO1
DB element
DSDO 120 TYPE defining board, signals
DI 1
DO 1.1
DSDI 110 TYPE
START M1 NAME
DI1.1
START NAME
PC program
PC element
IV
Switch gear
=DI 1.1/START
& S T = DO 1.1/START M1
= DI 1.2/CONDI-
TION D = 10
R
IV
= DI 1.3/STOP
Protection
3&(OHPHQWVDQG)XQFWLRQDO8QLWV
Besides the PC elements, the function library consists of functional units. Functional units are
available to supplement the library for more complex functions. A functional unit is a package
of different program functions such as PC element, data base element and operator’s functions.
This simplifies the realization of combined functions with both the control function and
associated operator’s handling via a display screen and keyboard.
The application can be a closed loop control function or a motor or valve control function
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.
Figure 1-43 illustrates the application of functional units in a complex burner control.
SEQ
DO & Stopp
DO
IV
SOV
DO
Operator
Station
Alarm: Flow Temp DI
AI F
MAX
Time contr. SP
MIN PIDCON SEQE1 CLAMP REF CV
EXTREF OUT AO
MV
AI F
Supervi. Burner
Furnace
)LJXUH 3ULQFLSOHRID)XQFWLRQDO8QLW$SSOLFDWLRQ
&RQWURO)XQFWLRQV
The main built-in control functions available for application building are grouped and presented
briefly below. Most of the functions are supported by PC elements, that is the PC elements are
the base of the functionality of the Advant Controller 450.
For a listing of those PC elements included in the basic system program module and the
different optional program modules, see Section 1.7.3.3, Program Module Contents.
For detailed function descriptions of the different PC elements, see the separate reference
manual, 3&(OHPHQWV$GYDQW&RQWUROOHU 6HULHV.
/RJLFDQG7LPH'HOD\V
• Basic Boolean functions
• Composite Boolean functions
• On/off delay, pulse generation.
6HTXHQFH&RQWURO
• General structuring functions
• Sequence control influenced by standard IEC 848.
'DWDDQG7H[W+DQGOLQJ
You can arrange text strings to be presented on the operator station display screen or used in
event printouts.
&DOHQGDU7LPH)XQFWLRQV
Date and time can be used when an automatic function shall be started or when a report is
printed out.
$ULWKPHWLF
Standard arithmetic expressions as well as special functions are available.
3RVLWLRQLQJ
Positioning is a general term for position measurement and position control of d.c. and a.c.
motors and hydraulically and pneumatically servo-controlled mechanisms in industry.
A special circuit board, DSDP 140A, is used together with a suitable pulse transmitter such as
QGFA 110, QGFA 110 V or the equivalent. (It is also possible to connect other transducers.)
The circuit board communicates directly with PC elements for rapid positioning in which the
pulse generator is used for feedback of actual values. A processor is provided on the circuit
board for the fast calculation in the inner loop of the positioning system. The positioning board
has a flexible design and is intended to perform several functions, together with different PC
elements:
• POS-A(0) Length measurement
• POS-A(1) Positioning with analog output signal
• POS-O(0) Positioning with digital output signal for three speeds
• POS-O(1) Positioning with digital output signal which can be pulsed
• POS-L Length measurement with digital output signal with coincidence.
The following functions and properties are available:
– Position measurement via an incremental pulse transmitter and a direction
discriminator and a hardware counter which updates a software counter at regular
intervals.
– Three pulse inputs adapted for the ABB pulse generator QGFA 110: A channel,
B channel and STROBE. Maximum frequency 80 kHz.
– Analog output for speed reference, 11 bits + sign. 0 to ±10 V or 0 to ±20 mA.
– Position control ON-OFF with fast, medium-speed or slow retardation to the interval
“correct position.” Position control ON-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 manual3RVLWLRQLQJ6\VWHP.
3XOVH&RXQWLQJDQG)UHTXHQF\0HDVXUHPHQW
These functions are used for different applications in the industry, such as position
measurement, flow measurement, speed measurement, synchronization of machine movements,
and so on. The pulse-counting function requires special hardware.
• The cycle time for the reading-in program is determined individually with the parameters
in a DB element. After the reading-in, the values are converted to process-related units and
checked against limits. The limits which are exceeded are stored in the data base.
• The pulse-counting/frequency measurement function requires hardware module
DSDP 150. This circuit board is used for both pulse counting and frequency measurement
and has inputs which can be connected to pulse generators with a frequency of up to
10 kHz.
• DSDP 170 is a circuit board which is primarily intended for positioning/length and
speed/frequency measuring. Maximum pulse frequency is 2.5 MHz.
• DP820 is a module which is primarily intended for positioning/length and speed/frequency
measuring. Maximum pulse frequency is 1.5 MHz.
5HSRUWV
The report function permits you to connect a printer to the Advant Controller 450 system to
print out simple reports.
Figure 1-44 shows an example of a simple report which is “edited” with the help of data base
and PC elements. Values, date and time are transformed into text strings.
PC program
PRINT
MAN control
or
TIMER
D=“SHIFTREPORT BOILER”
TEXT
TEXT
SHIFT REPORT BOILER
PC program D= “Time”
D ATE Time 1993-12-24 19:18:04
TIME
Acc. oil cons. 1.76 tons
PC program D =“Acc. oil cons.” Acc. water cons. 280 tons
Totalizer Exhaust gases (peak):
D=“tons”
CO 120 ppm
O2 1.8 %
)LJXUH ([DPSOHRI6LPSOH5HSRUW
As an alternative to a controller-connected printer, you can use the facilities from a large
operator station (Advant Station 500 Series, MasterView 800/1). Actually, this is the most
common way of printing information from any station in a control network. Advanced reports
can be arranged from the contents and layout viewpoint. Also, you can use a local operator
station for reports. In the latter case, the display information from a MasterView 320 is printed
out. Once the report/display is configured, it is possible to remove the MasterView 320. In other
words, MasterView 320 in such an application can be used as a configuration tool only.
For further information regarding report generation in operator stations, see the appropriate
separate documentation.
6XSHUYLVLRQ
Process supervision has an important role in a control system like Advant Controller 450.
Any logic state transition in the process or application program, or any limit transition of a
process variable or complex calculated variable, can be defined as a point of event.
Events can be time-stamped with a resolution down to 1 ms, which enables 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 Station 500 Series provides powerful ready-to-
use event and alarm handling.
0HDVXULQJ
You can connect process variables with different electrical representations as follows:
• Standard signal types, 4 - 20 mA, 0 - 10 V.
• Pt 100, Thermocouple
• Pulse, Frequency.
Pre-filtering is important in digital systems to obtain interference-free control and logging.
The irrelevant frequency content in the process signals must be limited.
Standard signals for current and voltage are pre-filtered in steep active hardware filters whereas
temperature measurement signals are filtered by integrating A/D conversion. In addition to
hardware filtration, the software can select digital filtration with single pole filters and with the
required break frequency.
In the case of temperature measurement, linearization is performed in accordance with the type
of Pt 100 transducer or thermocouple selected. Linearization through root extraction, for
example with pressure difference measurement, can be selected if required.
)HHGEDFN&RQWURO
Powerful functions for feedback control are provided with a great number of PC elements and
functional units. Examples of applications are:
• Basic PID control
• Cascade-coupled controllers
• Ratio control
• Manual control from central/local operator’s workplace
• Controlling final elements with two- or three-position action
• Override control
• Batch control
• Split range
• Gain scheduling or other adaptation strategies
• User-defined control strategies combining the range of available algorithms P, PI, PDP,
PIP, DER, INT, FILT-1P/2P, P-DEADB and RAMP.
The built-in features in one of the complex loop controllers, the functional unit PIDCONA, are:
– Several control modes with built-in priority scheduling
– Automatic tracking for bumpless control mode changeover
– Cascade 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 functions, for example
interlocking, start-up and shut-down sequences, calculations, process optimization and so on.
)X]]\&RQWURO
The function FUZZYCON allows the user to specify the control algorithm using fuzzy control,
which is an applied science of fuzzy theory. Moreover, the function supports multi variable
input and multi variable output, that is several controlled variables and manipulated variables
can be handled simultaneously. To the operators, FUZZYCON exposes the same “look and feel”
as other functions, that is PIDCON, with respect to object displays and dialogs. This is also true
for other run time features and most of the engineering tasks.
0RWRUDQG9DOYH&RQWURO*URXS6WDUW
High-level functional units are available for applications such as valve control or group control
of motors. The built-in features in one of the complex motor controllers, the functional unit
MOTCON, are:
• Supervision of control circuits
• Evaluation of interlocking
• Control of on/off
• Supervision of motor current
• Running of tests from the motor site
• Control from central/local operator’s station
• Manual/Auto running
• Forward/Reverse running or selection of High/Low speed.
• Presentation of Motor/MCU diagnostics (MOTCONI).
The functional unit MOTCONI has the same functionality as MOTCON. The difference is that
MOTCONI controls INSUM Motor Control Units (MCU) over the LONWORKS Network.
'ULYHV,QWHJUDWLRQ
For large control systems, built on Advant Controller 450, the connection to ACS 600 drive
systems is made via Advant Fieldbus 100. Each fieldbus node connects up to 24 drives through
an optical ring.
Adv a C o m ma n d
A d v a n t C o n t r o lle r 4 0 0 S e r i e s
I/O I/O
AF 100 S 8 0 0 I/O
O p t i c a l M o d u le B u s
9DULDEOH6SHHG'ULYH&RQWURO
Variable-speed motor drives can be directly connected to Advant Controller 450 via a
specialized interface board that resides in the controller. The board contains a pulse counter for
accurate rotational-speed measurement and outputs a compensation signal to an analog
converter. The accuracy normally associated with digital drives only is also made available to
analog drives. The board exchanges setpoints, measured values, start and stop commands and
indications with the drive controller.
&HQWUDO2SHUDWRU6WDWLRQ6XSSRUW$GYD&RPPDQG0DVWHU9LHZ
Using a central operator station, for example Advant Station 500 Series or MasterView 800/1
Series, provides a powerful operator interface to the process 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 is given below. For detailed information, see separate documentation.
0DLQWHQDQFH3HUVRQQHO
The main purpose of this type of interface is to support fault tracing and backup handling of the
application program. There are:
• Start mode selector, LED indicators and character display on the processor module
• Diagnostics LED indicators on most hardware modules
• Configuration tool setup for fault tracing and backup handling.
Otherwise, the normal use of a configuration tool is to configure the controller. It would
also be used to adjust and change the application in a level not reachable from an operator
station.
/RFDO2SHUDWRU
0LPLF3DQHO
Two alternatives are possible:
• Panel units, for example numeric display, keyboard, function keyboard, push button and
thumbwheel connected via Modbus protocol.
• ABB Active Mimic Controller.
An Active Mimic Controller module makes it possible to control active mimic panels from
an Advant Controller 450 via one or more RCOM links. You can use the module for local
collection of inputs from push-button switches (PBs), for updating of LEDs or lamps, and
for control of an alphanumeric text display.
The display unit displays a number of text strings with 20 or 40 characters. These text
strings are programmed according to the customer’s specification and located in a text-
PROM on the Active Mimic Controller module.
You place the module in large control room mimic panels or in traditional control desks,
or use it for small distributed operator panels in the process area.
/RFDO2SHUDWRU¶V6WDWLRQ
Two alternatives are available:
• MasterView 320
• Personal-computer-based operator station.
The operator’s station 0DVWHU9LHZ is a VT100-compatible terminal connected to
Advant Controller 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 on the display screen are
varied by the PC program via the data base and can consist of real numbers, integers or Boolean
variables. The operator can intervene in the process by changing, via the keyboard, the data
presented in the display.
You can also program, directly from the MasterView 320, certain keys to give signals to/from
the PC program, which in turn can affect the process directly. MasterView 320 is provided with
an event-handling function which permits the storing up to 100 events for each terminal.
Of these events, 16 can be presented on the display screen at one time. The event messages are
sent to the MasterView 320 terminal and can be programmed with a special PC element,
EVENT. You can present the event list on a display and/or you can obtain a copy of the event
list as a printout if required. Dialog and error texts associated with the MasterView 320 function
can be presented in different languages, which can be defined with the configuration tool.
SPEED REF
A 5,5m/s
0 0
B 16,7m/s
A B A
)LJXUH 977HUPLQDODQG.H\ERDUGIRU0DVWHU9LHZ
A feature you are offered when you use a personal-computer-based operator station is that it can
be connected via the communication link RCOM and a dedicated, or a public, telephone
network. However, you must be aware of its limited performance.
&HQWUDO2SHUDWRU
A central operator station of the Advant Station 500 Series or MasterView 800/1 type provides a
powerful operator’s interface.
Examples of the main functions are as follows:
• Presentation of user-designed process displays, standard 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 is
controlled via the signal and object files in the data base of the Advant Controller 450.
All of the information about the process signals connected and the process object are stored in
these files (see Figure 1-47 below).
Operator
Station
Presentation
Dialog
MasterBus 300
Data base
PC program
DI DO AI AO Obj.
file
Process
3ULQWHU
You can obtain printouts of reports, generated in the report function, or paper copies of event
lists when a MasterView 320 is included, with a printer connected to an Advant Controller.
For further information on the primary use of a printer for generating reports,
see Section 1.7.8.3, Control Functions, under the heading Reports.
The printer requirement specification is given in Section 3.2.6.3, Printer.
$YDLODELOLW\DQG6HFXULW\
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 OCS is designed to satisfy extreme demands for reliability, availability and security.
For further discussion of various aspects of reliability, availability and security, see separate
documentation. Some keywords follow:
• Solid mechanical and electrical construction
• Security against electrical interference
• High-quality components
• Well-tested electronic units
• Thoroughly developed and tested modular software
• Easily interpreted program language for application programs, AMPL
• Complete documentation
• Integral supervision and diagnostic functions
• Powerful tools for testing
• On-line replacement of faulty hardware units
• After-sale service
• Redundancy.
Below you can find important information regarding security. Descriptions of the provided
diagnostics and the possibilities of redundancy in the Advant Controller 450 also follow.
3URFHVV2XWSXWV%HKDYLRUDW,QWHUUXSWV
From the viewpoint of security, the behavior of the control outputs to the process in connection
to ordered or 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 CPU and I/O subrack).
In spite of the fact that an Advant Controller 450 is a very reliable system, reset of outputs to
zero cannot be guaranteed during all conditions. Always assume a combination of errors or an
incorrect system handling which can cause an output to behave in an unexpected way. This is of
great importance when it comes to personnel safety and preventing expensive technical
equipment from being damaged.
'XSOLFDWLRQIRU6HFXULW\
Duplication of control system functions is one way to ensure that all tasks are performed
correctly. It is, however, very important to emphasize that the security in a process control
system, when it comes to personnel safety, must never be based on duplication of system
functions alone. You must always consider other measures as well.
,QWHJUDWHG6DIHW\6\VWHP
In the most critical applications, a special design of the Advant OCS, the Master Safeguard,
is applicable. It is fully compatible with the rest of the Advant OCS products, including Advant
Controller 410/450. Master Safeguard operates on the same network and from the same type of
operator stations. Functionally, the Master Safeguard is almost identical to an
Advant Controller 410/450, and is configured and documented in the same way.
'LDJQRVWLFV
System level diagnostics, including the Advant Controller 450, have an error reporting and
indicating structure that makes use of system messages, console diagnostic displays and LED
status indicators to indicate the status of hardware.
Comprehensive system diagnostics not only detect problems, but also let an operator know
where a problem is located. The diagnostic features of the system provide for timely, reliable
detection and notification of both software and hardware errors.
The diagnostic philosophy for the Advant OCS is that single-fault situations are detected and
processed.
The diagnostics 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 use of diagnostics, among other things, see Chapter 5, Maintenance.
5XQ$ODUP5HOD\
The Advant Controller 450 provides one collective run/alarm relay for each processor module.
These relays are included in the supervision module TC520. The indicating contacts can be
reached via a connector on the module front. Within the limits of electrical data, you can use this
contact in any desired application function, for example, creating an audible alarm or
interlocking certain process objects in the event of a controller safety shut-down.
The main reasons for de-energizing the alarm relay and RSHQLQJthe alarm contact are:
• Fatal Error in CPU and memory
• Fatal Error in program execution
• Loss of power supply in the controller subrack
• Switch over depending on loss of communication on S100 I/O bus extension if
redundancy.
127(
Only a single contact function per processor module is available. They are
normally closed but are open when there is an error.
/(',QGLFDWRUV
Most of the replaceable hardware modules are equipped with LED indicators.
A green LED indicates running.
A red LED indicates fault.
Some modules provide additional yellow LEDs for increased maintainability, for example send
and receive information on communication modules.
,QGLFDWLRQVLQ$SSOLFDWLRQ6RIWZDUH
Diagnostics information is available in the data base and in PC elements, which means it is
possible to build up, for example, different control strategies with respect to the status of
relevant functions and hardware modules. It is also possible to arrange external fault
announcement of internal controller disturbances and faults.
6\VWHP0HVVDJHVDQG6\VWHP6WDWXV
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
– Processor module
– Power supply
– Auxiliary functions like fans, and so on.
– Communication
– Connected terminals and printer
– Process I/O boards and units.
Most of this information is also available with a connected engineering station, but the
engineering station is not arranged to suit an operator.
'LDJQRVWLFRI&38DQG0HPRU\
• Time supervision of operations
• Continuous parity check of RAM
– One-bit errors are corrected automatically
– Two-bit errors results in safety shut-down.
• Total check of RAM during start-up
• Supervision of checksums on program card
• Supervision of bus error.
3URJUDP([HFXWLRQ&KHFN
Execution check by “watchdog” is carried out with respect to three priority levels.
Task reference, supervision time and consequences at exceeded time are given below:
• Timer task - 100 ms - safety shut-down
• Application program - 5 s - safety shut-down
• Idle task - 30 minutes - system message about a system too heavily loaded.
'LDJQRVWLFRI,20RGXOHV
All I/O modules are checked regarding missing hardware or errors in the addressing logic.
It is common to all I/O modules that, if any error is detected, an alarm and a message go to the
operator. The error is also indicated with a red LED on the front of the board. The application
program handles necessary actions via the data base. Different types of I/O modules have
adapted diagnostics and error handling. For further information on this topic, see Chapter 5,
Maintenance.
'LDJQRVWLFRI3RZHU6XSSO\
• 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'LDJQRVWLFVDQG(UURU+DQGOLQJ
Adequate diagnostics and error handling are also available/possible for the following equipment
and functions:
• Communication links
• Terminal/printer connection
• Fans
• Redundant functions in general.
6XSHUYLVLRQ0RGXOH
The System Status Collector TC520 in the controller subrack performs certain system
supervision. Diagnostic signals from power supply units and fans within the cabinets are
connected to TC520.
The front connector of TC520 provides the connection for four extra user-defined supervisory
signals (24 V). Two of them are intended to be used for redundant I/O voltage supply
supervision. The signal cables may not be extended outside the controller cabinets due to the
risk of interference.
5HGXQGDQF\
In general, the following subsystems and functions are available with redundancy:
• Mains distribution network
• Voltage supply, 24 V
• Voltage regulation, 5 V
• Battery and charger
• CPU and memory
• Network communication
• GCOM
• MVI (Multi Vendor Interface) communication
• RCOM
• MasterFieldbus
• Advant Fieldbus 100
• S100 I/O Bus extension
• I/O module.
You can add redundancy within a specific controller in a flexible way to meet the desired
demands upon system availability.
The controller utilizes different principles of redundancy for included subsystems. Both hot
stand-by and independent parallel operation are used. Duplicated hardware is primarily used in
what is known as 1:1 implementation.
Maintainability is always provided by diagnostics, fault announcement and adequate unit
exchangeability.
0DLQV'LVWULEXWLRQ1HWZRUN
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 redundant a.c. networks, automatic
relay devices are used to maintain the power supply in case of a single network error.
The duplicated equipment is normally in parallel operation, sharing the load. In the event of a
single failure, the full responsibility is taken over bumplessly by one piece of equipment.
3RZHU6XSSO\9
Duplicated power supply units for 24 V d.c., secondarily wired by diodes, are utilized.
This is the same redundancy solution as for mains distribution network. The wiring diodes are
distributed to the 5 V voltage regulators in the controller subrack. When redundant powering of
I/O subracks is desirable, a voting unit is used.
9ROWDJH5HJXODWLRQ9
The stabilized 5 V supply is organized as n+1 parallel voltage regulator modules sharing the
load current. The n modules are required to meet the demand. The extra module gives what is
known as n+1 redundancy. In the event of a single failure, the full responsibility is bumplessly
taken over by the remaining equipment.
The n is equal to 1 in the standardized Advant Controller 450.
The 5 V supply is distributed as single supply to each module.
%DWWHU\DQG&KDUJHU
You can duplicate the battery unit and the backup power supply. The main reason to duplicate is
to double the battery capacity.
3URFHVVRU0RGXOH
Processor module redundancy is available. In this case, the controller contains two processor
modules, each including memory for system and application software. One processor 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 operation. You can replace the malfunctioning processor module while the
system is running. After the replacement is carried out, the system once again has a redundant
processor module.
If an error arises in the backup unit, you can also replace the backup unit while the system is
running.
Errors which occur in the backup unit can never affect the primary unit’s operation. The primary
unit and the backup unit are logically separated from one another.
Hardware errors in the primary processor module cause the system to perform a correct
changeover. These hardware errors are “single errors.”
The application programming and the communication are totally unaffected by the redundancy.
3URFHVVRU0RGXOH)DXOW7ROHUDQFH3ULQFLSOH
The principle of fault tolerance in the redundant processor modules is based on continuous
updating of the backup unit to the same status as the primary unit. This enables the backup unit
to assume control without affecting surrounding systems in a bumpless manner.
This principle involves dynamic division of the program execution into execution units and the
creation of rollback points at which the processor module’s status is completely defined.
In this context, the processor module’s total status is defined as the processor module’s internal
status, that is, the contents of the processor registers, plus the contents of the data memory.
The backup unit’s status is updated each time the primary unit passes a rollback point, enabling
the backup unit to resume program execution from the last rollback point passed, should the
primary unit fail due to error.
In order to minimize the amount of information involved in the update, the backup unit is
updated only with the changes taking place since the latest rollback point.
Between rollback points, these changes that writes in the data memory, are stored in a log 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 means the last execution unit is partially re-executed by the backup unit.
In order to re-execute a portion of the execution unit without affecting the peripheral units (I/O
and communication units), the peripheral units’ references are also logged between rollback
points. During re-execution, the results of the peripheral units’ references, which have already
been executed, are used, rather than re-executing them. The results of read operations are
retrieved from the log, and write operations pass without execution, since they have already
been executed. The peripheral units’ statuses, then, are not affected by the re-execution in any
way, except for the time delay which occurs.
The RAM included in the processor module provides automatic error detection and error
correction.
• If one bit becomes incorrect in a storage location, this is corrected automatically. If the
error repeats, a system message is sent to warn that the memory is about to become
defective.
• If two bits become incorrect in a storage location, the system changes over to the backup
unit.
1HWZRUN&RPPXQLFDWLRQ
There are two alternatives for network communication redundancy available.
Normally, the duplicated submodules are distributed to separate carrier modules, an
arrangement which provides maximum availability. See Figure 1-48.
You can also mount duplicated MasterBus 300 communication submodules in a common carrier
module. This gives rise to a common point of failure, that is, reduced integrity and reduced
availability.
2x MB 300
Submodule
carrier
Communication
submodule
CS513
)LJXUH 1HWZRUN&RPPXQLFDWLRQ$OWHUQDWLYH0RGXOH$UUDQJHPHQW
From a functional viewpoint, the redundant networks work in a hot stand-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 submodule which for GCOM is called CI543.
0DVWHU)LHOGEXV
The communication to a remote unit can be equipped with transmission media redundancy.
This includes:
• One communication interface submodule in the controller
• Two cables including duplicated modems
• One remote unit.
$GYDQW)LHOGEXV
The Advant Fieldbus 100 redundancy concept comprehends:
• Media redundancy
• Communication interface redundancy.
Media redundancy includes redundant cables and redundant modems.
Communication interface redundancy is achieved by using two interface modules CI522A
connected to a media redundant bus.
6,2%XV([WHQVLRQ
S100 I/O Bus Extension redundancy is available. In this case each I/O rack contains two bus
extenders. Each bus extender is connected to one processor module. The bus extenders that is
connected to the primary processor module is acting as primary, the others are backup (hot
stand-by). A faulty bus extender causes a processor module changeover by stopping the primary
processor module. The previous backup processor module is now acting as primary processor
module and previous backup bus extenders, connected to the new primary processor module,
are primary bus extenders.
A changeover, due to a faulty bus extender, is only activated when all backup bus extenders are
functioning. If a faulty backup bus extender exists, 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 primary units operation. The primary
units and the backup units are logically separated from one another.
The application programming and the communication are totally unaffected by the redundancy.
,20RGXOH
The controller primarily uses single process functions, for example transmitter, valve, or switch.
However, for the categories analog input and analog output, there are special I/O modules which
can be duplicated. Different requirements for single loop integrity or signal redundancy are met.
Please refer to Section 1.7.6.1, S100 I/O.
Duplicated hardware is kept together in the data base as one object. From a maintainability
viewpoint, duplicated hardware is handled individually. Functionally, the redundancy is,
however, invisible to the control application program. Duplicated hardware is wired in a
common terminal panel or connection unit.
You can mix redundant and non-redundant I/O modules in any application-adapted way.
Bus
extension
I/O subrack
Board $
Connection
unit Transducer
I/O subrack
4-20mA
Board %
The principle of redundancy is hot stand-by or parallel operation, depending on the design of
each module. For example, analog inputs use hot stand-by. Analog outputs use parallel
operation.
0HFKDQLFV
&DELQHWV
$YDLODEOH&DELQHW7\SHV
An Advant Controller 450 is normally installed in one or several cabinets, depending on the
number of centrally connected process I/O signals. The cabinet type is RM500 and it is
available in two versions with different dimensions (RM500V1 and RM500V2).
Single as well as double cabinets are used to house an actual installation, or a combination of
single-double cabinets (not screwed together on delivery).
&DELQHW)HDWXUHV
Figure 1-50 shows a cabinet of the RM500 type. Features and applications are listed below:
• Normally, there are no intermediate walls between cabinets designated to one controller
installation.
Intermediate walls are used between different controllers in a row of cabinets or between a
controller and other equipment to suppress interference.
(QYLURQPHQWDO$GDSWDWLRQ
RM500 cabinets are available with the following degree of protection ratings according to
IEC529; IP21, IP41 or IP54.
Independent of the protection rating, the controller subrack is, for cooling purposes, always
equipped with a fan unit.
IP21, the basic version of the cabinet, is ventilated by openings in the lower and upper end of
the door.
IP41 is ventilated by openings in the lower and upper end of the door. The openings are covered
by netting with openings 1mm2 or less.
127(
A heating element is mounted in the bottom of the IP41 cabinet. This heating
element shall be activated when the equipment in the cabinet is inactive.
The sealing in IP54 results in a decrease of permitted power dissipation compared to IP21 and
IP41. Please refer to Section B.6, Permitted Power Dissipation. Actions must be taken in certain
applications, for example, a heat exchanger can be installed.
(OHFWUR0DJQHWLF&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 information about the environmental immunity, including EMC qualities with or
without CE-marking, please refer to the data sheet ³$%%0DVWHU(QYLURQPHQWDO,PPXQLW\”.
&DELQHW&RQILJXUDWLRQ
Depending on the number of circuit boards necessary to control the process, an
Advant Controller 450 installation can contain up to one controller subrack plus five I/O
subracks located in up to six cabinets.
The controller subrack is always installed in the left-hand cabinet.
Single or double cabinets are used. Only the last one (to the right) can be a single cabinet.
I/O subracks and their associated connection units are, where possible, located in the same
cabinet.
You can add an extra cabinet (number seven) to the right of a given configuration, if necessary,
to house connection units. This cabinet cannot contain an I/O subrack.
For connection units in the extra cabinet, use extended-length cables to join the I/O subracks.
The controller subrack is mounted close to the rear backplane of the cabinet.
An I/O subrack is mounted in a hinged frame while the connection units for the different
I/O boards are mounted in the rear backplane. Use the 24-inch installation width for the
connection units in RM500V1.
Figure 1-51 shows a W\SLFDO cabinet configuration in a RM500V1 cabinet.
The location of subracks, 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
I/O Subrack
Controller Subrack
Modem Subrack
Connection Units
Power Supply
(SA16x)
6XEUDFNV
Many of the Advant Controller 450 components are installed in subracks. Subracks are fitted
with guide bars for circuit boards and other plug-in units. Each unit is connected to the
backplane of the subrack. There are two variants of subracks, both based on a 19-inch standard:
a controller subrack which houses the processor module and the various communication
modules and an I/O subrack which houses the S100 I/O.
&RQWUROOHU6XEUDFN
This subrack exists in one standard height, 400 mm, which includes a cable duct and fan unit.
The disposition of slots is shown in Figure 1-52.
30 30 65 65
B
l
i
9ROWDJH 9ROWDJH
n
5HJ$ 5HJ%
d
(option)
(op-
Pos 3.2 tion)
%DFNXS 6
%DFNXS
3RZHU 3RZHU X
6XSSO\ S
6XSSO\
H
$ %
U
(option) Y
Pos: 1 2 3 4 5 6 7 8
)LJXUH $GYDQW&RQWUROOHU&RQWUROOHU6XEUDFN6
All modules are individually fixed to the subrack with a locking device.
All connections are made from the front.
,26XEUDFN
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 functions. An I/O subrack is connected to the controller subrack and to the next I/O
subrack via the bus extension board, position 21 (20 and 21 in case of S100 I/O Bust Extension
redundancy).
)LJXUH )URQWRI,26XEUDFN
A locking bar at the upper front edge fixes the I/O boards once they are inserted.
An I/O subrack can be powered by a single 5 V regulator unit or redundant 5 V regulator units
located at the 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.
Connection cable
Plug-in units
)LJXUH ,26XEUDFN&RQILJXUDWLRQ
The rear side of an I/O subrack must be accessible. This is achieved by mounting the I/O
subrack in a hinged frame.
6XEPRGXOH&DUULHUDQG6XEPRGXOH
Submodule carriers are modules which fit the controller subrack only.
Carrier modules have no complete function. A carrier module has slots for specialized
submodules.
You can obtain the desired functionality by mounting submodules into the carrier module.
This is illustrated in Figure 1-55.
Submodule
carrier
Submodule
Submodule
Submodule Carrier
Submodule
Submodule
Inserted
submodules
6LGHYLHZ )URQWYLHZ
(Advant Controller 450
Controller subrack)
)LJXUH &DUULHU0RGXOHDQG6XEPRGXOH0HFKDQLFV
8VHU,QWHUIDFH
A normal controller installation uses different operator’s interfaces. A division into two main
categories can be seen with respect 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
Chapter 5, Maintenance.
Chapter 2 Installation
This chapter contains guidelines for planning the installation of your Advant Controller system,
see Section 2.1, Site Planning Environment. In addition, this chapter also describes the concrete
installation procedures on site, specific to Advant Controller 450, see Section 2.2, Setup.
This chapter does not, however, provide a complete list of measures to take with respect to
environment and other conditions on site. The equipment should be adapted to the actual
application by way of thoroughly accomplished system definition, ordering and design. You can
find descriptions of alternative solutions, design considerations, elsewhere in this manual.
Since each Advant Controller system is designed to meet your specific requirements, there is no
standard configuration that describes every system. Therefore, certain areas of the following
instructions are meant only as a guide for planning your specific installation. However, some of
the information covers specific requirements for proper system and equipment operation - you
cannot modify these requirements. The difference between a recommendation 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.
• The free space in front of cabinets. Also reflect on how much space is required to fully
open either a left-hand or right-hand hinged cabinet door (both exist). There must always
be space left for safety reasons even with open doors.
• Spare area for future enlargement of the equipment.
• A well-developed process connection, with or without marshalling facilities.
• Grounding by an effective net of copper bars.
• Cable routing with respect to installation rules.
• Availability of power and other utilities.
• Standards and legal regulations to be followed.
The following sections examine some of these factors in detail and provide recommendations
and requirements as necessary.
General
The Advant Controller system is designed for a demanding industrial environment. Alternative
cabinetry is available for different degrees of protective rating (IP21, IP41, IP54). Interference
from electrical sources is suppressed 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 conditions which Advant OCS products are designed to withstand, during
storage and transport as well as during operation, are specified in a separate environmental data
sheet. Limit values are given to: Corrosive gases, Temperature, Vibration, Moisture, Electro-
Magnetic Compatibility, and so on.
Most applications need no special arrangement. Standard cabinetry and installation according to
the rules suffice. Occasionally, you must consider special protection with respect to particular
situations.
Sealed cabinets are a good basic solution to prevent damage to electronic equipment from,
for example, corrosive gases, moisture and dust. However, sealing prevents the normal cooling
resulting from self-convection or forced cooling by a fan. In turn, this reduces, to a large extent,
the heat dissipation permitted in a cabinet.
Temperature
It is important to note the temperature within cabinets and in the surrounding environment and
atmosphere. Lower temperatures mean increased system reliability and availability.
The lives of wet, electrolytic capacitors and most semiconductors are greatly reduced if the
maximum permitted temperatures are exceeded.
For more information on design considerations, see Section 3.1.10.2, Heat Dissipation
Permitted in Cabinets.
Vibration
The cabinets must stand on 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 that are perceptible, but not
excessive). If vibrations or shock are a major problem, consider more extreme measures to
alleviate the problem.
Cabinetry
According to information given in the ordering documentation, Advant Controller 450 shall be
located in a EMC-proof cabinetry. Please note that the requirement is valid to controller cabinet,
I/O cabinet and connection unit cabinet, 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 cabinet, can be set up side by side with other cabinet types
and other equipment types, but the cabinet side plates must be ordered or not be removed if
included at the delivery.
Where several electronics cabinets of the same type, related to one controller with
S100 I/O, are to be set up in the same row, however, it is permissible to leave out or remove the
side plates between the cabinets.
General
• An Advant Controller 450 with I/O, ordered on one set of price lists, is designed with
cabinets that are to be placed side by side (no plates between the cabinets).
• All cabinets (single or double) sharing the same bus extension for S100 I/O (maximum
12 m) are connected to the same power switch. Exception; cabinets housing I/O with
object oriented connection units have a special arrangement, see figures below.
• An Advant Controller 450 with I/O is delivered in a number of single or double cabinets.
• 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 subracks.
• An I/O subrack is not filled with more than 18 (17) in case of S100 I/O Bus Extension
redundancy) boards, two empty slots are kept as spares for the future.
• The number of boards in an I/O subrack is limited to either the 18 (17) available slots in
the subrack or the available space for connection units within the double (single) cabinet.
• In each double (single) cabinet, space for one mounting bar (for connection units) is left
unused.
• The boards are placed in the I/O subracks in the order AI, AO, DO, DI starting in subrack
no. 1.
PS PS PS
SW
Mains
Conn.
units
PS Power Supply
SW Power Switch
I/O 2 I/O 2
PS PS PS PS
SW SW SW
Figure 2-2. Distributed Location of S100 I/O Cabinets (Example of Cabinet Configuration)
I/O 1
PS
SW
Mains
Ex., 2 subrack
Bus Extension, El. alt.
Opto
I/O 1
I/O 2
PS
SW
Mains
Ex., 3 subrack
Bus Extension, El. alt.
Opto
I/O 1 I/O 3
I/O 2
PS PS
SW SW
Conn.
units Mains Mains
PS Power Supply
SW Power Switch
Figure 2-3. S100 I/O with Object Oriented Connection Units (Example of Cabinet
Configuration)
• Normal start configuration is a double 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.
2.1.5 Grounding
Grounding in General
The signal processing electronics in Advant OCS, as well as all interference suppression for
external signals, are normally directly grounded to chassis and plant earth.
The plant earth potential must be stable and well defined, even in the event of ground fault in
low- and high-voltage equipment or lightning stroke. This claim for a grounding system is
common to the high-voltage equipment. The earth line joining the grounding systems should be
≥35 mm2 Cu.
Cabinetry
or equal
Protective
earth
Earth line
≥35 mm2
Protective Earth
Always provide Advant OCS cabinets supplied with 230 V a.c. with a protective earth.
hinders the use of connection units for voltage distribution. In such cases, you can use a bar with
the terminal block and fuse equipment required by the application.
If the transducer has galvanic isolation of the supply from the electronics otherwise, you can
ground its signal zero freely and where it is most suitable for measurement accuracy without
special voltage supply requirements such as group division, fusing and grounding.
2.1.6 Cables
When you are planning for the cable routing in the plant and selecting suitable cables to use,
there are some restrictions and rules to follow. These touch upon, among other things:
• The distance between Advant OCS cables and non-Advant OCS cables.
• The routing of communication cables.
• Mixing of signals and signal types within cables.
• The need for shielded cables.
For further information, please refer to the general document, Interference-free Electronics
Design and Applications, which also gives examples for choosing cables.
All cables are normally guided into a cabinet from below.
General
Normally, supply voltage to Advant OCS supply units and for field equipment 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 C is always an a.c. supply, regardless of whether a.c. or d.c. is utilized otherwise.
Preferably supply C should be an uninterruptable power supply. In situations where redundant
network A/B is used you can order a power distribution unit, SV542/543, which includes a
selector relay and an isolation transformer. The relay selects between, for example network A
and B and the transformer makes a secondary grounding of the network possible (adaption
class III/class II).
Class II, class III states the network quality with respect to for example, level of disturbances,
voltage variations, and so on. (according to IEC standards). Class II denotes higher quality than
class III.
You can use power supply units made by other vendors for, for example sensor supply, and
locate those units in an I/O cabinet. Such units must satisfy interference requirements in
accordance with the relevant standards in the same test classes as the Advant OCS equipment
and they must be CE-marked if equipment is going to be used within the EU and EFTA area.
Safety Switch
Close to the controller installation, there should be a safety switch enabling total power supply
disconnection of the equipment. This means a common switch for all supply voltages,
for example networks A, B and C discussed above.
The main use of the safety switch is to disconnect the power supply in a clear and safe way
during work in the cabinet.
Install the safety switch in a visible place (outside any cabinetry) within 3 m of the controller
installation.
a.c. Supply
Essential information includes:
• For the supply A (and redundant B) class II or class III a.c. networks can be used
alternatively as a standard solution.
• For the supply C there are different options. Select a suitable power distribution unit with
respect to available class II and class III networks and your requirement on redundancy.
See Table 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 an isolating d.c./d.c. convertor.
• Supply C is always an a.c. supply, see heading above.
Protective Earth
Always provide Advant OCS cabinets supplied with 230 V a.c. with a protective earth.
Consider such an alternative at an early stage in the design to ensure that it is located in the
cabinet to give optimum cable lengths.
Wiring is routed to different transducers and loads in the installation from the marshalling.
It is important that the leads to and from a transducer for an electric signal be in the same cable.
This requirement means that it is logical to distribute 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 connection unit can then be
dimensioned to protect the cable in the event of a short circuit.
Connection - +
unit
- Box 1
+ 0.1 A
Obj.1
0.1 A
1A Cable 1
1A
Obj.2
Box 2
0.1 A
Obj.3
0.1 A
Channel 1 Cable 2
0.1 A
.
. Obj.4
5
Obj.5
To ensure adequate ventilation, there should be a free space, 150 mm high, between the top of
the cabinet and the ceiling or the underside of any beam, duct or similar structure over the
cabinet. When cables enter the cabinet from above, 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 - 300 mm (11.8”)
– cabinet RM500V2 - 350 mm (13.8”).
• At hinged side of single door cabinet
– cabinet RM500V1 - 760 mm (29.9”)
– cabinet RM500V2 - 660 mm (26.0”).
• At hinged side of double door cabinet
– cabinet RM500V1 - 382 mm (15.0”).
The free space in front of the cabinet should be the width of the door plus the width of the aisle.
If a double door alternative is used, reflect the space required for any hinged frame. There must
always be space left for safety reasons even with open doors or frames bent outwards.
For dimensions of the RM500 cabinet type, see Appendix B, RM500 Cabinet - Data Sheet.
You can also find the estimated weight of a cabinet in that section.
NOTE
Please, observe lifting instructions enclosed with the cabinet!
2.2 Setup
The goal of this section is to tell you “how to” set up the product.
Follow the sequence of activities prior to power-up described below.
It is assumed that 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 double)
which are to be placed side by side.
Apply the setup instructions with respect to the specific design!
See Section 2.2.1, Safety Regulations through Section 2.2.7, Power Supply Connection for
general information, followed by individual setup descriptions for different parts of the
automation system. You can find this information under the following headings, if relevant:
• Assembly
• Electric Installation (including Power Supply)
• Functional Measures
• Preparation for Start-up.
Ordinary installation drawings, terminal diagram forms and connection documents for site
preparation and installation of electrical equipment also apply.
Necessary Outfit
The following kit is a minimum requirement:
• Ordinary hand tools.
• Universal instrument, for example digital multimeter.
• Test leads with 4 mm banana contacts and reducer contacts for a 2 mm test jack.
• Necessary parts of the documentation listed in Section 1.4, Related Documentation.
CAUTION
Observe the following safety rules:
• Avoid discharges of static electricity by grounding both yourself and tools before handling
circuit boards and other parts of the equipment.
• Use the grounded wristband installed in the cabinet when handling parts of the system.
• Handle the circuit boards carefully, particularly those which contain MOS components
which can be damaged by static electricity discharges. Note the warning label on the
circuit boards.
• Use, as far as possible, the grounded wristband when handling boards not stored in
envelopes of conductive plastic. This gives optimum protection against static electricity
discharges.
• Always store circuit boards in envelopes of conductive plastic when not installed in the
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 possible damage by ESD
(Electro Static Discharge).
NOTE
Please, observe lifting instructions enclosed with the cabinet!
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 not necessary.
If required, you can remove the side plates on the sides in contact when two or more cabinets
related to one controller with I/O are installed next to each other. The width of the cabinets is
reduced by 20 mm for each end panel removed. The side plates should remain in place, as
protection, on any cabinet which generates any degree of interference.
2.2.5 Grounding
This section shows you where to ground in an Advant Controller cabinet. If necessary, it also
shows you how to ground.
You should be aware of the common Advant OCS Installation Rules, which establish the
principles of grounding and answer the questions of when a piece of equipment, a circuit or a
cable shield should be grounded and why it should be grounded. It also gives alternative
solutions adapted to specific plant requirements.
2.2.5.1 General
A RM500 cabinet forms a stable ground plane for all equipment accommodated.
The signal processing electronics in the controller, as well as all interference suppression for
external signals, are normally directly grounded to chassis and plant earth.
General
Advant OCS or rather the application itself put some limited requirement on cable shielding.
Only a few types of process signals must be shielded and treated in a special way in the
controller cabinet. In the continued description of CE-marked and not CE-marked controller
design these cables are denoted category A and they include:
• Low level analog input signals
– Accuracy requirement shall be greater or equal to 12 bits
– Pt 100 and Thermocouple.
• High-frequency pulse transmitter signals.
Normally a single shield is used and it is grounded in the controller end of the cable.
Sometimes the application require a local grounding of the cable shield close to the transducer.
Specific rules apply then.
By different reasons other field cables may be shielded too. For example following a
company/plant standard. There is no requirement from the controller viewpoint. These field
cables are denoted category B.
Unshielded process I/O cables can be mixed with shielded process I/O cables.
Common to all cabinet designs is the horizontal mounting bar at the left hand side of the cabinet
inside, close to the bottom of the cabinet. They can be used to mechanically anchoring all types
of field cables, shielded and unshielded, when entering the cabinet.
CE-marked Design
Shields of category A cables which are to be directly grounded in the cabinet must be grounded
to the cabinet chassis, cable ducts or connection units, according to Figure 2-8. Use a short lead
(<50 mm) and thread-cutting screws.
Connection unit
≤ 5 mm (2”)
Connection of shield
X in cable duct with
tapping screw ST3.5x9.5
Process
I/O Cable
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 locally at the transducer are alternatively
to be connected via a capacitive decoupling device, located in the bottom of the cabinet.
That is similar solution to that used for certain communication cables. See Section 2.2.5.5,
Grounding of Communication Cable Shields.
Shields of category B cables can be handled in the same way as category A cables.
Cover
Shielded cables of the category A which are grounded locally at the transducer shall be left
ungrounded in a cabinet which is not CE-marked.
After anchoring and grounding of a category B cable shield in the horizontal mounting bar you
are free to cut the shield wherever it is most practical.
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 whole installation of the communication bus to
comply with a main rule: A bus communication cable shield must be directly grounded but only
in one end of the bus. That is in the cabinet where the first/last connected Advant Controller (or
other node) is located.
There is a supplement to the installation information given in separate communication user’s
guides.
CE-marked Design
I addition to the general instruction found above, further interference suppression of the cable
shield is made at the enclosure port by individual methods adapted to the different types of
communication. The schematic principles of direct grounding and h.f. grounding by a capacitor
are shown in Figure 2-10.
In one end
only
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.
Attachment Communication
of the Cable Cable
Capacitive
Decoupling
Unit, TX507
Expose shield
20-30 mm
(0.8-1.2”)
Cabinet Floor
Figure 2-11. Communication Cable Shield Grounded by Capacitor and Ferrite Coil
Each unit takes up to four communication cables and it also provides the mechanical anchoring
of the cable. Two units can be mounted side by side or, if necessary, on top of each other.
Certain spacers are used then. This imply a maximum of 4 units on a mounting bar (16 buses).
A split ferrite core should be used on each communication cable. They should be mounted at the
cabinet entry, see Figure 2-11, and have a series impedance of 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.
2.2.5.6 Grounding of “Internal” System Cable Shields, Connection Unit -- I/O Board
General
Use shielded cables to join distributed (> 3 m) 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.
I/O
subrack Connection Process
unit connection
I/O
board
Shielded cable Tinned
> 3 m (10 ft.) surface
CE-marked Design
A EMC-proof cabinet must be used for the I/O subrack and the connection units as well.
The cable shield shall be grounded in both ends according to Figure 2-12.
You must follow the main rule: Do not ground a signal at different points in the plant.
Cable duct
Connection unit
Cable
Mounting rail
There are some restrictions in mixing cables within a cabinet due to the risk of interference.
To describe the simple rules applicable at site installation, cables are divided in categories.
See Table 2-2 and the following rules:
• Within a category, you can mix cables arbitrarily.
• Keep the distance between cables belonging to different categories ≥50 mm.
• “Cabinet internal” couplings have their own defined spaces for routing.
Always keep the distance to other cables ≥50 mm.
2.2.7.1 General
Cabinets erected side by side, including a controller and I/O configuration, are regarded as a
unit which is joined to the power supply network at one single connecting point, a centralized
power switch unit. The switch unit is normally located in the controller cabinet.
The power supply is distributed to the I/O cabinets according to application. The power supply
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.
2.2.7.2 Installation
General
Ordering documents show which power supply alternative is applied.
An a.c., d.c., redundant or non-redundant supply is connected to the controller in the same way,
in principle. A terminal diagram form enclosed at delivery shows the relevant physical item
designations and connection points in the cabinet. You will also find the denominations supply
A, B and C applicable.
A summary of the main requirements of the networks A, B and C are given in Section 2.1.7,
Power Supply and Fusing.
The installation work to be done, supported by the terminal diagram form (circuit diagram), is:
• Connect network A
• Connect network B (if redundancy)
• Connect network C
• Connect the power supply units located in I/O cabinets. Use the ready-made cables and
plug-in contacts. They are marked with the destination item designations.
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
protective shield plate should be remounted.
2.2.8 Controller
Assembly
All equipment included in the controller is factory assembled. Cabinet arrangement and similar
questions are dealt with in the general setup instructions above.
Electric Installation
Apart from the process I/O connections and communication connections, which are treated
separately, there is little electric 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
enclosed at delivery.
Run/Alarm Relay
RB
9 Processor
Ind. B RB Module B
10 RUN
Configuration: No
AC 450
External clock TC520
S SYNCIN
12
SG COMM.SYNC
13
AC 450 TC520
Diagnostics at redundancy System status
(normally factory installed) display in
Voting units/Optical S100 bus extension modems operator station
A1 STATUS A1 (I/O) 24VA
1 or F1
A2 STATUS A2 (I/O) 24VB
2
or F2
AG COMMON A
0V
3
FAIL 24 A
FAIL 24 B
B1 STATUS B1 F3
4
Application notes
. 24 V d.c. inputs (A1, A2, B1, B2)
B2 STATUS B2
F4
. A1, A2 Alternative applic. (configurable):
5
BG COMMON B
- According to figure 6
Supervision of (I/O) 24 VA, (I/O) 24 VB
Error state = 24 V
- Free disposition
Supervision of F1, F2
Error state = 0 V or disconnection
. B1, B2 Free disposition
Supervision of F3, F4
Description/Configuration:
DB element AC 450
Error state = 0 V or disconnection
. Signal cables may not be extended outside the
controller cabinets due to the risk of interference
Functional Measures
• Adjust all included communication modules designated CS513 (MasterBus 300,
MasterBus 300E) with respect to the actual configuration before a power switch on.
You are directed to set the following by jumpering:
– Network number
– Node number
– Slave number
– Protocol type.
For instructions, see the manual MasterNet User’s Guide.
The data base elements in Advant Controller holding the corresponding data are
automatically updated at power-on/initialization.
• Set the start mode selector on the CPU module front (PM511) in the CLEAR position.
Assembly
The different parts of the bus extension are mainly factory assembled. These include:
• Bus master module which is included in PM511 in controller subrack
• Slave boards DSBC 174 or DSBC 176, located in each I/O subrack (two per I/O subrack in
case of S100 I/O bus extension redundancy, only valid for DSBC 174)
• Ribbon cables connecting subracks within a cabinet.
You are supposed to make the interconnection of the bus extension between cabinets.
Cabinets should be arranged side by side in a designated order. Ribbon cables with adapted
lengths are enclosed at delivery. The cables are marked with item designation at the connectors.
Electric Installation
Make use of the enclosed ribbon cables to interconnect the bus between the cabinets. Such a
cable is connected at one end and temporarily wound up and hung up on the wall side.
Figure 2-20 shows an example of a non-redundant installation. The actual ribbon cables are
illustrated with a thick line.
Controller Subrack
S S S
I/O Subrack I/O Subrack I/O Subrack
M
1 2 4
S S
I/O Subrack I/O Subrack
3 5
DSTC 176
M indicates master module in PM511 Termination unit
Connection on module front
S indicates slave module DSBC 174 or DSBC 176
Connection from behind
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 for I/O subracks.
Carefully fix the ribbon cables to fixing bars or the like with the help of cable straps.
If for some reason the cabinets are not arranged side by side then the bus extension cable must
be routed separated from other cables (>100 mm). A CE-marked design put the requirement that
the extension cable shield is additionally grounded by the cable clamp in the cabinet floor.
Functional Measures
Address Jumpering (DSBC 174, DSBC 176)
The jumpering group S1 defines the boards I/O address. Instructions on how to set a bus
extender board address are given in the S100 I/O Hardware Reference Manual.
Functional Jumpering
All jumpers in jumper group S3 on DSBC 174 are open when the bus extender is used in
systems based on CPU PM511 (and closed when used in systems based on CPU PM510).
Preparation for Start-up
Please see the general checklist in Section 2.2.15, Checklists.
Assembly
Circuit boards and connection units are normally factory assembled. 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 address, H’20 are
hard related to each other and supported by the configuration tool when creating the data base.
(Normally, this relation is never changed.) However, the relation to the physical location is
determined when the equipment to be delivered is designed. Initially, standard location is
followed, see Section 2.1.4, Standard Layout and Disposition of Cabinets. Customized layout is
possible whenever applicable.
Reorganization of boards and connection units is “theoretically” possible. I/O board addresses
are not hard related to physical location. The board itself is carrying the address. The question
is, are there sufficient cable lengths (board-connection unit) to do the work?
A reorganization also calls for changing the documentation of the equipment.
Electric Installation
Distributed Connection Units
Distributed (3 m - 15 m) connection units are joined to the I/O boards by adapted shielded
cables with plug-in connectors. The following instructions apply:
• Outside the I/O cabinet, route the cables separately from other cables.
– 100 mm distance in general to other cables
– 300 mm distance to cables conducting power supply >250 V a.c.
• Cable routing in cabinets, see Section 2.2.6, Cable Routing in Cabinets.
• Grounding of cable shields, see Section 2.2.5, Grounding.
Process Signals
Process signals are connected to the connection units according to site installation drawings
supported by:
• Assembly drawings enclosed at delivery
• Terminal diagram forms enclosed at delivery
• Connection examples in S100 I/O Hardware Reference Manual.
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.
• 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.
Functional Measures
Address Jumpering
All circuit boards are adequately jumpered with respect to address at the factory.
If you need them, you can find instructions on how to set an I/O board address in the
S100 I/O Hardware Reference Manual.
Functional Jumpering
There are some board types that require jumpering to determine an application function,
for example, selection of current/voltage signal, mains frequency, grounding, and so on.
Functional jumpering applies to the board types and connection unit types listed in Table 2-3.
Please check the relevance for your application and follow further instructions for the specific
board type/connection unit type given in the S100 I/O Hardware Reference Manual.
Readjustment
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 found in Section
5.5.12, Channel Adjustment on AO Board.
most effective to maintain the check from the automatically generated process I/O object
displays. The application data base must be loaded.
CAUTION
When you use a somewhat tougher method, be aware of the risk of “accidents.”
Short-circuiting and over-voltage can damage a limited part of the equipment,
for example, a process I/O board.
Power Supply
If you do not use a modem when communicating with a printer or a video terminal, you must
take an a.c. voltage supply with a protected earth (PE) from the Advant Controller cabinet, it is
not acceptable to use the closest or otherwise most convenient supply receptacle.
Make the connection as shown in Figure 2-21. The significant aspect is that the peripheral unit
should be grounded in the controller protective earth.
Advant
Controller Printer/
Video terminal
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
d.c.
a.c. d.c. powered system
no a.c. available
You are directed to always check that the utilized a.c. power supply meets the quality
requirements of the peripheral unit, (for example the class of the network).
Take into consideration the extra load caused by any peripheral unit:
• When an intermediate isolating transformer is used in the cabinet to convert a two-phase
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.
2.2.12.1 Printer
Assembly/Location
See instructions enclosed with the actual printer.
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 delivery documentation for the controller for information regarding location of
the communication module and the modem.
Cable routing in the cabinet is shown in Section 2.2.6, Cable Routing in Cabinets.
From the viewpoint of the Advant Controller, there are no restrictions on the mains power
supply of the printer, for example, no requirement for earthing and same supply. The controller
and the printer are galvanically isolated from each other by the communication modems.
Advant Controller
Line
Modem connections Modem
TC562 1 3 DSTC
2 4
3 1 X008
4 2
Shield 5 5 Shield
N L PE
Data Value
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 72
per line
Printer speed 160 characters/s
2.2.13 Communication
Please refer to the following separate documentation:
• 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 routing, and so on, see general information in
Interference-free Electronics Design and Applications.
A carefully accomplished electric installation is the basis of future interference-free operation.
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 Controller 450.
2.2.15.3 Supply
Table 2-7. Supply
Circuit boards Variant reference Check for lowest revision approved variant to
be used for the equipment and use replace-
ment of the same or higher revision number.
This item is mainly relevant to maintenance
and use of spare parts.
Circuit boards Assembly Check that all units located in the subracks
are properly inserted.
Analog input circuit Full accuracy in the DSAI 130A + DSTA 135 (131)
boards frequency range
The other analog units can have for some
frequencies in frequency range 0.15 MHz to
60 MHz error > 0.2%
(1) This application does not meet the limits for emission and therefore is not generally allowed within
the EEC area (EU, EFTA).
Communication with- Routing of cables More than 100 mm (3.9 inch.) away from
out modem other cables
MasterBus 300 Cable length Multiple of 23.4 m max. 500 m (1640 ft.)
MasterBus 300E Joints At odd multiple of 23.4 m (77 ft) (1, 3, 5 . . . .)
GCOM
(Ethernet) Outdoor installation Teflon cable in conduit which is grounded at
both ends.
An additional earth line > 35 mm2 routed in
parallel with the conduit and grounded at
both ends.
2.2.15.9 Miscellaneous
Table 2-12. Miscellaneous
Necessary Outfit
No special kit needed.
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.
Emergency Shut-down
An emergency stop should always be available. Adapt it to local statutory regulations. This is an
obligation of those responsible for the plant design and construction. The controller system does
not supply this specially arranged function.
NOTE
Check the location of the emergency stop and use it in an emergency
situation.
From an electrical and functional viewpoint, an emergency stop has the same consequences to
the controller and attached equipment as a safety shut-down. See below.
Safety Shut-down
The controller and its S100 I/O mounted in a row of joined cabinets are, from the mains power
supply viewpoint, an entity. Safety shut-down aimed at disconnecting the controller from the
mains is carried out in two ways:
• As prescribed in the site planning section, 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 the plant section controlled.
Since the safety switch is a plant component, this document cannot stipulate and describe
the design exactly. Please check the plant documentation in this respect carefully.
Instructions indicating the extent of the power supply shut-down should be attached to the
safety switch.
• You can also create a selective power shut-down of the entire electronics system using the
mains circuit breaker in the lower part of the cabinet where the controller subrack resides.
The breaker is labeled S1.
This circuit breaker sometimes also disconnects the field equipment supply for the plant.
NOTE
Sometimes exist several breakers. See Section 2.2.7, Power Supply Connection
Manual Stop
Besides the most drastic shut-down method—disconnecting the power supply—other methods
of “stopping” the controller are available to you.
You can stop program execution as follows:
• Use the operator’s interface on the processor module front.
– Set the start mode selector in 2 (STOP) position.
– Depress the ENTER button and the system stops.
• Use an engineering station connected to the controller.
– Command ECONFIG in an adequate session.
The result of a stop and its consequences are compatible for the two manual stop methods:
• Application program execution immediately stops.
• There is zero output to the process objects.
• Output relays are de-energized.
• There is no loss of process data (besides what is happening in the process in the
meantime).
• The system is ready for a restart. To perform a restart:
Set the start mode selector in 1 (AUTO) position and depress the ENTER button or
Command DICONFIG.
Automatic Stop
For the sake of completeness, the main reasons for an automatic stop are listed below:
• Loss of power supply
• Fault in power supply
• Fault in central processing unit and memory
• Other fatal error.
The result of an unintentional stop and its consequences are, from the viewpoint of design
philosophy, the same as for a safety shut-down (see above). However, when there is a fault
involved, other behavior must be taken into account.
After necessary measures, a restart can take place.
Necessary Outfit
The following kit is a minimum requirement:
• Ordinary hand tools.
• Universal instrument, for example a digital multimeter.
• Test leads with 4 mm banana contacts and reducer contacts for a 2 mm test jack.
• Necessary parts of the documentation listed in Section 1.4, Related Documentation.
• Specific documentation enclosed at delivery.
• Advant Station 100 Series Engineering Station.
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.
2.4.2.1 Power-up
If, for some reason, you desire a limited power-up, the minimum equipment necessary is:
• Processor Module PM511 including a program card
• Submodule Carrier SC5x0.
1. Check that the circuit breakers on the power switch units are switched off.
There is one circuit breaker for mains A (labeled S1) and one for mains C (labeled F1).
Redundancy adds another circuit breaker for mains B (labeled S1).
Reflect the relevance of:
– Power switch in the cabinet housing the controller subrack
– Separate power switch in any cabinet housing S100 I/O subrack with object oriented
connection units (OOCU)
– Separate power switch in physically distributed cluster of S100 I/O subrack.
2. Set the start mode selector on Processor Module PM511 in 3 (CLEAR) position.
NOTE
The CLEAR position is the only possible choice when you power up for the
first time.
processor module will be PRIMARY while the right processor module will be
BACKUP. Chapter 4, Runtime Operation explains alternative ways of starting.
See Figure 2-25.
There are also some negative indications, for example:
– Backup Power Supply SB511 (or SB510) red LED F (Fault)
red LED BF (Batt. Fault)
(Indicating that battery is not connected)
– S100 I/O boards red LED F (Fault)
(Indicating that the boards are not implemented)
– S100 I/O Bus Extenders DSBC 174 or DSBC 176 yellow LEDs INIT
and INHIB
(Indication that the boards 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 configuration by connecting the engineering station
directly to the processor module service port. If redundant processor modules connect to
the primary module. Configuration is also possible via the network if applicable and
desirable.
9. Finally, set the start mode selector on Processor Module PM511 in 1 (AUTO) position.
Repeat for an eventually redundant processor module.
WARNING
Do NOT push the ENTER button!
If correct indications fail to appear, trace the fault in accordance with the instructions given in
Section 5.5, Fault Finding and User Repair.
Controller cabinet
. SR511
Green LEDs, 5 V and 2 V
SB511
Green LED, IP
PM511
P2 Display
Green LED, RUN
SX554
Green LED, LIVE (24 V)
Circuit breaker(s)
S1, F1
2.4.2.2 Initialization
The power-up achieved by following the above instructions produces an automatic
initialization.
In general, you can start an Advant Controller 450 in four different ways, as selected with the
selector Start Mode on the processor module front. These ways and applications are described in
Chapter 4, Runtime Operation.
You can redimension in a later stage, but it is time-consuming work. The general rule is to plan
well from the start. Always dimension the spares!
Application
analyses
System
definition
Controller
system
configuration
Dimensioning
Creating
Data entry
(fill in)
From a configuration viewpoint, not all functions to create the infrastructure of the controller
are treated in the same way. Some of them are touched by all activities illustrated in the figure
above. Some are automatically included in the controller system and need only limited data
entry. For an overview, see Table 2-13, which features an outline 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, Configuration/Application Building for considerations, the maximum number of
items, and so on.
For data entry details, see the manual Data Base Element Reference Manual.
Table 2-13. Function List with an Outline of Controller System Configuration Information.
Table 2-13. Function List with an Outline of Controller System Configuration Information. (Continued)
Data Set Peripheral Yes CRDB DSP DSP_x Demand Basic cycle time can be
changed via APP command
PROFIBUS-DP: Yes CRDB CI541 PBx Demand
--PROFIBUS Slave CRDB PBS PBSx Demand
--PROFIBUS Slave CRDB PBSD PBSDx Demand
Descr.
LONWORKS: Yes CRDB LON LONx Demand When LON is created it
LONWORKS Device Yes CRDB LONDEV LONDEVx Demand automatically creates 2
LONCHAN channel data
LONWORKS Network Yes CRDB LONNVI LONNVx Demand
base elements, specify type
variable of input type
CI572 or CI573.
LONWORKS Network Yes CRDB LONNVO LONNVx Demand
variable of output type
LONWORKS Multiple Yes CRDB LONMNVI LONMNVIx Demand
network variable
LONWORKS Event Yes CRDB LONEVTR LONEVTRx Demand
treatment
LONWORKS Multiple No CRDB LONMREF LONMREFx Demand
references
EXCOM No CRDB CI531 RS232_x Demand When config. of CI531 the
disposition of HW module
V.24/RS-232-C No CRDB CI531 RS232_x Demand
CI531 channel 1,2 is entered.
(Terminal, Printer)
Possible values are:
PRI_01, XCOM_1, XCOM_2,
TERM_1, .....TERM_4
RCOM No CRDB CI532 MVIx Demand Function variant, RCOM or
MVI type, is defined by the
MultiVendor Interface Yes CRDB CI532 or MVIx Demand
used hardware module. For
(Standard protocol) MVIMOD (6)
example RCOM uses
CI532V01
MVI Free-programmable Yes CRDB CI535 or MVIx Demand DB element CI535 for module
communication MVIMOD CI535 and MVIMOD for
module CI538
(1) CRDB stands for the engineering tool command CReate Data Base.
(2) No data entry means that default values exist and it is not necessary to enter any data. User-unique names can be introduced if
desirable.
(3) The call name is used in connection to command CRDB.
A parenthesized ( ) call name indicates that the call name cannot be used with the command CRDB.
(4) The item designation (default name) or a user-defined name is used to access an element
with the command MDB, Modify Data Base. The item designation can always be used,
independent of whether or not a user-defined name exists
(5) Miscellaneous refers to different elements for different I/O board, I/O unit or I/O module types.
(6) Depending on protocol.
MasterView 300
Number of DISPLAYS
Number of VARIABLES
Data Tables & Trend Data
Number of TTD_LOGS
Number of TTD_VARIABLES
Number of TBL_CLASSES
Number of TABLES
Number of TBL_PARAMETERS
Size of DATA TABLES (kB)
Number of FILE ELEMENTS
Size of FILE DATA (kB)
Functional Units & Group Alarm
Number of SEQ_CTRL
Number of GENOBJ
Number of MMCX
Number of PIDCON
Number of PIDCONA
Number 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
Certain events and handling of the controller system result in clearing the RAM (set to zero).
A total RAM backup (DUAP/LOAP) is needed to restore the memory. Or a backup of the
application on flash memory card can be used. The latter feature was introduced by product
release 1.2. Table 2-15 shows the situations which result i clearing the RAM.
NOTE
The listed situations in Table 2-15, besides clearing the RAM, automatically:
WARNING
When the application program is started, the process to be controlled is
influenced.
NOTE
DIMPC must be performed to get update of I/O signals.
2.4.3.1 Printer
Power-up
Turn on the power to the printer.
Configuration, Printer
Check that all programmable parameters on the printer are set according to the tables below.
To check the parameters, please refer to the user’s manual of the printer in question.
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.
Necessary Outfit
The following kit is a minimum requirement:
• Ordinary hand tools.
• Universal instrument, for example, digital multimeter.
• Test leads with 4 mm banana contacts and reducer contacts for a 2 mm test jack.
• Necessary parts of the documentation listed in Section 1.4, Related Documentation.
• Specific documentation enclosed at delivery, drawings, and so on.
• Advant Station 100 Series Engineering Station.
In more complex installations, which include closed loop control, some additional test
equipment may be necessary/practical at tuning:
• Recorder with at least two channels
• Access to an operator station facilitating object display trim curves and trend curves.
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.
2.5.3 Commissioning
2.5.3.1 General
For a general description of how to set the controller in operation and start the execution 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,
Reference Manual.
2.5.3.2 Procedure
The application program is normally checked, one executing unit at a time. This is done by
deblocking the complete PC program (DIBM command) and successively deblocking the
execution units, one after the other. You can, for example, check that a flow valve functions and
then verify the start sequence for a pump motor, and so on.
After each sub-function is tested, a comprehensive function control is performed to verify that
all execution units function together.
Finally, a full scale check of the complete installation is performed to verify that the program is
in accordance with the plant specification.
CONTRM
(C1,C2,C3)
1 ON RUN 5
2 >SINGLE
3 R MODP 6
Modify permission
A, B and C constitute interpreters. If an attempt is made to set a time outside the limits specified
or to another interpreter, a system message is presented.
NOTE
All PC elements within a control module have the same periodicity.
The order in which several executing units with the same periodicity are executed is controlled
by the call parameter C2. If no value is specified for C2, the system places this executing unit in
the first vacant space in the cycle time table which specifies the order of execution.
Use the command MV to change the value of C2 to move an execution unit in the execution
sequence, for example, MV PC1.1:C2.
General
As mentioned in the setup instructions for process I/O, it is advantageous to make an integrated
check of process equipment and wiring and the corresponding control function. You make this
check in a circuit-by-circuit procedure. The data base is then used as one checkpoint.
An engineering station reads status/values and simulates control signals to the process objects.
When an operator station is included in the system, it is most effective to maintain the check
from the automatically generated process I/O object displays.
You may need to simulate digital and analog input signals which are normally generated by the
process. Suitable methods to do this follow:
• Digital inputs: Activate the 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 signals: Use a signal generator for analog signals.
Use a simple test coupling as a voltage generator. This consists of a potentiometer coupled
over a suitable voltage source which gives ± voltage.
A current source which can give sufficient current, 20 mA, is required for current signals.
Enter analog test signals as close to the ordinary signal generator as possible to test the
process wiring.
Digital and analog output signals are obtained by setting the required values in the data base via
the engineering station. This means entry of values from the keyboard for the data base elements
concerned (property VALUE).
The system designer provides test specifications with the limits permitted.
As each channel is tested and approved, you can set a test flag “TESTED” in the data base with
the help of MDB. This is not essential, however, for the program function since you can use
simpler methods such as marking the channels on the connection diagram to register the test
procedure.
Input Signals
Figure 2-28 shows in principle where to check an input signal in an S100 I/O application.
DI boards provide X90 connector and DI channel LEDs.
AI boards provide X90 connector, a test terminal X3 and a common-to-all-channels A/D
conversion indicating LED.
See separate documentation for detailed information.
Engineering station
DB elements
Board
Operator station TYPE Signal
ERR
NAME
VALUE
- Object display ERR
- Trend curve
Connection
unit
Process Input Data base PC program
object board
X3
X90 AI
DI ch. (A/D)
Figure 2-28. Principal Block Diagram of S100 I/O Input Channel, Test Points
and that the change is registered by the property VALUE on the display screen in the
engineering station. For MDB, use GVD for dynamic updating of the values on the
display screen.
– Change the input signal to a low level. Check that the yellow LED on the input board
extinguishes and that the property VALUE is changed.
• Analog Input Signals
Figure 2-28 shows where you can check an analog input signal in an input channel.
Proceed as follows to check an analog input channel:
– Check first that all data base connections are filled in correctly for the signals to be
checked, also and that 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 X3.
– Check that the value read on the display screen (property VALUE) is the same as the
simulated value set. Check the complete signal range.
For a description of the adjustment of analog input signals, see Chapter 5, Maintenance.
Output Signals
Figure 2-29 shows in principle where you can check an output signal in an S100 I/O application.
DO boards provide X90 connector and DO channel LEDs.
AO boards provide X90 connector.
For detailed information, see separate documentation.
Engineering station
DB elements
Board
TYPE Signal
ERR
NAME Operator station
VALUE
ERR
- Object display
- Trend curve
Connection
unit
PC program Data base Output Process
board object
DO ch. X90
Figure 2-29. Principal Block Diagram of S100 I/O Output Channel, Test Points
PCPGM (20,1)
D=1 1 ON RUN 5
D=0 2 R
CONTRM (20,2,0)
D=1 1 ON RUN 5
D=0 2 >SINGLE MODP 6
D=0 3 R
OSC-SIN
1-PC1.1:RUN 1 EN O 5 P
D=1.0 2 TC ERR 6 P
D=2.000 3 AMP
.1
PC1
PC1.1.1 OSC-SIN
:1 EN IB PC1.1:5 1
:2 TC ITR D=1.0
:3 AMP IR D=2.000
:5 O OR =AO1.1 =AO1.1 P
:6 ERR OB =DO1.1 =DO1.1 P
Necessary Outfit
The following kit is normally a minimum requirement:
• Ordinary hand tools.
• Universal instrument, for example, digital multimeter.
• Test leads with 4 mm banana contacts and reducer contacts for a 2 mm test jack.
• Necessary parts of the documentation listed in Section 1.4, Related Documentation.
• Specific documentation enclosed at delivery.
• Advant Station 100 Series Engineering Station.
In more complex installations, which include closed loop control, some additional test
equipment may be necessary/practical at tuning:
• Recorder with at least two channels.
• Access to an operator station facilitating object display trim curves and trend curves.
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.
On-Line/Off-Line
On-line means that all work can be carried out while the controller is in full operation.
Because of the risk of making manual mistakes in such handling, and the possible severe
consequences to the process controlled, it is recommended that you use this on-line facility
restrictively.
The best method of working:
The system is stopped and the voltage supply is disconnected when a new function is
installed.
Disconnection of the mains supply may have impact on dynamic information stored in the
application program. For example counter/register content, integrator content and so on, will be
lost if not secured by special considerations in the application program design. However this is
general design considerations. The controller should manage “normal” mains supply
interruptions.
Summary of Aspects
Enlargement/Addition Dimensioning
Function/Equipment Comments
On-line Off-line of Data Base
NOTE
Remember that the control function of the system ceases and the process being
controlled is affected.
4. Screw the connection unit to the mounting bar at the rear wall of the cabinet. Ensure that
the screws make contact with the tinned surface of the earth plane of the circuit board for
effective grounding.
It is also of the utmost importance that you tighten the screws properly to give a reliable
earth connection. See Figure 2-32.
5. Screw the board connector with connection cable to the desired slot in the subrack and
connect to the connection unit in the opposite end. See illustration in Figure 2-33.
6. Ensure that there is no tension in the wiring, especially if it may be necessary to swing the
hinged subframe for the I/O subrack.
7. Set the I/O address and other functional jumpering on the board.
Addressing and functional measures like jumpering are described in the reference manual
S100 I/O Hardware.
8. Provide access to the desired position in the subrack by loosen the locking bar in front of
the boards.
9. Insert the I/O board carefully in the subrack without reaching the rear plane contacts.
Ensure that the board slides in the guides in the subrack.
CAUTION
At insertion, use the grounded wristband.
Eventual
grounding Grounding
of signal Thread-cutting
M6x10 screw
Cable duct
Connection unit
Cable
Grounding Mounting rail
Self-tapping ST 3.5x9.5
screw (B6x9.5)
Connection cable
Plug-in units
Start-up
The start-up is carried out in different ways, depending on the main working mode, on-line or
off-line.
If a board is added on-line, the different I/O channels are put into operation as the adequate data
base is created and the application functions are built and started (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 and started (deblocked).
If the board is added off-line because REDIMENSION of the data base was necessary (no
spares available), the following start-up sequence is applicable.
A data base dump DUTDB and a PC program dump DUTPT are presupposed.
1. Follow the general instructions in Section 2.6.7, Power-up Ahead of Program Loading.
2. Perform the controller system configuration:
a. Load the data base dump, LOTDB and REDIMENSION.
b. Create the additional data base, DIMDB.
c. Perform data entry of additional data base, MDB.
d. Dump and load (compress) the data base, DUTDB/LOTDB.
e. Load the PC program dump, LOTPT, and REDIMENSION PC program tables,
if necessary.
3. Perform configuration/application building:
a. Populate the additional data 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 module changes over and indicates P1 (working mode OPERATION).
The system is now started and ready for operation.
Perform the final stages, which include start of executing application programs, successively,
especially those application programs which are affected by the additional I/O board. Do one
PC program at a time.
WARNING
When the application program is started, the process to be controlled is
influenced.
Verification
Make functional tests, including process functions, applicable.
Extension On-line
1. Check module identities.
2. Check module position 2 (item designation 108, see Appendix D, Item Designations) for
visible damage, dust, etc.
3. Set start mode selector on the new processor module in STOP position.
CAUTION
Do not forget the general rule: Reflect on the danger of ESD. Use the
grounded wristband when handling circuit boards.
Extension Off-line
1. Shut down the system by setting the start mode selector on the existing processor module
in STOP position. The display shows -3.
The entire process control is shut down!
2. Check module identities. If the existing module is withdrawn, insert again.
Keep the start mode selector in 2 (STOP) position.
3. Check module position 2 (item designation 108, see Appendix D, Item Designations) for
visible damage, dust, and so on.
4. Set start mode selector on the new processor module in 2 (STOP) position.
CAUTION
Do not forget the general rule: Reflect on the danger of ESD. Use the
grounded wristband when handling circuit boards.
12. Set the start mode selector on the new processor module in the same position as the
existing processor module.
13. Push the ENTER button on the new module.
Check the display. A correct installation gives the following indications in sequence:
a. b2 (UPGRADING), b1 STANDBY) after < 90 sec.
b. LEDs DUAL on both processor modules light up.
The left processor module is now PRIMARY while the new one is BACKUP.
14. Make a basic function test. Manual changeover is described in
Chapter 5, Maintenance.
15. Give the command DICONFIG. The resulting working modes are:
PRIMARY P1 OPERATION
STANDBY start in b2 UPGRADING and then transition to b1 STANDBY
CAUTION
Do not forget the general rule: Reflect on the danger of ESD. Use the
grounded wristband.
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 program tables as well. For relevant information on
these topics, look elsewhere in this manual or see separate documentation.
1. Follow the general instructions given in Section 2.6.7, Power-up Ahead of Program
Loading.
2. Perform the controller system configuration:
a. Load the data base dump, LOTDB or TRDBS, as applicable.
3. Perform configuration/application building:
a. Load the PC program dump, TRPCS.
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 module changes over and indicates P1 (working mode OPERATION).
The system is now started and ready for operation.
Perform the final stages, including start of application program execution, successively.
WARNING
When the application program is started, the process being controlled is
influenced.
Verification
Make functional tests, including process functions, applicable.
NOTE
Do not push the ENTER button!
&KDSWHU &RQILJXUDWLRQ$SSOLFDWLRQ%XLOGLQJ
'HVLJQ&RQVLGHUDWLRQV
This section tells you some of the things you need to think about during configuration and
application building.
This follows the primary structure outlined in Section 1.7, Product Overview, however, some
subsections have been added. The information is given as concisely as possible under the
following headings, as relevant.
• $SSURSULDWH+DUGZDUHDQG6RIWZDUH
What is necessary to achieve a function.
,QWHUIDFHWR$SSOLFDWLRQ3URJUDP
• *XLGHOLQHV
Typical information:
– Location of hardware
– Recommendations
– Limitations.
)RULQIRUPDWLRQRQWKHSRVVLEOHQXPEHURILQVWDQFHVSOHDVHVHH6HFWLRQ7HFKQLFDO
'DWD,QFOXGLQJ&DSDFLW\ 3HUIRUPDQFH
3URGXFW6WUXFWXUH
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 and the software
structure of the product differ. A functional option may require extra hardware, but the software
is included in the basic program module. Or an optional program module may support several
functional options (each with a dedicated hardware).
*HQHUDO6\VWHP8WLOLWLHV
$SSURSULDWH+DUGZDUHDQG6RIWZDUH
Most functions and equipment described as General System Utilities are included in the basic
unit of a controller (smallest unit to be ordered) loaded with the basic system program. You can
enlarge this platform further with alternatives and options.
6\VWHP&ORFN
$SSURSULDWH+DUGZDUHDQG6RIWZDUH
No extra hardware or software is needed.
To achieve external synchronization, the “minute pulse” is connected to the System Status
Collector TC520, see Figure 3-1.
Synchronization input electrical data is given in Section 3.2.1.4, System Clock.
7&
SYNCIN
12
COMMON SYNC
13
)LJXUH ([WHUQDO6\QFKURQL]DWLRQRI6\VWHP&ORFN
5XQ$ODUP5HOD\
$SSURSULDWH+DUGZDUHDQG6RIWZDUH
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.
7&
RA
7 Processor
RA module A
External 8 RUN
equipment
RB
9 Processor
RB module B
10 RUN
$GGLWLRQDO6XSHUYLVRU\,QSXWV
No extra hardware or software is needed.
The Supervision Unit TC520 is used according to Figure 3-3.
Electrical data: see the module description in Appendix A, Hardware Modules.
Application: see Section 2.2.8, Controller, heading Electric Installation.
STATUS B1 F3
Free disposition 4
within cabinets STATUS B2 F4
5
COMMON B
6
)LJXUH &RQQHFWLRQRI$GGLWLRQDO6XSHUYLVRU\,QSXWV
7HUPLQDO 6HWWLQJ
F1 “NO”. (Because normally the signal “I/O 24V A error” is connected to digital input
A1 of TC520 (1)).
(“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 digital input A2 of TC520 (1).
“YES” if there is a user defined signal connected to digital input A2 of TC520 (1).
F3 “YES” if there is a user defined signal connected to digital input B1 of TC520 (1).
F4 “YES” if there is a user defined signal connected to digital input B2 of TC520 (1).
(1) See sections “Power Supply modules” and “TC520” in the Data Base Elements Advant
Controller 400 Series - Reference Manual.
Note that input A1 may be used HLWKHU for supervision of 24V A in I/O subracks 25 user
defined function F1.
For supervision of 24V A in I/O subracks, set terminal IO24VA to “YES”.
For supervision of user defined function F1, set terminal F1 to “YES”.
Input A2 may be used HLWKHU for supervision of 24V B in I/O stations 25 user defined function
F2.
%DFNXSRI$SSOLFDWLRQ3URJUDP
$SSURSULDWH+DUGZDUHDQG6RIWZDUH
7DEOH %DFNXSRI$SSOLFDWLRQ3URJUDP+DUGZDUHDQG6RIWZDUH
6XEPRGXOH
FDUULHU6& 3URJUDP
)XQFWLRQ 6XEPRGXOH 3HULSKHUDO &RPPHQWV
PRGXOH
Backup of application MB510 X X QC07-BAS41 A PCMCIA card of
program suitable memory
size must also be
used
*XLGHOLQHV
• No restrictions in location of submodule and submodule carrier in controller subrack. Use
leftover slot on a submodule carrier if possible.
• Advant Station 130 Engineering Station and AdvaBuild On-line Builder supports the
preparation of flash cards (PCMCIA) with application dumps.
• $GYD%XLOG2QOLQH%XLOGHU8VHU¶V*XLGH describes the work procedures in detail.
• You can find an overview regarding work procedures in Section 5.7.2, Backup of
Application.
3RZHU6XSSO\
$SSURSULDWH+DUGZDUH
Alternative power supply systems are available. When you order, you can select a suitable
alternative. Do not be concerned with number of included parts, but rather the number of power
supply units. This number is calculated with respect to the actual number of I/O subracks.
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 Section 2.1, Site Planning Environment.
• Auxiliary equipment in the controlled system is normally powered separately from the
control system power supply.
• Heavy current on/off loads areDOZD\V powered separately.
• An exception to the second point above is analog outputs, for example 0-10 V, 4-20 mA,
which are powered by the system power supply. Please note, galvanically isolated analog
outputs are powered separately.
• You can use the system power supply for transducers provided that:
$OWHUQDWLYH 0D[3RZHU6XSSO\
6WDQGDUG&RQILJXUDWLRQ 5HTXLUHPHQW
$OWHUQDWLYH
Controller subrack 25 A
$OWHUQDWLYH
Controller subrack 25 A
I/O 1 subrack
$OWHUQDWLYH
Controller subrack 25 A
I/O 1 subrack
I/O 2 subrack 10 A
$OWHUQDWLYH
Controller subrack 25 A
I/O 1 subrack
I/O 2 subrack 25 A
I/O 3 subrack
$OWHUQDWLYH
Controller subrack 25 A
I/O 1 subrack
I/O 2 subrack 25 A
I/O 3 subrack
I/O 4 subrack 10 A
$OWHUQDWLYH
7DEOH 5XOHVIRUWKH&DOFXODWLRQRI1XPEHURI3RZHU6XSSO\8QLWV
$OWHUQDWLYH 0D[3RZHU6XSSO\
6WDQGDUG&RQILJXUDWLRQ 5HTXLUHPHQW
Controller subrack 25 A
I/O 1 subrack
I/O 2 subrack 25 A
I/O 3 subrack
I/O 4 subrack 25 A
I/O 5 subrack
Considering the cost of spare parts, a uniform type of power supply unit (25 A) is sometimes
profitable.
At redundancy, the number of units extracted from the information in Table 3-2 is doubled.
&XUUHQW&RQVXPSWLRQ
As a rule, an SA168 (25 A d.c.) supply unit is used to supply equipment with one I/O subrack.
If the Advant Controller 450 has another I/O subrack, it is equipped with another SA162 (10 A
d.c.) in cabinet 2. If the system has three I/O subracks, the extra supply unit is replaced by an
SA168. Please note that the supply unit types given are for 230 V a.c. mains supply.
Corresponding types for 120 V a.c. mains supply are available.
The current consumption with 24 V is obtained in the following way:
)XVLQJLQ'LVWULEXWLRQ%RDUG
The system is protected with adequate internal fusing. In addition to fusing distributed to
different apparatus, there are common miniature circuit breakers in the power switch and
distribution units in the cabinets (see the terminal diagram form for the actual power supply
system).
The superior distribution board fusing protects the equipment with respect to:
• Internal fusing in the Advant Controller
• Rated current of connected equipment
• In-rush current at power switch-on
• Need to protect the power supply cables to the equipment installed.
For a guide to dimensioning the fusing, see below.
When necessary, you can make a more accurate current consumption calculation to obtain exact
data for fusing. This calculation should focus on the actual number and type of circuit boards in
the different subracks.
DF1HWZRUN$%
7DEOH 'LVWULEXWLRQ%RDUG)XVLQJDF
'LVWULEXWLRQERDUGIXVLQJ
5HFRPPHQGHG
1RRISRZHUVXSSO\XQLWV6$;
9DF 9DF
FRQQHFWHGWRWKHVDPHOLQH
)XVDEOH )XVDEOH
0&% 0&%(1)
OLQN OLQN
1 16 A K16A 20 A K25A
2 16 A K16A 20 A K25A
3 16 A K25A 25 A K32A
4 20 A K32A 30-35 A K50A
5 25 A K32A 35 A K50A
6 25 A K50A 35 A K50A
(1) MCB = Miniature Circuit Breaker
The in-rush current at power switch-on must be considered at the fuse dimensioning.
Consequently, you must include redundant power supply units (connected to the same line) in
the calculation of number of units. Normally, redundant power supply units are connected to
separate lines.
DF1HWZRUN&
To reflect the in-rush current and the current rating for the applied power switch and distribution
unit (SV54x), the distribution board fusing should be in the range 10 - 20 A.
GF1HWZRUN$%
For practical reasons, the fusing at d.c. supply is based on the number of included I/O subracks.
Here, out of necessity, an almost “worst case” view is taken.
With respect to the actual power supply distribution within the Advant Controller installation
and planned distribution board fusing, please use the figures in Table 3-4 to calculate a suitable
distribution board fusing.
The fuse dimensioning current in the table is settled with respect to:
• lowest supply voltage (19 V/38 V for 24 V and 48 V d.c. systems, respectively)
• efficiency factor of the power supply unit SD150 (ca 0.75)
• margin (1.25 x calculated load current).
The minimum fuse rating is determined by the miniature circuit breakers in the actual power
switch and distribution units.
At 24 V d.c., the minimum value is normally 50 A. At 48 V d.c., the minimum value is 25 A.
7DEOH 'DWDWR6HWWOHWKH'LVWULEXWLRQ%RDUG)XVLQJGF
)XVH'LPHQVLRQLQJ&XUUHQW
,WHP 5HFRPPHQGHG
9GF 9GF
Controller subrack 19 A 9.5 A
I/O subrack 18 A 9A
(1) (1)
Field equipment
(1) If a power supply unit for field equipment, type SD150, is included, please use a formula to
calculate the Fuse Dimensioning Current.
)XVH'LPHQVLRQLQJ&XUUHQW)'&
General:
FDC = Load effect ⋅ 1/Efficiency factor ⋅ 1/Lowest supply voltage ⋅ Margin
At 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 supply units SD150 connected to the same line is
normally no problem and consequently, you should not consider it when dimensioning the
distribution board fusing. In continuous operation, they will share the load.
A more practical installation of redundancy uses duplicated line voltages. Then identical fusing
according to the above table and rules are realized.
Some application examples for the d.c. mains supply are given in Figure 3-5.
50/25A d.c
I/O subrack 1
E 99
Advant Controller 450
Distribution board
Power switch and
distribution unit Power supply
$$ Controller subrack
50/25A d.c
50/25A d.c
I/O subrack 1
Power supply
d.c Field
d.c equipment,
e.g., load effect 240 W
F 9
Advant Controller 450
Distribution board
Power switch and
distribution unit Power supply
$ Controller subrack
50A d.c
50A d.c
I/O subrack 1
50A d.c
I/O subrack 3
8QLQWHUUXSWHG3RZHU6XSSO\836
In the event of a power failure, the controller is shut down safely. During the dead time,
the current supply of the RAM and the system clock is backed up by a battery package.
To prevent shut down, you can feed the controller by a UPS.
In addition, make the actual load (VA, W) considerations with respect to information given in
Table 3-5 and Table 3-6 when a UPS is dimensioned. Firs half period peak values given are
close approximations at 0.2 ohm net impedance, 230 V, 50 Hz. Corresponding figures at
0.1 ohm net impedance, 115 V, 60 Hz are obtained by multiplying with a factor 1.5.
7DEOH 5HTXLUHPHQWRQ836IURP9ROWDJH6XSSO\8QLW6$
'DWD 9DOXH
First half period peak value at switching on 60 - 80 A
cos ϕ >0.7
Crest factor (peak current / RMS current) <2.6
7DEOH 5HTXLUHPHQWRQ836IURP9ROWDJH6XSSO\8QLW6$
9DOXH
'DWD 1XPEHURIXQLWV
First half period peak value at switching on 25 A typical 45 A typ. 80 A typ.
120 A worst case 160 A wc 200 A wc
cos ϕ >0.7
Crest factor (peak current / RMS current) <2.0
3URFHVV,QWHUIDFH
$SSURSULDWH+DUGZDUHDQG6RIWZDUH
No extra software is needed, the basic system QC07-BAS41 is sufficient.
No extra hardware is needed besides the desired I/O unit if:
• Spare slot in an I/O subrack is available (S100 I/O)
• MasterFieldbus communication is available (S400 I/O)
• Advant Fieldbus 100 and an S800 I/O station is available (S800 I/O).
Supported I/O boards (S100 I/O), I/O units (S400 I/O) and I/O modules (S800 I/O) are listed in
Section 1.7, Product Overview. Besides the board/unit type designation, you can also find
information about suitable connection units and internal cables in that section. Further
guidelines are given below.
,QWHUIDFHWR$SSOLFDWLRQ3URJUDP
Each board/unit/module is normally represented by aGDWDEDVHHOHPHQW. The same applies to
the individual channels of the board/unit/module. For a digital input board in the S100 I/O,
there is a superior DI board element and 32 Digital Input (channel) elements.
For an S400 I/O unit or S800 I/O module, there is a corresponding superior element defining the
unit (AX unit, DX unit) or module. Comparing the different I/O system S100 I/O, S400 I/O and
S800 I/O the individual channel elements are almost identical.
The superior elements are created by the user/configurer. As a result, the relevant individual
channel elements appear automatically.
Some board types listed below have one or several 3&HOHPHQWVas the interface to the
application program.
Pulse Counter and Frequency Measurement Module DP820:
Data Base Element DP820 is used to configure the module.
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 PC elements, COUNT-DP, FREQ-SP, and FREQ-MP, are used for varying
applications together with the board DSDP 150.
Pulse Counting and Frequency Measuring Board DSDP 170:
The following PC elements are used for communication with the board.
– PCU-COM Starts and supervises DSDP 170
– PCU-I Reads values from channels
– PCU-O Sets parameters and issues commands
– PCU-SS Gathers data from several channels simultaneously for up to
five boards.
Weighing boards DSXW 110 and DSXW 111:
The following PC elements are used for communication with the boards.
– SCALE Provides the logical interfacing between PC programs and the local
weighing function on the weighing board
– SCALEDOS Provides the logical interfacing between PC programs and the local
dosing function on the weighing board.
With the given DB element, PC element and board type as a reference, you can find functional
and hardware descriptions in:
'DWD%DVH(OHPHQWV$GYDQW&RQWUROOHU 6HULHV5HIHUHQFH0DQXDO
3&(OHPHQWV$GYDQW&RQWUROOHU 6HULHV5HIHUHQFH0DQXDO
6,2+DUGZDUH5HIHUHQFH0DQXDO
*XLGHOLQHV
The following sections, Section 3.1.4.1, S100 I/O System and Section 3.1.4.2, S400 I/O System,
guide you in selecting suitable I/O for an application and some design rules.
By way of introduction, the question of centralized I/O or distributed I/O is discussed.
A combination of centralized I/O and distributed I/O can often be an appropriate solution.
&HQWUDOL]HG,2
The traditional method of building control equipment with a central assembly of all electronics
in the control or equipment room is still the most common. There are several reasons for this:
• Not all processes are suitable for distribution of I/O functions. In some cases, safety or
environmental requirements with respect to equipment and maintenance personnel may
make a process unsuitable.
• 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 central switch gear for control of the motor
supply.
'LVWULEXWHG,2
Cables and wiring represent a large part of the costs of a control system. It is, therefore,
an obvious advantage if a communication bus can transport a large number of signals between
an Advant Controller 450 and a distributed I/O unit and have separate signal leads only between
the I/O unit and the process. The wider the process is dispersed geographically, the more
profitable distributed I/O becomes.
The option to supplement the distributed I/O function with independent small controllers for
fast logic control makes this type of system configuration even more attractive economically.
The control in the distributed controller can, in addition, be integrated with the Advant OCS.
In connection to a revamp, you can locate distributed I/O units in an existing marshalling area as
interface between an old installation and a new control system.
6,26\VWHP
*XLGHOLQHV*HQHUDO
There are certain restrictions in number of I/O subracks, number of I/O boards and number of
signals of different categories. Please see Section 3.2, Technical Data Including Capacity &
Performance.
There are no restrictions on location and mixing of boards of different categories in an I/O
subrack. There are, however, some production rules to facilitate ordering and rapid delivery.
See Section 2.1.4, Standard Layout and Disposition of Cabinets.
When you design a control system, it is desirable to leave some spare capacity. It is practical to
have approximately 10% to 20% of the channels as spares. The same recommendation is valid
for spare space in subracks.
You can add new I/O boards on-line provided there are spare items in the data base. Reflect the
need when you make the data base dimensioning.
*XLGHOLQHV$QDORJ,QSXWV
General
With current signals and series coupling of loads, the total resistance 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 are used when it is necessary to
ground measurement circuits at different places in the system. This means you can use
transducers which require grounding of the signal zero. Fusing occurs in groups at six fuses
which can be used for an optional number of channels.
DSAI 130
DSTA133, DSTK 221L3
DSAI 130A
DSTA 135, DSTK 221L3
16 differential wit individually power limit transducer power supply for applications with
considerable accuracy requirements. Common Mode Voltage up to 100V (50V DSAI 130A) is
acceptable.
DSAI 130
DSTA 137, DSTK 221L5
DSTA 137 provides object oriented connection to DSAI 130 and DSAO 130. Regarding input
features please refer to DSAI 130 using DSTA 131 above. No fusing of power supply
distribution. However, individual protection per channel is available by means of a PTC resistor.
DSAI 130A
DSTA 138, DSTK 221L5
DSTA 138 provides object oriented connection to DSAI 130A and DSAO 130A. Regarding
input features please refer to DSAI 130A using DSTA 131 above. No fusing of power supply
distribution. However, individual protection per channel is available by means of a PTC resistor.
DSAI 133
2x DSTA 002A, DSTK 222L3
DSAI 133A
2x DSTA 002B, DSTK 222L3
32 single ended and unipolar current inputs, which means that the transducers or their power
supply can be grounded only within a geographically limited area, where the ground potential is
the same as the system ground.
127(
There are two connection units due to the number of input channels.
In a redundant configuration two DSAI 133 can be connected to the same connection units.
The redundant inputs 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 grounded thermoelements. Earth the channels not connected to transducers.
NOTE
You can use only one type of thermoelement per board.
DSAI 155A
DSTA 156B, DSTK 225SL3
Used for JURXQGHGand QRQJURXQGHG thermo elements. Earth channels to which transducers
are not connected.
DSTA 155, DSTA 155P
Placed out in the process to minimize the length of expensive compensation cable from
thermoelements. The unit measures the temperature at the cold junction. Locate it at a place
with small temperature variations and, naturally, at a place conveniently located with respect to
all of the transducers connected to the board concerned.
DSTA 155P has pluggable screw terminals.
*XLGHOLQHV&RPELQHG$QDORJ,QSXWVDQG2XWSXWV
DSAX 110
DSTA 001A, DSTK 223L3
DSAX 110A
DSTA 001B, DSTK 223L3
Eight single ended, unipolar current inputs and eight supervised current outputs, which means
that transducers or their power supply can be grounded only within a geographically limited
area, where the ground potential is the same as the system ground.
In a redundant configuration two DSAX 110 can be connected to the same connection unit.
The redundant inputs and outputs are handled by the application programmer in the same way
as the other analog inputs and outputs.
*XLGHOLQHV$QDORJ2XWSXWV
DSAO 110
DSTA 160, DSTK 223L3
Used when considerable accuracy and galvanic isolation between control system and load,
channel by channel, are required. The load resistance may be a maximum of 500 Ω with 20 mA
and 1000 Ω with 10 mA.
DSAO 120
DSTA 170, DSTK 223L3
Used when considerable accuracy is required. You can ground the load 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. The load resistance may be a maximum of 600 Ω for current
and minimum 1000 Ω for voltage output.
DSAO 130
DSTA 180, DSTK
Used with moderate demands for accuracy (inaccuracy 0.4%). Do not ground the load. The load
resistance may be a maximum of 1 kΩ with 20 mA and 2 kΩ with 10 mA, @ U24 ≥ 25 V.
DSAO 130A
DSTA 181, DSTK 221L3
Used when considerable accurancy is required. You can ground the load 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 850Ω with a current signal.
DSAO130
DSTA 137, DSTK 221L5
DSTA 137 provides object oriented connection to DSAI 130 and DSAO 130. Regarding output
features please refer to DSAO 130 using DSTA 180 above.
DSAO130A
DSTA 138, DSTK 221L5
DSTA 138 provides object oriented connection to DSAI 130A and DSAO 130A. Regarding
output features please refer to DSAO 130A using DSTA 181 above.
DSTY 101
With DSTY 101 (insulation amplifier), you can obtain insulation at individual input and output
channels. The insulation is obtained between primary and secondary sides and to the supply.
*XLGHOLQHV'LJLWDO,QSXWV
You can choose between scanned or interrupt-controlled inputs when you select the digital input
board. The different methods of reading inputs are as follows:
• Scanned inputs
The software scans the digital input boards and updates the data base in
the Advant Controller 450 at regular intervals. This causes the load in the controller to
remain constant, irrespective of the frequency of change at the inputs.
• Interrupt-controlled inputs
The data base in Advant Controller 450 is only updated when the values at the inputs are
changed. This gives more exact time-tagging with event handling of the inputs. Interrupt-
controlled inputs also mean a lower load with low to moderate frequency of change.
DSDI 110A
DSTD 150A / DSTD 190, DSTK 221L3
DSDI 110AV1
DSTD 150A/DSTD 190V1
DSTK221L3
Scanned 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 and fusing for
smaller groups of channels but naturally requires that the 0 V sides can be connected. The two
groups are galvanically isolated from the internal electronics.
DSDI 110A DSTK 226L3
DSDI 110AV1 DSTK 226L3
32 scanned or interrupt-controlled digital 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). You can connect up to four of the
connection units listed below to this board and cable. Division between the different connection
units is a free choice. The properties of the inputs are decided by the selected connection units.
Each connection unit contains eight inputs.
DSTD 195 (replacing DSTD W110)
A connection unit with eight inputs for 24 V d.c. All channels are galvanically isolated.
*XLGHOLQHV'LJLWDO2XWSXWV
Advant Controller 450 can be equipped with digital outputs of static type (semiconductor) and
with a relay contact. The different output types have partially different properties.
Certain significant properties are presented below:
• Static outputs
These generally have a long service life, even with a high frequency of change.
• Relay outputs
These have a shorter service life than static outputs. When the output is frequently
changed, it is subject to wear and its service life is shortened. They can withstand
occasional higher voltage. Different system voltages can be accommodated on the same
board. A certain degree of inductive load can be accepted. Small load currents with low
voltage (<40 V) can give contact problems.
In the control of two-phase motors (with a phase-displacing capacitor between the forward and
reverse windings), a reverse voltage considerably higher than the system voltage can be induced
over the capacitor. This voltage is induced over the open control function and can result in the
maximum permitted voltage being exceeded. This can be a problem with a.c. 230 V and with
the use of DSTD 108P.
DSDO 115
4xDSTD 108/DSTD 108L, DSTK 226L3
With these connection units four times eight closing relay outputs, 24 - 250 V a.c./d.c. max 3 A
are obtained. The relay contacts have a safety circuit (RC-link) for spark suppression.
For supply and grounding purposes, 32 completely individual channels are obtained.
Each connection unit (DSTD 108) is 120 mm long. The four connection units are connected to a
DSDO 115 with a divided ribbon cable, DSTK 226L3. The minimum load on the relays is 2.5
VA but the lowest is 100 mA with 24 V.
A variant of connection unit DSTD 108L is used for low-current loads (maximum 200 mA).
DSDO 115/DSDO 115A
DSTD 145, DSTD 147, DSTD 148, DSTK 226L3
These variants of connection units provide object oriented connection to DSDI 110A/DSDI
110AV1 and DSDO 115/DSDO 115A.
The general feature of DSDO 115/DSDO 115A, including connection unit, are: Thirty-two
channels, relay output, 24 - 250 V a.c./ d.c., max 3 A. 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.
DSDO 115
DSTD 110A / DSTD 190, DSTK 221L3
DSDO 115A
DSTD 110A, DSTK 221L3
/DSTD 190V1, DSTK 234L3
These give short-circuit-protected static outputs for 24 V d.c. (transistor outputs). The load
current may be a maximum of 150 mA per channel for DSDO 115 and 0.5A for DSDO 115A.
The supply is divided in the connection unit into two groups of 16 channels each. Each has a
common supply and 0V. The outputs are galvanically isolated from the internal electronics.
DSDO 115A, DSTK 226L3
32 digital outputs. You can connect up to four of the connection units listed below to this board
and cable. Division between the different connection units is a free choice. The properties of
the outputs are decided by the selected connection units. Each connection unit contains eight
outputs.
DSTD 108P
Connection unit with eight closing relay outputs, 24 - 250 V a.c./d.c. max 3 A. The relay
contacts have a safety circuit for spark suppression. For supply and grounding purposes,
32 completely individual channels are obtained. Each connection unit (DSTD 108) is 120 mm
long. The minimum load on the relays is 2.5 VA but the lowest is 100 mA with 24 V. With
pluggable screw terminals.
DSTD 108LP
Same as DSTD 108P but for maximum load current on it is 200 mA.
DSTD 109P
Connection unit with eight static outputs, 24 V 2 A with common power supply.
Each connection unit (DSTD 109P) is 120 mm long. With pluggable screw terminals.
DSDO 120
DSTD120A, DSTK 220L3.2
Static outputs for 24 V - 48 V d.c. (transistor outputs). The board is designed to withstand a load
up to 1 A per channel. The supply is divided in the connection unit into two groups of eight
channels each. Each has a common supply and 0V. The outputs are galvanically isolated from
the internal electronics.
*XLGHOLQHV3XOVH&RXQWLQJDQG3RVLWLRQLQJ%RDUGV
DSDP 140A
DSTD 150A/DSTD 190, DSTK 225SL3
A positioning loop for positioning up to 80 kHz.
DSDP 150
DSTD 150A/DSTD 190, DSTK 225SL3
Twelve channels 5/12/24 V d.c. for pulse and frequency measurement up to a maximum of
10 kHz. Pulse or frequency measurement is selected optionally for each channel pair. 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&RQQHFWLRQRI6WDWLF&RQYHUWHUV
DSDC 111
DSTX 110, DSTK 224L3
A board to connect a thyristor converter with analog control of d.c. motor operation.
6,26\VWHP
*XLGHOLQHV$QDORJ,QSXWVDQG2XWSXWV
With current signals and series coupling of loads, the total resistance may not exceed the
resistance through which the sensor output can be driven.
The referred type designations below are valid for S400 I/O Units.
DSAX 452
This is a combination unit for 14 analog inputs and 6 analog outputs for applications which
require considerable accuracy. You can ground the transducer and load if the difference in
potential between the load ground and the DSAX 452 ground is within the specification.
The equivalent resistance caused by the ground voltage drop and the load resistance concerned
together is not to exceed 650 Ω with a current signal, ≤ 20 mA.
Both inputs and outputs can suppress moderate CMV in the range ±10V for voltage input and
±20 V for current input. This means, in practice, that you can ground the transducer and load
freely within a geographically limited area in which the difference in ground potential is within
the specification.
The unit has an integrated voltage source providing d.c. 24 V for transducer supply. The voltage
is fused. This supply can also be used for supply to the outputs which can then drive a current
signal through a load of 650 Ω. Additionally the outputs can be supplied from an external supply
unit. You can then increase the load resistance for the current signal towards 1000 Ω.
*XLGHOLQHV'LJLWDO,QSXWVDQG2XWSXWV
DSDI 452
DSDI 451 (expansion unit)
Thirty-two scanned inputs for 24 V. All channels have a common signal return. Transducer
supply is obtained from a common fused source. External voltage supply and fusing for groups
less than 32 channels are possible, but the return sides of the different 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 on DSDI 452. The outputs are completely separated relay contacts for
24 V - 240 V a.c./d.c. The recommended minimum load on the contacts is 2.5 VA but a
minimum of 100 mA with 24 V d.c. Units with an additional letter L are equipped with low-
voltage relay contacts. Maximum load on the contacts is 200 mA. The recommended minimum
load on the contacts is 5 mA or 0.05 VA.
DSDX 454(L)
DSDX 453(L) (expansion unit)
Combination unit for 20 digital inputs (48 V) and 12 digital outputs. The inputs have the same
qualities as the inputs on DSDI 454. The outputs are completely separated relay contacts for
24 V - 240 V a.c./d.c. The recommended minimum load on the contacts is 2.5 VA but a
minimum of 100 mA with 24 V d.c. Units with an additional letter L are equipped with low-
voltage relay contacts. Maximum load on the contacts is 200 mA. The recommended minimum
load on the contacts is 5 mA or 0.05 VA.
6,26\VWHP
The general information given by way of introduction in Section 3.1.4, Process Interface is
adequate for an S800 I/O system. Otherwise you are referred to the 6,28VHU¶V*XLGH.
&RPPXQLFDWLRQ
3URYLGHG/LQN7\SHV
$SSURSULDWH+DUGZDUHDQG6RIWZDUH
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 to the controller end of the communication.
7DEOH /LQN7\SHV+DUGZDUHDQG6RIWZDUH
6XEPRGXOH
3URJUDP &RPPHQWV
/LQNW\SH 6XEPRGXOH FDUULHU6& 3HULSKHUDO
PRGXOH
MasterBus 300 CS513 X X QC07-BAS41 See separate (1) (2)
*XLGHOLQHV&RPPXQLFDWLRQLQ*HQHUDO
Communication among different computers gives rise to a load divided among the
communication link itself and the main CPU of the involved computers. This must be
considered when you design a distributed control system.
A basic rule, always relevant, is to limit the frequency of the information transfer to what is
really needed by the application. Event-controlled transfer (if possible to execute in a secure
way) is preferred to cyclic transfer.
The main CPU is always loaded by a communication. The significance depends on the actual
design. For the MasterBus 300, there are two different implementations in Advant
Controller 450. One utilizes the main CPU on the processor board and another utilizes a
dedicated slave processor on the submodule carrier. The latter represents a significantly lower
load to the main CPU (but higher cost). The same information applies to MasterBus 300E.
The variants of implementation are designated with respect to the implementation:
• MasterBus 300 (executed in main CPU).
A submodule 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/RFDWLRQDQG([SORLWDWLRQRI+DUGZDUH
No restrictions in location of submodule and submodule carrier in controller subrack.
Use leftover slot on a submodule carrier provided the carrier is suitable to the actual submodule,
see Table 3-7 and Guidelines below.
*XLGHOLQHV0DVWHU%XVH[HFXWHGLQPDLQ&38
• You cannot mix MasterBus 300 (executed in main CPU) and MasterBus 300 (executed in
slave CPU) within the same controller.
• From a cost viewpoint, submodule carrier SC510 is preferable.
You can use other type, SC520, however you cannot mix two Masterbus 300 (executed in
main CPU) on the same carrier SC520.
*XLGHOLQHV0DVWHU%XVH[HFXWHGLQVODYH&38
• You cannot mix MasterBus 300 (executed in slave CPU) and MasterBus 300 (executed in
main CPU) within the same controller.
*XLGHOLQHV0DVWHU%XV(H[HFXWHGLQPDLQ&38
• You cannot mix MasterBus 300E (executed in main CPU) and MasterBus 300E (executed
in slave CPU) within the same controller.
• From a cost viewpoint, submodule carrier SC510 is preferable.
You can use other type, SC520, however you cannot mix two Masterbus 300E (executed in
main CPU) on the same carrier SC520.
*XLGHOLQHV0DVWHU%XV(H[HFXWHGLQVODYH&38
• You cannot mix MasterBus 300E (executed in slave CPU) and MasterBus 300E (executed
in main CPU) within the same controller.
*XLGHOLQHV%XV([WHQVLRQWR6,2
• S100 I/O Bus Extension is included on the Processor Module PM511.
• See separate hardware manuals for important restrictions on the distribution (cable
lengths, location, and so on) of the communication bus.
*XLGHOLQHV(;&20
• Communication interface CI531 has two ports V.24/RS-232-C. Each port can be used for
any combination of EXCOM, printer or MasterView 320.
*XLGHOLQHV956&
• Use the basic V.24/RS-232-C interface for printer and MasterView 320 communication.
• Communication interface CI531 has two ports V.24/RS-232-C. Each port can be used for
any combination of EXCOM, printer or MasterView 320.
*XLGHOLQHV5&20
• Communication interface CI532V01 has two ports. Both ports have the same protocol.
*XLGHOLQHV0XOWL9HQGRU,QWHUIDFH6WDQGDUG3URWRFRO
• Communication interface CI532Vxx or CI534Vxx has two ports. Both ports have the same
protocol.
• CI532Vxx is delivered with a standard protocol, for example RCOM, MODBUS,
Siemens. Different protocols are sold as different articles: CI532V01, CI534V02 and so
on. “V” stands for variant.
• Combining CI532Vxx, CI534Vxx, CI535 and CI538 is restricted, see Section 3.2.4.1,
Provided Link Types.
*XLGHOLQHV09,)UHHSURJUDPPDEOH&RPPXQLFDWLRQ
• The free-programmable MVI modules CI535/CI538 have two ports. Both ports have the
same protocol.
• CI535 and CI538 are delivered without protocol. The user defines the protocol.
• Combining CI532Vxx, CI534Vxx, CI535 and CI538 is restricted, see Section 3.2.4.1,
Provided Link Types.
$SSOLHG&RPPXQLFDWLRQ
,QWHUIDFHWR$SSOLFDWLRQ3URJUDP
7DEOH $SSOLHG&RPPXQLFDWLRQ8VHG/LQNVDQG,QWHUIDFHWR$SSOLFDWLRQ3URJUDP
6RIWZDUHLQWHUIDFH
(TXLSPHQW 8VHGOLQNV /LQN $SSOLFDWLRQ
'%HOHPHQWV '%3&HOHPHQWV
Advant Controller 410/450 MasterBus 300/300E CS513 (2) DS, DAT
(RCOM is an alternative)
Advant Station 500 Series OS MasterBus 300/300E CS513 (2) 6XEVFULSWLRQ&RPPDQG
(YHQWV
Advant Station 500 Series IMS MasterBus 300/300E CS513 (2) 6XEVFULSWLRQ&RPPDQG
(YHQWV
Advant Station 500 Series ES MasterBus 300/300E CS513 (2) 6HWRIFRPPDQGV
&RQILJXUDWLRQGDWD
MasterPiece 200/1 MasterBus 300/300E, RCOM CS513 (2) DS, DAT
MasterView 800/1 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 I/O MasterFieldbus CI570 I/O element
S800 I/O Advant Fieldbus 100 CI522A, I/O element
CI810A/CI820
Advant Controller 70 Advant Fieldbus 100 CI522A, AC70 DSP (Data Set Periph.)
DAT, EVS(R)
MasterPiece 51 MasterFieldbus CI570, PX PC: COM-MP51
TYRAK L, SAMI MasterFieldbus CI570, CV PC: COM-CVI1,
COM-CVO1
AdvaSoft for Windows GCOM CI543
MasterPiece 90 MasterFieldbus CI570, PX MFB-IN, MFB-OUT
Advant Controller 110 Advant Fieldbus 100 CI522A, AC110 DSP (Data Set Periph.),
(RCOM is an alternative) DAT, EVS(R)
6RIWZDUHLQWHUIDFH
(TXLSPHQW 8VHGOLQNV /LQN $SSOLFDWLRQ
'%HOHPHQWV '%3&HOHPHQWV
ACV 700, DCV 700 Convertor Advant Fieldbus 100 CI522A DSP (Data Set Periph.),
DAT
Advant Station 100 Series ES Internal bus --- 6HWRIFRPPDQGV
&RQILJXUDWLRQGDWD
ABB Prologger, DCS Tuner EXCOM CI531, CAPXCOM DS, DAT,
Read DI, DO, AI, AO
Printer V.24 / RS-232-C CI531, CAPPRI PC: TEXT, PRINT
MasterView 320 V.24 / RS-232-C CI531, TERMPAR TERMGEN, TERMDYN,
TERMDIS, TERMREF,
TERMSTR
Advant Controller 55 RCOM CI532 MS, DAT
ABB Active Mimic Controller RCOM CI532
Other manufacturers’ equipment PROFIBUS-DP CI541 PC: PB-S, PB-R,
PB-DIAG
DB: PBS, PBSD
LONWORKS Network LON,LONCHAN PC: LON-R, LON-S
DB: LONDEV,
LONNVI, LONNVO,
LONMNVI, LONEVTR,
LONMREF
MultiVendor Interface CI532 MS, DAT
- MODBUS (via CI532V02)
- Siemens 3964R
MultiVendor Interface MVIMOD MVB, DAT
- MODBUS (via CI534V02) MVICHAN
- Allen-Bradley DF1 MVINODE
MVI Free-programmable
communication
- via CI535 CI535 MS, DAT
- via CI538 MVIMOD MVB, DT
MVICHAN
MVINODE
(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-switches on the communication interface board CS513. From the
network communication viewpoint, the system is then automatically configured at power-up. See strapping information in the manual
0DVWHU1HW8VHU¶V*XLGH In addition to the data base element CS513, which shows basic communication parameters, further
parameters are found in the elements NETWL, TL, TU, BM, NM. Those latter elements are meant for advanced users.
*XLGHOLQHV'DWD6HW&RPPXQLFDWLRQ
'HVLJQDWLRQRI'DWD6HWV
Data Sets (DS) are used with signal exchange between, for example, controllers. A Data Set is
defined by a data base element which states if it is a transmitting or receiving Data Set, the cycle
time and from where the information is received or to where it is transmitted. The data base
element for a Data Set also refers to a number of DAT elements. These DAT elements contain,
in turn, the values which are to be transmitted/received.
When a DS and associated DAT elements are allocated names, it is important to be able to trace
the origin of the data, that is, where the data originates. One way is to give a Data Set a name in
accordance with DS “from node number” - “to node number”. If a Data Set is transmitted from
node 12 to node 11, it is given the name DS12-11. Associated DAT elements can be given the
name DS12-11.R1 (which is obtained automatically if a real DAT element is created with the
help of DS).
As an alternative, you can give DAT elements function-describing names (of up to 12
characters).
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
the beginning. If, despite the above actions, there are load problems in the controller or on the
bus, you can transmit data event-controlled. Use the PC element SENDREQ for this. You can
use the “VALID” flag on the data base element for a receiving Data Set and the DAT element as
a “Fresh data available” flag.
3URFHVV&RQWURO
$SSURSULDWH+DUGZDUHDQG6RIWZDUH
For the available general function block library included in the basic system program and
different additional system programs, see Section 1.7, Product Overview.
You are also referred to information regarding necessary hardware and software given in other
sections in this chapter. These sections are more focused on concrete functions.
,QWHUIDFHWR$SSOLFDWLRQ3URJUDP
The controller data base is the normal interface to the application program.
For example, there are different data base elements representing process interface such as
Analog Input, Digital Output, and so on.
$SSOLFDWLRQ%XLOGLQJZLWK$03/
This section is not intended to be a formal guide to application programming but rather a
collection of suggestions and ideas for program design and structuring. The following are
general rules for program design:
• Structure the application program (see below).
• Write programs that are as readily understandable as possible.
• Avoid “smart” programming unless absolutely necessary to achieve the necessary
performance.
• Prepare a draft PC diagram in which the required function is built up with the help of PC
elements.
• Use the largest elements possible.
• Use the most powerful elements possible.
• Use the principles of typical solutions (type circuits).
6WUXFWXULQJRIWKH$SSOLFDWLRQ3URJUDP
When structuring the application program, you must satisfy these three requirements:
• Structuring in accordance with the structure of the plant and the process.
• Structuring in accordance with execution time.
• Function orientation from the typical solution aspect.
The structure elements primarily 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 short cycle time. Note, however, that there
may be occasions such as at start, stop and emergencies when you must run all programs (-parts)
simultaneously. If there are such occasions, they determine how hard the controller can be
utilized.
Use the following as rules of thumb when structuring:
• Do not place the whole application in just one PC program.
• It is preferable that you place independent parts of the application program which have no
data exchange or a limited data exchange in different PC programs.
• A control module (CONTRM) delimits a function to which a special cycle time is applied.
• A function module (FUNCM) delimits a function consisting of several control modules or
divides a control module into subfunctions.
• Use more than three levels with structure elements only in exceptional cases.
• Use BLOCK elements to close part of a control module when reducing the load on the
controller.
127(
Writing to the data base continues while the blocking is active.
Use a simple pin diagram when you are structuring the application program.
6LJQDO([FKDQJHEHWZHHQ3&3URJUDPV
The main purpose of the division of the application program into PC programs is to divide the
application into independent parts which have no signal exchange with each other. It can,
however, be practical to divide the application into PC programs despite a limited signal
exchange between the parts. The signals are then exchanged through a DAT element in the data
base.
Use a consistent designation philosophy and a booking list. In certain cases, you can justify the
use of a binary DAT element for only one binary value in order to make it possible to allocate a
relevant plain language name to the element/signal.
2SHUDWRU¶V,QWHUIDFH
/RFDO2SHUDWRU
$SSURSULDWH+DUGZDUHDQG6RIWZDUH
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 separately.
Software supporting the operator function is included in an optional program module
QC07-LOS41.
&HQWUDO2SHUDWRU
$SSURSULDWH+DUGZDUHDQG6RIWZDUH
Communication with a central operator’s station, Masterview 800/1, Advant Station 500 Series
Operator Station or Advant Station 500 Series IMS Station, is an application of
MasterBus 300. 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, the named operator station products and their application are described
separately.
Software supporting the operator function is included in an optional program module
QC07-OPF41.
$YDLODELOLW\DQG6HFXULW\
*HQHUDO*XLGHOLQHV
Control system availability is often discussed in relation to industrial processes, power
generation systems, machines, and so on. Redundancy is one instrument to reach high system
reliability and availability.
The advantages of such redundancy include:
• Improved personnel safety
• Less risk of machine damage
• Reduction of expensive production loss
• Less demand for shift work by highly paid, qualified maintenance personnel.
Processes and machines are seldom identical and it is often necessary to adapt the solution of
the redundancy problem to the application concerned. It may be sufficient to equip particularly
sensitive process sections or functional parts with control system redundancy. The level of
redundancy considered necessary varies and can be, for example:
• 100% availability necessary - Hot stand by
• Stop for some seconds acceptable
• Stop for some minutes acceptable
• The possibility of controlled manual stopping of the process required.
When studying an operational malfunction 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 configuration,
study the question broadly. Base the result on the construction and requirements of the process
and the total function. “A chain is no stronger than its weakest link.”
By taking into consideration the risk of malfunction when designing a specific control system,
you can obtain a high degree of availability at minimum cost.
The distribution of sensitive I/O channels to different circuit boards is a form of risk-spreading.
You can divide application programs into an independent basic function and a more advanced,
perhaps optimization, auxiliary function, dependent on sensitive measurement functions.
This means that production need not be stopped when parts, both within the control system and
externally, do not function correctly.
Other means of increasing system availability, irrespective of the configuration selected,
are maintenance resources such as spare parts and the availability of trained personnel.
'XSOLFDWLRQIRU6HFXULW\
'$1*(5&$87,21
'XSOLFDWLRQRIFRQWUROV\VWHPIXQFWLRQVLVRQHZD\WRHQVXUHWKDWDOOWDVNVDUHSHUIRUPHG
FRUUHFWO\,WLVKRZHYHUYHU\LPSRUWDQWWRHPSKDVL]HWKDWWKHVHFXULW\LQDSURFHVVFRQWURO
V\VWHPZKHQLWFRPHVWRSHUVRQQHOVDIHW\PXVWQHYHUEHEDVHGRQGXSOLFDWLRQRIV\VWHP
IXQFWLRQVDORQH<RXPXVWDOZD\VFKHFNRWKHUPHDVXUHVDVZHOO.
In the most critical applications, a special design of the Advant OCS, the Advant Safety System,
is then applicable.
5HGXQGDQF\
$SSURSULDWH+DUGZDUHDQG6RIWZDUH
Redundancy is achieved by duplication of actual hardware modules.
Options for redundancy in Advant Controller 450 are described in Section 1.7.10.2,
Redundancy. It is not necessary to order extra software to support a duplication of hardware.
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 field instrumentation and other production
equipment.
– Costs of production stop vs. increased costs for a system with high availability.
– Vulnerability, price and performance with different alternatives.
• Separate redundant parts as far as possible to avoid common points of failure.
– Make use of separate I/O subracks for redundant I/O boards.
– Make use of separate submodule carriers for redundant communication interfaces.
• Be aware of the increased need for maintenance and spare parts to keep a high level of
availability.
0HFKDQLFV
See Chapter 2, Installation in this manual, Section 2.1, Site Planning Environment in particular.
+HDW'LVVLSDWLRQ
&DELQHW9HQWLODWLRQ
To avoid overheating, when ambient temperatures are high, take into consideration the heat
dissipated in the electronics cabinet. This is particularly important for cabinets with protection
degree (IP41, IP54) with considerable circuit board equipment and ambient temperatures at
levels approaching 40°C.
The frequency of faults is estimated to be doubled for each 20°C increase in temperature.
It is, therefore, important to maintain as low a temperature as possible where the equipment is
installed.
The different hardware modules in the controller and the I/O system have different outputs of
heat. Accurate calculation of the heat produced by the system requires knowledge of the
modules and the work cycle.
+HDW'LVVLSDWLRQ3HUPLWWHGLQ&DELQHWV
The maximum permitted temperature below 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 rise
within the cabinet, which results in a maximum permitted ambient temperature of 40°C
(55°C - 15°C).
In critical applications with subracks fully equipped and cabinets arranged in groups, you may
need to make a calculation of the actual power dissipation and an estimation of the temperature
rise within the cabinet. Calculation is recommended at system enlargement too.
Some data to be used in calculations is given below. Power dissipation for different hardware
modules is collected in Appendix E, Current Consumption and Heat Dissipation.
Cabinets including a single subrack normally have no temperature rise higher than 15°C,
irrespective of the disposition of the subrack, cabinet type and location of the cabinet.
&DELQHWVLQ*URXSV
When cabinets are installed in groups, reduce the permitted power dissipation in accordance
with Figure 3-6. The permitted power dissipation in a particular cabinet is the power specified
in Appendix B, RM500 Cabinet - Data Sheet multiplied by a factor from Figure 3-6.
0.95 0.95
&DELQHWV 0.9 0.9
)LJXUH 5HGXFWLRQ)DFWRUVIRU&DELQHWV,QVWDOOHGLQ*URXSV
&DOFXODWLRQRI+HDW*HQHUDWHGLQD&DELQHW
When you are calculating the heat generated in a cabinet, add up the heat generated by the
different circuit boards. To this sum, add the heat generated by the power supply units and other
equipment such as an extra modem, extra unit for supply of power to transmitters and so on.
See Appendix 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 of number of units
because of the load shedding.
The total power dissipated in the cabinet can be written as follows:
0DLQWHQDQFHDQG5HSDLU
From the maintenance viewpoint, use as few module types as possible in the hardware
disposition of a control system. This is most relevant with the process I/O design.
Standardization of I/O signal types and other electrical qualities is important to minimize the
spare part stock.
If possible, do not use “smart programming” when you make an application program.
Your solutions must make sense to the maintenance people in the event of disturbances and
following trouble-shooting.
([SDQVLRQ3RVVLELOLWLHVDQG6SDUH&RQVLGHUDWLRQV
([SDQVLRQ3RVVLELOLWLHV
You can connect a new Advant Controller 450 to an existing control network
(MasterBus 300) without affecting other stations and controllers. The new controller is
automatically incorporated in the communication system.
You can expand the controller step by step, that is the system can be enlarged and made more
complex in different ways. Examples of such areas are:
• Process I/O
• Communication with external computers 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 expansions and operations on-line.
Some preparations are necessary when you are dimensioning the system since the dimensioning
commands DIMDB and DIMPC are only available off-line. Practically, this is not a problem.
A number of spare instances in the database and spare PC program structures should always be
defined for future limited expansions.
Extensive reconfiguration and enlargement of the system is normally linked to revamping the
plant. Shut-down of the system and off-line work is then advisable.
6SDUH&RQVLGHUDWLRQV
In addition to what is said above regarding spare instances in the data base and spare space for
additional application programs, there is a simple rule of thumb for the hardware design:
You can add new I/O modules on-line. It is practical to have approximately 10% to 20% of the
channels spare. The same recommendation is valid for spare space in subracks.
0HPRU\&DOFXODWLRQ
Advant Controller 450 provides sufficient RAM for most applications (Table 3-9).
Other practical limits are normally attained before RAM is used up. A combination, however, of
huge PC programs, thousands of I/O points and a large number of logs with the shortest possible
log interval requires a lot of RAM. In such cases, you are advised to make a memory estimation
as soon as possible in the preliminary design work.
Empirical formulas are necessary for you to make a quick estimation of the memory
requirement. Table 3-9 for memory requirement calculation is presented below.
Forms for you to use in practice are given in Appendix G, Memory Calculation.
An explanation of the memory requirements of the different functions follows. You can assume
that the items listed include sufficient memory for common applications of a PC element. If the
application concerned has a special requirement in one or more respects, for example, the PC
program can be very complex, it may be necessary to adjust the memory requirements for this.
See the PC element manual for information regarding the memory requirements of individual
PC elements.
When discussing the memory, please note that there is a limit. The local data area 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.
([SODQDWLRQRI0HPRU\5HTXLUHPHQW
$,$2 An application with two four-input ADD elements (or other typical elements) is
assumed for each channel.
','2 An application with two four-input AND gates (or other typical gates) is assumed for
each channel.
3,'&21The feedback control loop consists of a PIDCON PC element with all size
parameters set to 1 and one PIDCON data base element.
3,'&21$The feedback control loop consists of a PIDCONA PC element with all size
parameters set to 1 and one PIDCONA data base element.
0$1671The manual station consists of one MANSTN PC element with all size parameters
set to 1 and one MANSTN data base element.
5$7,2671 A RATIOSTN PC element with all size parameters set to 1 and one RATIOSTN
data base element.
*(1&21*(1%,1*(186'An application corresponding to that in the manual for
functional units is assumed for each functional unit.
9$/9(&21The valve control consists of a VALVECON PC element with all size parameters
set to 1 and one VALVECON data base element.
027&21The motor control consists of a MOTCON PC element with all size parameters set
to 1 and one MOTCON data base element.
*5283The group start consists of an application corresponding to that in the manual for the
functional unit GROUP. The group start contains eight steps. The logic for control and
presentation contains around 70 PC elements. Subordinated functional units of the type
MOTCON are not included in this figure.
6(4 The sequence is assumed to consist of a sequence head, 10 steps and one data base
element SEQ.
7(;7Consists of one data base element TEXT.
7DEOHKDQGOLQJ The figures are calculated for one table with 10 rows and 100 values per row.
0DVWHU9LHZThe displays are assumed to have 40 text strings with 20 characters and 30
dynamic values. The event list is assumed to accommodate 100 events.
&HQWUDORSHUDWRUVWDWLRQThe numbers for logs are based on a log with 10 variables each with
240 stored values. Each value takes approximately 5 bytes.
Each group member in the group alarm function is assumed to be included in three group alarm
objects.
0DVWHU%DWFKThe number for PROCESSES is based on 50 storage vessels, four sections
and 20 operations with six recipe variables each.
6SDFHIRUVWRUDJHRI8VHU'LVNHWWHFRQWHQW 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.
6SDUH5$0DUHD Reserve RAM capacity is required because information about memory
requirements of the different functions is generalized and inherently uncertain. This RAM
compensates for minor departures from the data constituting the basis of the memory
requirement presented. Extra memory is also required when commissioning to permit smaller
adjustments of the application program.
7RWDO5$0UHTXLUHPHQW Must be less than the RAM size of the processor module.
7DEOH &DOFXODWLRQRI5$0UHTXLUHPHQW
)DFWRU
2EMHFWW\SH 5HPDUN 7RWDO 5$0UHT
NE\WHV
AI/AO signals S100 I/O x 0.30
S400 I/O (MP 51 not included) x 0.30
S800 I/O x 0.27
DI/DO signals S100 I/O x 0.26
S400 I/O (MP 51 not included) x 0.26
S800 I/O x 0.14
S800 I/O station No. of S800 I/O stations on AF 100 x 0.40
Calculated signals For presentation and event handling in x 0.30
AS 500 Series operator stations (includ-
ing signals via Advant Fieldbus 100)
)DFWRU
2EMHFWW\SH 5HPDUN 7RWDO 5$0UHT
NE\WHV
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 signals x 0.50
VALVECON Excluding I/O signals x 0.60
MOTCON Excluding I/O signals x 0.80
GROUP Excluding I/O signals(1) 1 x 3.00
SEQ Excluding I/O signals x 1.00
DAT No. of DB elements 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
(3)
No. of displays x 2.00
No. of MasterView 320 with event lists(4) x 9.00
AS 500 Series Basic requirement for QC07-OPF41 1 x 799.00
operator station
No. of trend data storage logs(5) x 12.00
and IMS Station or
MV800/1 Group alarm, No. of group objects x 0.13
No. of group members x 0.09
MasterBatch 200/1 Basic requirement for QC07-BAT41 1 x 418.00
No. of SECCONx1.7+OPCONx6.0+ x 1.00
TANKCONx1.8
No. of processes(6) x 25.00
PROFIBUS DP No. of PROFIBUSES x 1.20
Number of PROFIBUS slaves x 0.80
)DFWRU
2EMHFWW\SH 5HPDUN 7RWDO 5$0UHT
NE\WHV
LONWORKS No. of LONWORKS Communication x 65
Network modules (CI572/CI573)
No. of LONWORKS devices x 0.2
No. of LONWORKS variables x0.06
(input and outputs)
No. of LONWORKS multiple network x 0.33
variable
No. of LONWORKS Event Treat x 0.14
No. of MasterBus x 8.00
300/300E,
RCOM/RCOM+,
GCOM and
MultiVendor Inter-
face
User Defined Basic requirements for QC07-UDP41 1 x 132.00
PC elements
Storage of user defined PC elements(7) 1 x 150.00
Space for storage of User Diskette contents(7) x 100.00
Basic requirements for QC07-LIB41 1 x 32.00
Basic requirements for QC07-LIB42 1 x 479.00
Basic requirements for QC07-FUZ41 1 x 40.00
Basic requirements for QC07-COM41 1 x 33.00
Basic requirements for QC07-BAS41 1 x2207.00
Spare RAM area(8) 1 x 40.00 40.00
$SSUR[LPDWLYHWRWDO5$0UHTXLUHPHQWLQNE\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) 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 is known.
(8) Recommended value for most systems.
(9) Must be less than the RAM size of the processor module (8 or 16 Mbyte).
&38RSWLPL]DWLRQ/RDG&DOFXODWLRQ
This section deals with the program execution capacity of an Advant Controller 450. It provides
answers to questions such as, “What can I expect the load generated by my 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.
:KDWLVWKH&38WRGR"
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 functions are activated simultaneously. A schematic presentation of the priority
system follows.
$GYDQW&RQWUROOHU3ULRULW\6\VWHP
Priority
Clock (Timer task) PV67$//
+LJK
PC and I/O with cycle times, 10, 20, 40 ms
Interrupt-controlled DI
AI-channels with cycle times 5, 10, 30, 60, 300 and 600 secs
MasterBus 300
System status
Data Set-communication
EXCOM
)LJXUH $GYDQW&RQWUROOHU3ULRULW\6\VWHP
There is a “stall level” between the different levels. This means that the system must execute all
functions, including all PC-control operations, at least each fifth second for the system to
continue operation. If an operator station or an engineering tool is connected to the controller,
a warning consisting of a system message is presented on the display screen if all functions are
not executed within a 30-minute period. This protection is provided to guarantee that all
functions in an Advant Controller 450 have sufficient time to perform their 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.
&38/RDG&DOFXODWLRQ
With certain heavy load situations in an Advant Controller 450, or if you want to determine if
one controller is sufficient for a particular application/load, it may be valuable to perform a CPU
load calculation.
In the development of standard solutions, including type circuits of different scales, other
working methods are strongly recommended. The best result is obtained by load measurement
in an actual target system. For CPU load measurement, see the use of the ANPER command in
the manual $03/&RQILJXUDWLRQ$GYDQW&RQWUROOHU 6HULHV.
Load calculation is not intended to give absolute values, but rather to indicate the magnitude of
the load generated by the different parts. The calculation also provides an excellent basis for
determination of where optimization would be most effective 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:
$FFXUDWHPHWKRG2) 6KRUWFXWPHWKRG2)
Approx. 4 % + 3) Approx. 4 % + 3)
Base load
PC and Process I/O Detailed analysis and calculation Use of EAF load data 1)
(Application)
Subscription, Detailed analysis Typical 4%
Command, Events
Detailed analysis Typical 4%
Data Set, EXCOM
∑ 100 % ∑ 100 %
1) EAF is the abbreviation for
Estimated Application Function
)LJXUH &38/RDG&DOFXODWLRQ0HWKRGV
$GGLWLRQDO,QIRUPDWLRQIRU5HGXQGDQW3URFHVVRU0RGXOHV
The performance of redundant processor modules is reduced to 95% in relation to a single
system. Divide all load figures given by 0.95.
+RZFDQDQ([FHVVLYH&38ORDGEH5HGXFHG"
First analyze the application to determine where you can take the most effective optimization
action. Primarily, you can take optimization action in three areas, I/O, PC and communication.
As usual with optimization, it is most profitable to optimize the part which uses the most CPU-
power.
Recommendations for optimization in these three areas are given below.
,2
• If many interrupt-controlled DIs with high frequency of change are used, it can be optimal
to go over to cyclically scanned DI, if this is permissible from the time-tagging viewpoint.
The form for “Calculations of CPU-load from inputs” can indicate if this is optimal with
interrupt-controlled or scanned DI.
• Are I/O signals scanned with an unnecessarily short cycle time? I/O signals normally need
not be scanned more often than the cycle time of the execution unit in the PC in which they
are used. Note that it may be necessary 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 the accuracy
requirement must be considered.
3&
• Check that no execution unit is executed with an unnecessarily short cycle time.
• If possible, break out parts of an execution unit or execution units and allocate to these a
longer cycle time.
• Utilize the option to block execution units when they need not be executed. It is also
possible to introduce a BLOCK element here when only parts of an execution unit can be
blocked.
&RPPXQLFDWLRQ
• You can transmit Data Sets event-controlled on a MasterBus 300 with the help of the PC
element SENDREQ. Use the VALID flag in the receiving DS as an acknowledgment that
the signal is received.
• Always present digital signals on the operator station screen with event-controlled update
in combination with 9 sec cyclic update, to get fast updating on changes while minimizing
the load.
*HQHUDO6\VWHP8WLOLWLHV
&38
*HQHUDO7HFKQLFDO'DWD&DSDFLW\
7DEOH 7HFKQLFDO'DWDRI&38DQG0HPRU\
'DWD $GYDQW&RQWUROOHU
CPU type MC68040
Clock frequency 25 MHz
RAM (total) 8 alt. 16 MByte
RAM (for application) Calculate from Table 3-9
3HUIRUPDQFH*HQHUDO
The load caused by different subsystems in the controller is reported below. To start with, you
will find an overview. The following headings cover details to respective subsystems, apart
from individual PC element load data, which is included in the PC element manual.
All performance data is based on actual measurements in Advant OCS configurations.
For instructions on how to make calculations, see Section 3.1.14, CPU-optimization, Load
Calculation.
127(
The performance of redundant processor modules is reduced to 95% in relation to
a single system. Divide all load figures given by 0.95.
The load from cyclic functions in Advant Controller 450 is built up as shown in Figure 3-9.
Subscription, Command
and Event Handling
Logging
Others
Reserve
Recommended min
)LJXUH /RDGIURP&\FOLF)XQFWLRQV2YHUYLHZ
3HUIRUPDQFH%DVH/RDG
The fix base load 4 % of a controller can be further subdivided as follows:
• General load 1.5%
including basic network communication load (MasterBus 300)
irrespective of number of links, redundancy or type of communication interface module
(that is utilization of slave CPU or not).
• PC and Process I/O related load 2.5%
This latter load does not exist in working mode CONFIGURATION.
A variable base load exist. Each additional node on the network will increase the load 0.15 % if
SC510 is used. This extra load will not appear if the SC520 is used.
3HUIRUPDQFH3&DQG3URFHVV,2$SSOLFDWLRQ
3URFHVV,2+DQGOLQJ
In addition to the base load, the following handling times apply to the various I/O channels.
All times are in msec and per channel, where not otherwise indicated.
%DVLFWLPH $GGLWLRQRQFKDQJH
&KDQQHOW\SH
(each execution) (VALUE changed)
AI 0.20 0.15
DI scanned 0.20/board 0.05
DI interrupt -- 0.60
AO 0.02 0.18
DO 0.003 0.13
AIC 0.003 0.08
DIC 0.003 0.05
AOC 0.003 0.03
DOC 0.003 0.03
(1) Channels with NORMAL_TREAT = 1 (event handling selected) will give rise to
increased load when the event occurs, which means VALUE changed (DI) or
LIMIT exceeded (AI), this is not included in the table. However this is taken care
of by having the stipulated reserve capacity.
3&6\VWHP
In addition to the base load of the PC interpreters (included in base load given above), the CPU
load generated by the PC system is composed of the following parts:
• PC element execution. The PC element manual contains information on the load from each
PC element.
• Reading and writing of data to/from the data base. Each time a value is read from the data
base to a PC element, or written to the data base from a PC element, 2 microsecs are spent.
When a process output channel is written, add the time for I/O handling.
(VWLPDWHG$SSOLFDWLRQ)XQFWLRQV
Use the following execution times and load figures when the shortcut method of CPU load
calculation is applied:
• One feedback control loop takes approximately 0.8 ms.
Thirty feedback control loops with the cycle time 1000 ms thus give approximately 2.5%
load. (Complexity: 1- PIDCON, 1- AI, 1- AO and several calculation and logic elements.)
• A corresponding feedback control loop as above but using PIDCONA takes approximately
1.0 ms.
• One feedback control loop for a three-position actuator takes approximately 1.0 ms.
Ten such loops with the cycle time 2000 ms give approximately 0.5% load.
Complexity: 1- PIDCON, 1- CON-PU1, 2- AI, 2- DO and some calculation and logic
elements.
• When cascade-coupled regulators are applied, consider approximately each loop in the
cascade as a single loop. Use the figures above.
• A simple feedback control loop takes approximately 0.5 ms.
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 approximately 1% load.
Complexity: 1- AI alt. 1- AO.
• One measuring circuit, for example mass flow measuring, max/min selector, application
adapted linearization, and so on takes approximately 0.4 ms.
Complexity: 1- AI, some 5 arithmetic elements and logic elements.
• A motor drive takes approximately 0.7 ms.
Fifty motor drives with cycle time 1000 ms give approximately 3.5% load.
Complexity: 1- MOTCON, 1-AI, 5- DI (interrupt), 1- DO, some logic elements.
• An on/off valve control takes approximately 0.3 ms.
Fifty valve controls with cycle time 1000 ms give approximately 1.5% load.
Complexity: 1- VALVECON, 2- DI, 1- DO, some logic elements.
The execution time of a digital signal DI or DO with attached interlocking logic depends of
certain conditions. Table 3-12 gives you some alternative applications.
7DEOH ([DPSOHRI([HFXWLRQ7LPHVRI'LJLWDO6LJQDOV
/RDGH[DPSOH
VLJQDOV3&
6LJQDOW\SH &KDQJHIUHTXHQF\
HOHPHQWF\FOLF
&RQGLWLRQ
WLPHPV
3HUIRUPDQFH6XEVFULSWLRQ&RPPDQGDQG(YHQW+DQGOLQJ
6XEVFULSWLRQ
The load in an Advant Controller 450 caused by a central operator station or information
management station subscription is a linear function of the number of “objects” (for example,
AI, DI, PIDCON) subscribed for and of the update frequency. The load only comes up when a
subscription is utilized.
127(
The capacity of the communication bus must also be considered in the
performance 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 object types and
communication module CS513 with a slave CPU is presupposed.
Always present digital signals with event-controlled update in combination with 9 sec cyclic
update, for fast updating on changes while minimizing the load.
The total load in the controller from subscriptions for displays should normally not exceed
20%.
Load (%)
3 1 s Update
time
6& 2
REMHFWW\SHV
3s
1
9s
10 20 30 40 50 60 70 80 90 100 110 Number
of objects
1s
Load (%)
3
6& 3s
REMHFWW\SHV 2
1 9s
6& 2
(utilization of slave 1s
CPU)
REMHFWW\SHV 1
3s
9s
10 20 30 40 50 60 70 80 90 100 110 Number
of objects
Load (%)
3 1s
6&
(utilization of slave 2
CPU)
3s
REMHFWW\SHV 1
9s
10 20 30 40 50 60 70 80 90 100 110 Number
of objects
)LJXUH /RDG&DXVHGE\6XEVFULSWLRQ
&RPPDQG
The load in a controller caused by a command from an operator station or an information
management station is non-recurrent and relatively small. It can be disregarded.
(YHQW+DQGOLQJ
I/O signals (including calculated variants) with NORMAL_TREAT = 1 (event handling
selected) will give rise to increased load when the event occurs, which means VALUE changed
(DI) or LIMIT exceeded (AI). However this is taken care of by having the stipulated reserve
capacity.
3HUIRUPDQFH'DWD6HWZLWK0DVWHU%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 CPU load caused by the basic network communication between
two nodes is included in the CPU base load figures given.
Load (%)
SC510
2 SC520
(utilization of
slave CPU)
1
4 8 12 16 18 Number of
DS / sec.
Load [%]
SC510
4
3
SC520
(utilization of
2
slave CPU)
4 8 12 16 18 Number of
DS / sec.
3HUIRUPDQFH0DVWHU9LHZ
The resulting CPU load in Advant Controller 450 from one MasterView 320 is given in
Figure 3-13.
Load [%]
10
4 See text
10 20 30 40 50 Number of
max. 48 variables/sec
On the X-axis you can find the update requirement from a display, which is SUHVHQWHGRQWKH
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.
3HUIRUPDQFH/RJJLQJ
The load caused by each individual log can be estimated from the diagrams and models below.
Finally make an addition.
The lowest configured value of sampling interval or log interval for an actual log is used when
entering the 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,QWHUYDOVVV
( )
1s
log interval
(sampling interval
2.0 at mean value log)
1.5
2s
1.0
0.5 5s
10 s
6 12 18 24 30 Number of
variables
in the log
0HGLXP/RJ,QWHUYDOVVV
Load (%)
12 s
0.5 log interval
(sampling interval
at mean value log)
0.4
0.3 20 s
0.2
30 s
0.1
20 40 60 80 100 Number of
variables
in the log
/RQJ/RJ,QWHUYDOV≥PLQXWH
A typical load caused by a single long interval log including 100 variables can be set to 0.05%.
3HUIRUPDQFH2WKHUV
*HQHUDO
A number of applications of communication links are dealt with below. The communication link
itself will give rise to a small controller CPU load. This load is specified for each application
and should be finally added when the 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.
'DWD6HW3HULSKHUDOZLWK$GYDQW)LHOGEXV
Data set peripherals (DSP) are cyclically transmitted to their respective destinations, with a
cycle time selectable in the range 32 ms to 4096 ms.
The Advant Controller 450 CPU load from data set peripheral communication can be estimated
from the curves given in Figure 3-16 and Figure 3-17.
R = Receiving
Load (%) S = Sending
5
R
S
4
)LJXUH /RDG&DXVHGE\'63ZLWK$GYDQW)LHOGEXV%DVLF&\FOH7LPHPV
The basic cycle time for the DSP scan task is set to 32 ms with the APP command.
Add the basic link load = 0.2 % (no sending/receiving).
R = Receiving
Load (%) S = Sending
R
3
S
)LJXUH /RDG&DXVHGE\'63ZLWK$GYDQW)LHOGEXV%DVLF&\FOH7LPHPV
The basic cycle time of the DSP scan task i 512 ms (default value).
Add the basic link load = 0.2 % (no sending/receiving).
'DWD6HWDQG$,$2','2ZLWK(;&20
The load in an Advant Controller 450 caused by a communication with an external computer
using EXCOM is approximately the same irrespective of if the actual controller is a transit node
or a slave node in the communication. The computer is always master.
Reflect the following when you read the load data at different transmission 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.
• To minimize the CPU load and to get high communication throughput you should apply
several signals in each message.
$ 2 signals / message
% 4 signals / message
& 8 signals / message
Load (%)
0.6 (30) 45 61
& % $
0.4
0.2
12 24 36 48 60 Messages / sec
)LJXUH /RDG&DXVHGE\(;&20ELWVHF
$ 2 signals / message
% 4 signals / message
& 8 signals / message
Load (%)
270
4 $
2 125
%
1
& (50)
)LJXUH /RDG&DXVHGE\(;&20ELWVHF
$ 2 signals / message
% 4 signals / message
& 8 signals / message
Load (%) 345
6 $
3 167
(70)
%
2 &
)LJXUH /RDG&DXVHGE\(;&20ELWVHF
3HUIRUPDQFH5HVHUYH
This is a matter of the disposition of the total CPU load. A reserve of 15 to 20% is
recommended. See Section 3.1.14, CPU-optimization, Load Calculation
5HGXQGDQW3URFHVVRU0RGXOHV
3HUIRUPDQFH
&38ORDG
The performance of redundant processor modules is reduced to 95% in relation to a single
system. Divide all load figures by 0.95.
8SJUDGLQJ7LPH
Time required to upgrade the system from SINGLE to DUAL status.
With 8 Mbyte RAM <90 s
&KDQJHRYHU7LPH
Typical 5 - 10 ms
Maximum 25 ms
0HPRU\
*HQHUDO7HFKQLFDO'DWD&DSDFLW\
6\VWHP6RIWZDUHDQG$SSOLFDWLRQ3URJUDP
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\%DFNXS7LPH single CPU system (8 or 16 MByte) min. 4 hours
redundant CPU system min. 2 hours
(after ≥20 h of recharging).
6\VWHP6RIWZDUH%DFNXS
Program card with flash PROM (PCMCIA)
Number of program cards (min. 1) max. n1 (n1 + n2 ≤4)
$SSOLFDWLRQ3URJUDP%DFNXS
Optional program card with flash PROM (PCMCIA).
Various memory sizes available.
Cannot be mixed with System Software Backup
in a single program card.
Number of program cards. max. n2 (n1 + n2 ≤4)
0HPRU\5HTXLUHPHQW
Use empirical formulae to permit practical estimation of the memory requirement of the
different functions. Please refer to Section 3.1.13, Memory Calculation. For detailed
information regarding the memory requirements of different PC elements, see the reference
manual 3&(OHPHQWV$GYDQW&RQWUROOHU 6HULHV.
6\VWHP&ORFN
*HQHUDO7HFKQLFDO'DWDRIWKH6\VWHP&ORFN
Inaccuracy expressed as drift in time max. 0.1 ms/s
(stand-alone system)
When a controller is included in a control network, the clock is
synchronized to a master clock, for example the clock in an operator station
or a dedicated controller.
The accuracy is then related 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
Relative time error with time-tagged events, see Section 3.2.3, Process Interface.
The external synchronization input is, from an electrical viewpoint, compliant with PC
standards. For data, see Table 3-13 below.
7DEOH &ORFN6\QFKURQL]DWLRQ(OHFWULFDO'DWDIRU0LQXWH3XOVH
'DWD 9DOXH
Input signal “0” = -50 to + 2 V
(opto coupled input type) “1” = +12 to + 60 V
Filter time constant ≤1 ms
Pulse length >10 ms
Triggers at positive flank
3RZHU6XSSO\
Current consumption is a complex matter when it comes to a flexible control system concept.
For rules for calculation of current consumption and dimensioning of distribution board fusing,
see Section 3.1.3, Power Supply.
A quick guide of power consumption to use in a very preliminary phase of work on a project or
anytime you need estimated figures for planning purposes follows.
Note that average figures are given. That means:
• Average equipped subracks
• Most common mixture of modules.
In other respects, 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+DUGZDUH5HIHUHQFH0DQXDO
7DEOH (VWLPDWHG6\VWHP3RZHU&RQVXPSWLRQ
&RQWUROOHUDQG 3RZHUFRQVXPSWLRQ
QXPEHURI,2VXEUDFN FRVϕ>DWDF
-- 240 W
1 420 W
3 780 W
5 1140 W
3RZHU6XSSO\,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.
3URFHVV,QWHUIDFH
*HQHUDO7HFKQLFDO'DWD&DSDFLW\
(YHQW+DQGOLQJ
For each object type, there is a buffer in the controller for event bursts. These buffers have the
following capacity:
1. The time limit is valid at lowest permitted supply voltage 19.2 V and maximum load (worst
case)
7DEOH 6L]HRI%XIIHUIRU(YHQW%XUVW
2EMHFWW\SH %XIIHUVL]H
DI 200 events
AI 40 events
PIDCON 90 events
PIDCONA 90 events
GENOBJ 70 events
MANSTN 30 events
RATIOSTN 30 events
SEQ 30 events
MOTCON, VALVECON, 350 events
GROUP, MMCX
If an event burst exceeds the capacity of a buffer, the “lost events” are marked in the data base
file and sent to the operator station with time marked “uncertain” when the load decreases.
These events will not be missing in the event and alarm lists if MasterBus 300 is used.
The maximum steady state rate is 2 events/sec.
Momentary event bursts with higher frequency are handled
as described above.
5HODWLYHWLPHHUURUZLWKWLPHWDJJHGHYHQWV
• Events handled within a controller utilizing S100 I/O or
S800 I/O with SOE functionality <2 ms
• Events handled within a controller utilizing S400 I/O 10-100 ms
(The event is time tagged when the signal arrives at the controller.
Time error depends on scanning selected.)
• Events handled within 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 be evaluated from the expression:
Maximum relative time error = a + b + c
a = scan cycle time of the Fieldbus Communication Interface 5 - 100 ms, not configurable
b = Cycle time of Advant Fieldbus 100 (set by the user, terminal INSCANT)
c = scan cycle time of the process data communication in Advant Controller 450
(set by the user, terminal SCANT).
• It is also possible to receive events from Advant Controller 70/110 using Advant
Fieldbus 100, or from Advant Controller 55/110 using RCOM/RCOM+. The relative time
error between events for different configurations are given in Table 3-16. A condition for
the table is that all events are connected to one Advant Controller 410/450.
(YHQWVJHQHUDWHGE\ 5HODWLYHWLPH
%XV HUURU
&RQWUROOHU 0RGXOH&DOF PV
Advant Fieldbus 100 Advant Controller 110 DI650 <2
Advant Controller 110 Calculated in AMPL <2 + Sct (1)
Advant Controller 70 Calculated in AMPL <2 + Sct (1)
RCOM/RCOM+ Advant Controller 110 DI650 <50 (2)
Advant Controller 110 Calculated in AMPL <50 + Sct (1) (2)
6,2
*HQHUDO7HFKQLFDO'DWD&DSDFLW\
Please note that you must consider practical limits when the data below is applied:
• Space in the used cabinet
• CPU load
• Integrity aspects
• Availability aspects.
7DEOH &DSDFLW\6,2
'DWD 9DOXH
(1)
No. of buses (bus extension) 1
Near side bus
No. of ”nodes” (I/O subrack and/or optical modems) max. 5
Total length of el. bus extension cable max. 12 m (39 ft.)
Far side bus
Total length of optical bus extension cable max. 500 m (1640 ft.)
No. of ”nodes” (I/O subrack) max. 5
Total length of el. bus extension cable max. 12 m (39 ft.)
No. of I/O boards per subrack max. 20 (2)
No. of DI boards 48
(3)
DI signals max. 2300
No. of DO boards 48
DO signals (3) max .1489
No. of AI boards 32
(3) (4)
AI signals max. 910
No. of AO boards 32
AO signals (3) max . 963
No. of other board types
DSAI 133 (5), DSAI 133A (5) 48
DSAX110, DSAX 110A 48
DSDP 150 4
DSDP 170 48
DSDC 111 (6) 24
DSDP 140A (6) (7) 24
(1) Single or redundant.
(2) The maximum is 19 when S100 I/O Bus Extension redundancy is used.
(3) This total includes S100 I/O signals, S400 I/O signals and calculated signals.
(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 31 channels. DSAI 151 with 14 channels. DSAI 155A with 14 channels.
(5) A range of modems and connection units are available for the different communication media.
See respective communication User’s Guide.
(6) DSDC 111 and DSDP 140A occupy two I/O addresses.
(7) The maximum recommended number of DSDP 140A boards is 10.
6,2
*HQHUDO7HFKQLFDO'DWD&DSDFLW\
Please note that you must consider practical limits when the data below 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) max. 16
No. of DI signals (2)
max. 2300
No. of DO signals (2) max. 1489
No. of AI signals (2) max. 910
No. of AO signals (2) max. 963
(1) Including products like MasterPiece 51, TYRAK L, SAMI, etc.
(2) This total includes S100 I/O signals, S400 I/O signals, S800 I/O signals
and calculated signals.
6,2
*HQHUDO7HFKQLFDO'DWD&DSDFLW\
Please note that you must consider practical limits when the data below is applied, for example:
• Space aspects
• CPU load
• Integrity aspects
• Availability aspects.
'DWD 9DOXH
No. of AF100 buses max. 8
No. of I/O stations/bus max. 79/32 (1) (2)
No. of I/O modules per station max. 24
No. of cluster per station 8 (3)
'DWD 9DOXH
No. of I/O modules per cluster 12 (3)
No. of DI signals (4) max. 2300
No. of DO signals (4) max. 1489
No. of AI signals (4)
max. 910
No. of AO signals (4) max. 963
No. of DP820 Pulse Counter channels ca. 1700 (5)
(1) 32 is valid for a twisted pair communication media within a segment.
(2) If other stations than S800 I/O stations are used on the same Advant
Fieldbus 100, the maximum number of S800 I/O stations must be reduced
with corresponding 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.
&RPPXQLFDWLRQ
3URYLGHG/LQN7\SHV
*HQHUDO7HFKQLFDO'DWD&DSDFLW\
7DEOH 3URYLGHG/LQN7\SHV&DSDFLW\
/LQN7\SH 1XPEHURILQVWDQFHV
MasterBus 300 (executed in main CPU) max. 2 buses (1) Tot. max. 2
MasterBus 300E (executed in main CPU) max. 2 buses(2)
MasterBus 300 (executed in slave CPU) max. 6 buses (1) Tot. max. 6
MasterBus 300E (executed in slave CPU) max. 6 buses (2)
Bus Extension to S100 I/O max. 1 link (Single or redundant.)
MasterFieldbus max. 7 buses
max. 16 units per bus
7DEOH 3URYLGHG/LQN7\SHV&DSDFLW\
/LQN7\SH 1XPEHURILQVWDQFHV
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 (executed in slave CPU) within the
same controller.
(2) You cannot mix MasterBus 300E (executed in main CPU) and MasterBus 300E (executed in slave CPU) within the
same controller.
(3) Max number of communication modules, CI572 or CI573, is four.
(4) Please note that EXCOM, RCOM and MVI also utilize V.24/RS-232-C at the physical layer (electrical interface).
(5) RCOM and MVI (available protocol) use the same type of communication interface CI532Vxx or CI534Vxx.
MVI (free-programmable facility) uses communication interface CI535 or CI538 and GCOM uses CI543.
CI532Vxx, CI534Vxx, CI535 and CI538 have two physical channels each.
The following restrictions are valid:
- No of CI532Vxx +CI534Vxx + CI535 + CI538 + CI543 ≤ 5.
- Max number of physical channels is nine (limit in software).
$SSOLHG&RPPXQLFDWLRQ
*HQHUDO7HFKQLFDO'DWD&DSDFLW\
Normally there are no limits in capacity beyond the limits placed by the actual link for the
application. Extended information for certain applications are found below. Regarding the
maximum number of links available in Advant Controller 450, you can find information in
Section 3.2.4.1, Provided Link Types above. For further technical data such as load data,
performance, maximum lengths, for the different links, see separate documentation.
3URFHVV&RQWURO
*HQHUDO7HFKQLFDO'DWD&DSDFLW\
Primarily, an application program for process control is “softly” limited by different
considerations like: CPU load, integrity, availability, security, and so on. You can find
information on these topics in part elsewhere in this manual. Some key data put “hard” limits on
an application program for process control. The main key data are listed below.
)XQFWLRQ 0D[LPXPQXPEHU
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 173
GENOBJ (GENUSD+GENBIN+GENCON) 528 (in total)
MOTCON+MOTCONI+VALVECON+GROUP +MMCX 595(in total)
PIDCON 234
PIDCONA 203
MANSTN 420
RATIOSTN 330
GRPALARM 151
GRPMEMB 2978
Data transfer and Communication:
DAT 32000
TEXT 32000
3&3*0
max. 99 Max. deep is 9 levels
(practically 4 - 5)
Structuring element
max . 999
or
Structuring element Block/PC element
max. 999 max. 256
)LJXUH 6WUXFWXULQJ/LPLWV
/RJJLQJ
The following table shows the logging capacity of Advant Controller 450. Note, however, that
the CPU load and the RAM requirement must also be considered.
$VSHFW /LPLW9DOXH
Max. no. of logs 15
Max. no. of variables/log 127
Max. no. of storable values/variables 32767
(common to all variables in the log) (The free amount of RAM usually sets a
lower limit)
Log sampling intervals 1, 2, 3, 4, 5, 6, 10, 12, 15, 20, 30 s
(in discrete steps) 1, 2, 3, 4, 5, 6, 10, 12, 15, 20, 30, min
1, 2, 3, 4, 5, 6, 12, 24 h
1 week
2SHUDWRU¶V,QWHUIDFH
/RFDO2SHUDWRU6WDWLRQ
*HQHUDO7HFKQLFDO'DWD&DSDFLW\
The number of local operator stations is limited to 4.
&HQWUDO2SHUDWRU6WDWLRQ
*HQHUDO7HFKQLFDO'DWD&DSDFLW\
The number of operator stations of the types Advant Station 500 Series and MasterView 800/1
is limited to 16.
3ULQWHU
*HQHUDO7HFKQLFDO'DWD&DSDFLW\
You can use printers which satisfy the following requirements with Advant Controller 450.
7DEOH 3ULQWHU'DWDZKLFK0XVWEH)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
Signals used and pinning in the communication board CI531 for RS-232-C are shown in
Table 3-24.
7DEOH 3ULQWHU6LJQDOV56&
$YDLODELOLW\
The reliability and availability of an Advant Controller 450 and its I/O can be calculated on
request. Such a calculation can be adapted to the actual application and it can be extended to
include all Advant OCS equipment in an automation system.
$SSOLFDWLRQ6WDUWXS
Not applicable. See Chapter 2, Installation.
7XWRULDO
The aim of this section is to give those who are inexperienced in this area a VKRUWJXLGH through
the different phases of a controller design project. There are methods and tools developed to
make such project work effective in a variety of aspects. No references are made to methods and
tools in this section because that is beyond the scope of this product manual.
Whenever possible, concrete references are made to suitable sections in this manual or to other
documentation. The novice reader will preferably read the Introduction (Chapter 1) and
Section 3.1, Design Considerations in this manual completely before starting the design work.
,QWURGXFWLRQWRWKH'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
• Maintenance.
Individual requirements on particular supporting processes like electric, instrument air, cooling,
and particular subplants and sections are given in the Plant Design Documents. Here you can
also find documents which are the basis of the control system design. Examples of such
documents commonly used are:
• Function Descriptions (detailed)
• P&I diagram
• Instrument lists
• Motor lists
• I/O lists
• Applicable standards (plant, domestic, international).
'HVLJQ3URFHGXUHV
The following four main stages can be identified in the control system design procedure:
• 6\VWHP'HILQLWLRQ
Based on process control application analyses, a definition of the equipment must be
made.
The system definition phase is supported by this manual, especially Chapter 1, which gives
an overall introduction from the functional and available resources viewpoints and, of
course, Section 3.1, Design Considerations. In addition, Section 3.2, Technical Data
Including Capacity & Performance gives some important information.
The $GYDQW2&63URGXFW*XLGH gives you an overview of the available product
alternatives and possible options. Not “every combination” is either practical or offered.
&RQWUROOHU6\VWHP&RQILJXUDWLRQ
The controller system configuration is the practical work required to create the
infrastructure of the controller, that is the computer resources to maintain the application
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 Elements
– DB Elements
– Functional Unit descriptions (adequate parts)
– Application Examples: Measuring, Feedback Control.
Please refer to Section 1.5 for further document information.
• ,QVWDOODWLRQ
This is not really a design procedure. However, during the design there are certain
installation considerations to take care of, for example the connection to the process. It is
mentioned here as a reminder.
6\VWHP'HILQLWLRQ
System definition in the actual context is a definition of the equipment required.
As a basis of the system definition, it is assumed that superior design stages have resulted in an
overall rough application-functional identification. It is further assumed that a scheme of the
functional distribution is available. Thus, a rough allocation of functions to different controllers
is available.
&RQILJXUDWLRQ$SSOLFDWLRQ%XLOGLQJ
The next step is to make a detailed function identification and to design the application program
based on AMPL. Finally, you implement the program.
To sum up, the main activities are:
• Circuit identification with respect to
– Standard type circuits (typical solutions)
– User-defined type circuits
– User-defined circuits
– User-defined PC element.
• Structuring
• Definition of functional interface to other system
• Execution control work-through
• Design of start-up program which include securing of application dynamic data during
power supply disconnection
• Configuration/Implementation
This is mostly an interactive session using an engineering station.
Some of these activities, subactivities and other similar subjects of interest are dealt with below.
1DPLQJ
All global objects are identified (and accessed) by unique names which you define within an
application project. Certain objects are given default names by the system, which you can
change later. From the system’s point of view, the name structure is flat. However, since a name
is a visible ASCII string, you can implement any kind of structure in naming objects.
Names are introduced in a controller via data base elements representing the actual object.
In general, the designation (connection NAME) on the data base element must be unique in the
controller. Designations referred to from an operator station via a Control Network must also be
unique in the total process control system connected to that network.
When defining signals, it is important that the signals be given names which are well considered
and will not have to be changed at some later stage.
With auto-generation of a PC-diagram, the signal names are printed in the diagram. This is 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 designation philosophy for objects in the process control system must be established when
the signals are named. (Following relevant standards.) The designations should preferably be
hierarchic so that objects and signals are given associative names.
A feedback control loop for level control named LICA 104 (LICA = Level Indication Control
Alarm) is an example.
The PID controller object is assigned the name LICA 104 while the actual value (the feedback
signal) is suitably designated LT 104 (LT = Level Transmitter) and the controller output value
LV 104 (LV = Level Valve). These names are obtained from one of the standards for
designations in process industries, ISO 3511.
$GYDQW&RQWUROOHU 3URFHVV
LV 104 Control
valve
PID controller
LICA 104 AO LV 104
LT 104 Level
transmitter
AI LT 104
)LJXUH ([DPSOHRI'HVLJQDWLRQVLQD)HHGEDFN&RQWURO/RRS
7\SH&LUFXLWV
Type circuit building is a very important aid in the configuration procedure. A type circuit is the
largest common collection of PC elements which occurs at several places in the application
program.
A type circuit can be, for example, a certain type of feedback control loop or a panel control unit
with push buttons and lamps. An advantage obtained by working with type circuits is that the
work in designing the application program 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 become standardized.
$SSOLFDWLRQ%XLOGLQJZLWK$03/
This phase is carefully supported by separate documentation as mentioned earlier. Some general
notes and rules regarding application building and structuring are also given in Section 3.1.6.1,
Application Building with AMPL, where the subject is dealt with from other vantage points.
&RQILJXUDWLRQ,PSOHPHQWDWLRQ
This phase mainly comprises the interactive work carried out with the help of an engineering
station, for example Advant Station 100 Series ES connected to the target system. It is supported
by separate documentation as well, mostly the reference manual, $03/&RQILJXUDWLRQ$GYDQW
&RQWUROOHU 6HULHV.
A recommended procedure is “cut” from that document:
1. Make a copy of the original user diskette. The original is supplied together with the
engineering station.
2. Activate the MasterBus 300, RCOM, GCOM and 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 functions in the engineering
station are stored on the user diskette.
$SSOLFDWLRQ3URFHGXUHV
For information on how to achieve an application function from a configuration viewpoint,
please see separate manuals. A summary of available documentation is given in Section 1.5
Related Documentation.
&RQILJXUDWLRQ$SSOLFDWLRQ%XLOGLQJ0HQXV
Please refer to the separate reference manual, $03/&RQILJXUDWLRQ$GYDQW&RQWUROOHU
6HULHV.
The backup unit functions in parallel with the primary unit in any of the following working
modes:
STANDBY, UPGRADING, STOPPED and OFFLINE.
The LED display on the BACKUP processor module front indicates the working mode with the
codes
b1, b2, -3 or -4.
b1, working mode STANDBY:
The backup unit is synchronized and ready to resume control of the system should the
primary unit malfunction.
In this mode, the DUAL LEDs on the front of both processor modules lights.
b2, working mode UPGRADING:
The backup 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.
1 = AUTO 2 3
2 = STOP 1 4
3 = CLEAR
4 = OFFLINE
The controller reads and utilizes the start mode selector position at the following occasions:
• When you press the ENTER button on the processor module front.
• At power-up.
1 (AUTO):
Warm start, that is the application program is restarted.
If the controller was in the working mode CONFIGURATION, it remains in the working
mode CONFIGURATION.
If the controller was in the working mode OPERATION, it remains in the working mode
OPERATION.
2 (STOP):
Go to the working mode STOPPED.
3 (CLEAR):
Cold start, that is clear RAM (controller system configuration and application program are
erased).
The controller goes to the working mode CONFIGURATION.
4 (OFFLINE):
Go to the working mode OFFLINE.
Manual Selection
In order to ensure manually that a given processor module will be PRIMARY, you can follow
the sample procedure below:
1. Set the other processor module’s start mode selector to 2 (STOP) before initialization.
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).
Event : Power-up
Resulting
working mode OPERATION CONFIG. STOPPED OFFLINE
P1 P2 -3 -4
Starting CON
point:
OP
Resulting
working mode OPERATION CONFIG. STOPPED OFFLINE
P1 P2 -3 -4
4.1.6.1 DICONFIG
Resulting
working mode OPERATION CONFIG. STOPPED OFFLINE
P1 P2 -3 -4
4.1.6.2 ECONFIG
Resulting
working mode OPERATION CONFIG. STOPPED OFFLINE
P1 P2 -3 -4
4.1.6.3 RECONFIG
Resulting
working mode OPERATION CONFIG. STOPPED OFFLINE
P1 P2 -3 -4
(Recommended
Start mode selector: setting)
(STOP) 2
2 3 2 3 (CLEAR) 3 2 3
(AUTO) 1 4 1 1 4 1 4 (OFFLINE)
4
Starting
point: CON S
OP
C
Actions executed -Install
by the controller Programmed start
system SW
-Erase
Initialize and application
start application
R A
Resulting
working mode OPERATION CONFIG. STOPPED OFFLINE
P1 P2 -3 -4
A AUTO
C CLEAR
S STOP
(Recommended
Start mode selector: setting)
2 3 2 3 (CLEAR) (STOP) 2 3 2 3
(AUTO) 1 4 1 1 4 1 4 (OFFLINE)
4
A
Resulting
working mode OPERATION CONFIG. STOPPED OFFLINE
P1 P2 -3 -4
A
Resulting
working mode OPERATION CONFIG. STOPPED OFFLINE
P1 P2 -3 -4
System
Program
Applic.
1 Program Data Set
comm.
Data Base
Dialog
Engineering Console Pres.,TTD
Station comm. Data Area COS
for
PC program 2 3
DSA__
Process PM511
Interpreter comm.
PC program DSD__
PC element Master
execution Fieldbus
code Advant CI570
Fieldbus
100
CI522A
3BSE 002 415R701 Rev A
LONWORKS
CI572/
CI541V1 CI573
1 Events PROFIBUS-DP
DSXW 110 DSDP 140A DS__
2 Events, Alarm CI541V1
Weighing Positioning Misc.
3 Alarm
Advant® Controller 450 User’s Guide
Section 4.1.8 System Program
Hardware
Kernel DI
Interrupt MB300
handling EXCOM
Start-up Etc.
MB 300, etc.
Process comm.
Interpreter
MB 300, etc.
Process comm.
Interpreter
4.1.9.3 PC Program
You can divide a control task into a number of functional sections. The division is performed
primarily in accordance with the functional structure of the control task and can also be in
accordance with the requirement of different cycle times in the process. A PC program can
accordingly be 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
element FUNG-1V, a function generator. The figure also gives a rough outline of the supporting
elements for the break-points of the desired function (curve).
Figure 4-13 shows the desired application function.
FUNG-1V
(C1)
1 X Y 10
REG-G 2 BAL ERR 11
3 BALREF BALREFO 12
4 XTAB
5 YTAB
REG-G
Y C1
Y K+1
Y
YK
Y2
Y1
X1 X2 XK X X K+1 X C1
X – XK
- × ( Y K+1 + Y K )
Y = Y K + ------------------------
X K+1 – X K
4.1.10 Execution
The execution is organized by the interpreter which, in accordance with the PC program, calls
the correct code for the PC element concerned from the library of PC elements.
4.1.10.1 Interpreter
The interpreter is a system program which organizes the execution of the different program
modules with the periodicity required. The interpreter also checks if any unit is blocked, if 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 designated A, B and C.
A has the highest priority and C the lowest (see Figure 4-14 below).
The standard cycle times obtained are given in the figure. For a more detailed description of the
configuration of cycle times, see the manual AMPL Configuration.
10ms 20ms 40ms 50ms 100ms 200ms 250ms 500ms 1000ms 2000ms
Cycle time
The allocation of priorities to the interpreters means that the execution of PC elements with
cycle times associated with 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 interrupted by the execution of other PC
elements.
CONTRM CONTRM
50ms 50ms
Data
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 number
specifies the order in which the execution units are executed during the same cycle time.
If, in the example, the place number 1 is specified for the execution unit 1 and the place number
2 is specified for unit 2, the required function is obtained.
The different execution units may well belong to different PC programs, but they must all have
the same cycle time. For units with different cycle times, there is no defined sequence.
A required start sequence can, however, be obtained by controlling the start conditions for the
execution units included.
1
& 20
2
Address to data
for input 1
Memory map
Address to data
for input 2
Address to data
for output 20
Figure 4-16. Order of Execution for PC Elements, AND Gate with two Inputs
PC 1 PCPGM
.1 CONTRM
.1 FUNCM
.1 AND (2)
.2 OR (4)
.4 DIV
.3 ADD
.10 OR (4)
.3 FUNCM
.1 ADD (3)
.2 OR (4)
.3 AND (2)
Note that the item designations of the individual PC 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.
you can select interrupt-controlled scanning of digital inputs by selecting the parameter SCANT
to INTERRUPT. You can select different values of SCANT in the range 10 ms to 600 s.
See the reference manual Data Base Element for available standard scanning times.
Inputs scanned at intervals of 10 ms - 2 s are scanned under the corresponding PC interpreter to
obtain close synchronization between scanning and PC execution. The synchronization
functions if the scanning time and the cycle time for the PC belong to the same interpreter.
There is no scanning if the PC program is not dimensioned. Scanning of inputs with the
standard times 5 - 600 s is not synchronized.
CONTRM
(50ms)
Digital input
board
.20
ON MOTOR ON
S
OFF
R
.21
MOTOR OFF
S
Assume that execution of element .20 is followed by an interrupt caused by the digital input
signal changing status from 1 to 0. When the execution is resumed with element .21, the signals
MOTOR ON and MOTOR OFF are active simultaneously. The system automatically introduces
a reading-in element (an “invisible” GET element) which reads the values of the input signals at
the beginning of the execution of the unit and stores them in the local data area to prevent such
faults.
.11 .2
COMP
Limit Value > limit
ACT
.10 Analog
output
max
Value
A value is calculated in the execution unit with the cycle time 500 ms and a limit check is
performed on the calculated value. These values (VALUE and VALUE > LIMIT) are connected
to an execution unit with cycle time 50 ms where the logical signal VALUE > LIMIT controls
an analog output 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 element (an “invisible” PUT element).
The purpose of the reading-out element is to ensure that the output signals from an execution
unit only become legible for PC elements within other execution units when all PC elements
within the unit have been executed.
If output signals from an execution unit are to be stored in the data base, all data base points are
updated when all PC elements within the unit have been executed.
PC 1
PCPGM
(20,1)
Control module executed PUT element for
under interpreter A .1 data to
data base
CONTRM
(40,2)
DB= G X P DB=
DB= G X P DB=
DB= G X P DB=
G
GET element for G P
data from module
with higher priority
4.1.13 Diagnostics
During system initialization as well as during operation, the system itself checks that the
hardware is serviceable. For a description, see Section 1.8.10 Availability and Security. In that
section, you can find information on diagnostics and process output behavior at faults and
interrupts.
Chapter 5 Maintenance
•
DANGER - CAUTION
Observe the following:
• Use only approved hoisting equipment when lifting cabinets. See lifting instructions
enclosed with the cabinet.
• Never switch on the voltage supply of the cabinet during installation work. However
replacement of modules in subracks can be done on line, that is while power supply is
switched on. Special instructions are given for the work with power supply units.
• Power supply units in a “live” system, i.e while the mains supply is switched on, 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 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 process objects.
• Never press the system ENTER (initialization) if you do not know what happens in the
system with an initialization. The command RECONFIG is equivalent to an ENTER in the
CLEAR mode.
• Remember that the control system can be controlled from an engineering station connected
at another node via a MasterNet. For example it can be stopped, configured and started
remotely.
• Remember that an Advant Controller 450 starts automatically when voltage is applied if
this is not prevented by means of the data base element START. You can also prevent start-
up of an Advant Controller 450 by setting the START MODE selector in the STOP
position.
DANGER - CAUTION
Observe the following:
• Use only approved hoisting equipment when lifting cabinets. See lifting instructions
enclosed with the cabinet.
• Never switch on the voltage supply of the cabinet during installation work. However
replacement of modules in subracks can be done on line, that is while power supply is
switched on. Special instructions are given for the work with power supply units.
• Power supply units in a “live” system, i.e while the mains supply is switched on, 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 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 process objects.
• Never press the system ENTER (initialization) if you do not know what happens in the
system with an initialization. The command RECONFIG is equivalent to an ENTER in the
CLEAR mode.
• Remember that the control system can be controlled from an engineering station connected
at another node via a MasterNet. For example it can be stopped, configured and started
remotely.
• Remember that an Advant Controller 450 starts automatically when voltage is applied if
this is not prevented by means of the data base element START. You can also prevent start-
up of an Advant Controller 450 by setting the START MODE selector in the STOP
position.
CAUTION
Observe the following safety rules:
• Avoid discharges of static electricity by grounding both yourself and tools before handling
circuit boards and other parts of the equipment.
• Use the grounded wristband installed in the cabinet when handling parts of the system.
• Handle the circuit boards carefully, particularly those which contain MOS components
which can be damaged by static electricity discharges. Note the warning label on the
circuit boards.
• Use, as far as possible, the grounded wristband when handling boards not stored in
envelopes of conductive plastic. This gives optimum protection against static electricity
discharges.
• Always store circuit boards in envelopes of conductive plastic when not installed 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 ESD
(Electro Static Discharge).
5.2.3 Safety
Check that all screwed joints and connections within the cabinets are tightened effectively.
Ensure that wiring, circuit boards and other electrical components are undamaged.
Pay particular attention to overheating, damaged insulation or signs of wear.
5.2.4 Cleanliness
Remove dust and any other soil from the cabinet with a vacuum cleaner. Use a lint-free cloth,
dampened with methylated spirits to remove stubborn dirt.
System halt codes are shown on the processor module character display.
You can find solid information along with the halt code/system message and fault finding
descriptions in Section 5.4, Error Messages and Section 5.5, Fault Finding and User Repair
below.
NOTE
A message is deleted from the message queue in the system as soon as it is
transmitted to the engineering station. It is important to log the information to a
printer.
5.5.1 Introduction
Diagnostics are available in different forms for rapid localization of the source of the equipment
malfunction. Hardware error is usually corrected by replacing the faulty unit, which is returned
to ABB for repairs. The least replaceable unit is normally a circuit board or an apparatus like a
power supply unit.
Disturbances and system halt caused by software error are commonly solved by a manual
system restart. Sometimes you must load the application program, reinforcing the need for
actual backup copies. In such situations, it is strongly recommended that you take careful note
of all available stored error codes and system messages before an eventual program loading and
new initialization. Then contact ABB for further information.
External faults in process wiring and transducers can also affect the function of the controller.
However, this type of fault is not discussed in this manual.
Debugging of PC programs is described in the reference manual AMPL Configuration Advant
Controller 400 Series.
Engineering Station
• Halt codes stored in a stopped system. Read with the command LSYSHI:
– Show error or halt code. See Section 5.4, Error Messages.
• System messages. Read with the command LSYSM ALL:
– Most information in coded form
– Give information about probable cause of malfunction.
See Section 5.4, Error 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, there is
limited or no system diagnostics support on channel level.
A tank can indicate high level because of an error in the current output stage to a control valve.
An oil flow can indicate low value because of a lost measured value which in turn is caused by
an input amplifier fault, and so on.
To minimize the down-time, it is important in such cases that the operator have a good overview
and knowledge of the plant functions.
It is also essential that the control system design, in addition to the normal control functions,
include supervision of important process objects and their system inputs and outputs as well.
Figure 5-2. System Status Display Advant Controller 400 applied to Advant Controller 450
Function: Supervision of the 24 V power supply for the subrack containing the processor module.
(only relevant when two redundant branches A and B are installed).
Plain System Message
at fault: POW SUPP ST 24 V supply A/B faulty Net xx Nod yy
Actions at fault: 1. See Section 5.4.9.5, Check of Power Supply
Block Diagram:
Hardware Software
24 V distribution
SR511
24VA
System status OS
DB; AC450
Controller Power Supply
PM511 + SB510/511
A 24VA_ERR
24 V supply A
24VB DIAGN. B
24VA
Y/N
Function: Supervision of redundant 5 V regulators in the subrack containing the processor module
Function: Supervision of particular 5 V regulator in the subrack containing the processor module.
(only relevant when redundant 5 V regulators are installed).
Plain System Message
at fault: POW SUPP ST Voltage Regulator faulty Net xx Nod yy
Actions at fault: 1. Replace the regulator pointed out
2. See Section 5.4.9.5, Check of Power Supply
Automatic
configured
⇒ Program
card
DIAGN.
SWERR
Program card 1.1
Automatic
configured
⇒ Program
card
DIAGN.
ER R
Program card 1.1
Automatic
configured
Function: Supervision of the 24 V power supply for one or several I/O subracks (collecting alarm).
Each branch A/B is supervised if redundant branches are installed.
Plain System Message
at fault: POW SUPP ST 24 V I/O supply A/B faulty Net xx Nod yy
Actions at fault: 1 See Section 5.4.9.5, Check of Power Supply
Block Diagram:
Hardware Software
AC450 Cabinets
24 V distribution I/O Subrack
DSSS 171 n
24VA 2
1
DIAGN. DB; AC450 System status OS
TC520 I/O Power Supply
24VB A1 A IO24VA_ERR
D IAGN. 24 V supply A
1)
Fault Y/N IO24VA
A2 B
⇒ 24 V D IAGN.
0V AG
1) If the inputs A1, A2 are applied to I/O 24 V
X2 X1 X1 X2 Supply A/B supervision then the F1, F2
FA FA FB FB terminals on the AC450 data base element
TC560V1 must be set to “NO”. (That is the indication
F1, F2 deleted).
TC561V1
24 V distribution
DIAGN I/O Subrack
DIAGN
DIAGN
24 V A n
2
1
DSSS 171
24 V B
Function: Supervision of redundant 5V regulators in one or several I/O subrack (collecting alarm)
Block Diagram:
Hardware Software
24 V distribution 3
DSSS 171 DSSR 170 2
24VA 1
5V
DSBB 172B
REGFAIL System status OS
24VB DSBC 174/176 REGMISS DB; AC450
I/O Power Supply
I/OREG_ERR
DIAGN. Reg. redundancy
Y/N I/OREG
Function: Supervision of the fan unit in the controller subrack. Note! The Fan Unit requires 24V dc
(24VA and/or 24VB) for reporting FAN ERR (active fault signal)
Plain System Message
at fault: Fan for CPU faulty Net xx Nod yy
Actions at fault: 1. Check function in cabinet
2. Check fuses in the fan unit RC527
3. Check electrical signal
4. Replace fan unit
Block Diagram:
Hardware Software
Fan Unit TC520 DB; AC450 System status OS
X3
Fault ⇒ 24 V 1 FN FAN_ERR
DIAGN. Controller fan
2 0V FAN
Y/N
Superv.
24VA
Fan 1-3
24VB
Fault ⇒ 0 V +
X207 IOFANERR
DIAGN. I/O fan
- 0V IOFAN
Y/N
1)
Fault ⇒ 0 V F1 A1
DIAGN.
F1_ERR
F1
Fault ⇒ 0 V F2 A2
F1 or user defined
Y/N text
F3 B1
Fault ⇒ 0 V ‘text’
F1TEXT
Fault ⇒ 0 V F4 B2
1) If the inputs A1, A2 are applied to I/O 24 V
0V AG/BG 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).
Block Diagram:
Software function only
DB; AC450 System status OS
Use r
PCF1 con nectio n
*) N ot visible on
the element
*) Not visible on
the element
DB; EXCOM
ERR
S100 I/O 1
Stat Act Name Stat Act Name Stat Act Name Stat Act Name
AI1 AO1 DI1 DO1
AI2 AO2
AI3
Block Diagram:
Hardware Software
DB; XX-board
XX board System status
´Name´ NAME
Stat
ERR
D IAGN.
´Name´
Oper. stn. Act
dialog 1/0 SERVICE
S100 I/O 2
Block Diagram:
Hardware Software
DB; Misc Board
XX board System status
´Name´ NAME
ERR ´Name´
D IAGN.
. 1/0 IMPL
Board 1 Board 2
Stat Act Name
Stat Act
AXR1
AXR2
AXR3
Block Diagram:
Hardware Software
DB; AX Redundant
XX board 1 System status
´Name´ NAME
Stat
ERR1
D IAGN.
Board 1
Act
Operator 1/0 SERVICE
XX board 2 station
dialog ACT_BRD ´Name´
1/2 Stat
ERR2
D IAGN.
IMPL Board 2
1/0 Act
S100 I/O bus extension HW
Actions at fault : 1. See the separate manual Advant Fieldbus 100 and Data Base Elements AC 400 Series
Fieldbus PROFIBUS
1 1 PBS1 PBS
1
1 2 PBS2 PBS
Actions at fault : 1. See the separate manual PROFIBUS-DP and Data Base Elements AC 400 Series
1/0 IMPL
LONWORKS
1 1 LONDEV1 LONDEV
1
1 2 LONDEV2 LONDEV
3 4
2
Actions at fault : 1. See the separate manual Advant Interface to LONWORKS User’s Guide
and Data Base Elements AC 400 Series
1/0 IMPL
Figure 5-9. System Status Display, Advant Fieldbus 100 Bus Unit
MasterFieldbus
Function : Status information for a MasterFieldbus with connected S400 I/O units
Actions at fault : 1. See the separate manual MasterFieldbus and S400 I/O
Block Diagram :
Hardware Software
XX unit B
DB; XX unit1)
(status) Station 2
ERR
DIAGN.
DB item design.
. A
ERRTYPE
B
Incl. MasterFieldbus comm. HW 1/0 IMPL
(modem, CI570, SC5xx)
1) Ex. of XX units: AX unit, DX unit
PX unit, CV unit
2 DI810_1 DI810
3 DI810_2 DI810
Power Supply A/B (power supply redundancy) Text1/Text2 (physical comm. media redundancy)
green The A/B power supply is OK green The ”Text” is OK
red cr The A/B power supply is erroneous red cr The “Text” is erroneous
Actions at fault : 1. See the separate manual S800 I/O User’s Guide
Block Diagram:
Hardware Software
CI810 DB; C I810 System status
´Name´ N AME Status
ERR Station 1
DIAGN.
WARNING DB item design.
Act or Name
DIAG
A
SERVICE
B
EX_STAT1 Pow er Supply
. EX_T EXT1 A
EX_STAT2 B
EX_T EXT2
Text1
I/O Module DB; I/O Module 1) Text2
´Name´ NAME 2
ERR
Status Module
DIAGN.
WARNING DB item design.
Act
DIAG or Name
SERVICE
2 DI810_1 DI810
3 DI810_2 DI810
Power Supply A/B (power supply redundancy) Text1/Text2 (physical comm. media redundancy)
green The A/B power supply is OK green The ”Text” is OK
red cr The A/B power supply is erroneous red cr The “Text” is erroneous
Actions at fault : 1. See the separate manual S800 I/O User’s Guide
Introduction
Perform fault finding in a systematic and logical manner.
You must make a distinction between a system which has been in operation and a system which
has not been operated previously. In the latter case, always check the following indications first,
if relevant:
• The cabinet has mains voltage connected
• All circuit boards are plugged in correctly
• All connections are made correctly
• All boards are jumpered correctly.
If these checks do not correct the malfunction, continue with the procedures described below.
I II III
Alarm Conclusion drawn from
process behavior
Cabinet
Announciation
AdvaCommand
Presentation System Status
Description
(Separate
Documentation) Engineering
station
(- System messages
Indication - Faulty unit /function - Halt code)
description - Pointer to
advanced fault
Section 5.4.2.1, finding
Replacement Replacement
instructions instructions
Practical
Fault Finding Classification
Reference information
Advanced
Product fault finding 2) Covered by
methods 2) Automation University
ABB Industrial SystemsSweden
AB
documentation Training courses
Source of
Failure
Replacement
Instructions
A Complex Scenario
The system diagnostics does not always point out a replaceable unit. Fault finding must be done.
In, for example, a stand-alone system, the following 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 with respect to the indications. See Section 5.5.4, Fault
Classification and Scheme of Measures.
5. Outgoing from the fault classification you will probably proceed with advanced fault
finding. Some hints and general fault finding procedures are given in the following
sections. However practical experiences from a training course is normally needed to get
to the source of failure.
6. When localized, the faulty module is replaced.
Common user repair is described in Section 5.5.10, User Repair.
7. For instructions for restarting a system after a fault is corrected, see
Section 5.5.16, System Restart, INIT.
A general rule when dealing with complex indications is:
A fault indication in a superior function makes indications in subordinated functions
mostly inapplicable.
For example, if the processor module indicates red FAULT, there is probably no relevance in
any red FAULT indications on communication modules.
NOTE
Make sure that the operations are being performed on the backup module!
All maintenance functions that can normally be performed in the OFFLINE mode can now be
carried out, except for referencing process I/O modules.
DANGER - CAUTION
It is important to be aware of the local requirements for safety when starting and stopping
the Advant Controller 450.
Manual Changeover
Prior to the Changeover. Check
• DUAL LED’s on both processor modules lit
• Start mode selector on both processor modules in the same position (for example AUTO)
• Primary processor module in working mode P1 or P2
(P1 = OPERATION, P2 = CONFIGURATION)
General
Fault finding in the controller cabinet is carried out as follows.
Before replacing a power supply unit or a fuse or resetting a MCB try to check for a reason of
the fault. If deemed too time consuming, it is always possible to try the easy way and “look for
the smoke”.
Scenario A - Fault Finding
Total shut down is verified.
First guidance and measures to be taken, see Figure 5-15.
F 2V 5V
1)
See Section 5.5.10.5,
Replacement of 5 V Regulator
2)
If fault remains there is an overload
in the controller subrack
I/O subrack
(rear side) 24VF
Y
< 18 V I/O Subrack 1
N
24 V Check for a disconnection
Fuse blown N in the 24 V power supply
24 V ok
distribution
Y
F1
Fuse blown N Replace DSSR 122
Y See Section 5.4.10.5,
Replacement of 5 V Regulator
Replace fuse
0V 5V
Test 5 V
Fuse protected +24 V
to the backplane
F 2V 5V
1)
See Section 5.5.10.5,
Replacement of 5 V Regulator
BLIVE
AFAIL
BFAIL
LIVE
FAIL
PBC
OFF ON ON OFF ON ON OFF Supply branch A fault 1. First check the fuses F501/F502
on I/O subrack DSRF 187A
ON OFF OFF ON ON ON OFF Supply branch B fault (rear side)
2. Check for a disconnection in the
24 V power supply distribution
BLIVE
AFAIL
BFAIL
LIVE
FAIL
PBC
OFF ON ON OFF ON ON OFF Supply branch A fault 1. First check the fuses F501/F502
on I/O subrack DSRF 187A
ON OFF OFF ON ON ON OFF Supply branch B fault (rear side)
2. Then see Figure 5-19 2)
1)
See Section 5.5.10.5,
Replacement of 5 V Regulator
2)
Valid to the power supply units
for I/O subrack 2...3
Replace SA16x
F BF BP IP
OFF OFF OFF ON Normal operation ------
OFF OFF OFF OFF Lost supply voltage or 1. See notes below 1), 2)
blown fuse F1 2. Replace fuse in SB510/511
ON ON --- ON Battery fault or SB510/511 fault Replace battery unit first. Make a test. If not
successful replace SB510/511
3)
Replacement instructions in Section 5.5.10.6,
Replacement of Backup Power Supply and
Section 5.5.10.7, Battery Exchange
• Red LED HLT (HaLTed) means a serious fault. The controller has stopped. The system
halt information is probably missing or incomplete. The recommended actions are:
1. Restart the controller. See Section 5.5.15, System Restart following Maintenance
Activities.
If HLT still occurs it is possible to interpret new halt code information from the display
and continue with step 2.
2. Reload the software and restart. See example in Section 5.5.17, Loading of Application
Program.
If HLT still occurs continue with step 3.
3. Replace the processor module.
• Yellow LED TO (Time Out). Normally OFF. Sometimes it flashes under normal
conditions to indicate that an I/O board has been addressed but does not respond. A board
can be withdrawn for repair or a board can fail.
• Green LED BC means that the backup voltage for RAM is connected
• Green LED DUAL means that a redundant processor is ready. If the controller includes
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 the communication with a
connected engineering station
– Yellow LED HI I - High speed input
– Yellow LED HI O - High speed output
– Yellow LED LO I - Low speed input
– Yellow LED LO O - Low speed output.
5.5.9.8 I/O
This section deals with the S100 I/O. Follow the instructions and make conclusions applicable.
The corresponding information for the S400 I/O and S800 I/O can be found in a separate user’s
guide MasterFieldbus and S400 I/O and S800 I/O User’s Guide respectively.
• Each I/O board has a red Fault indication LED. Replace a board with a LED which
indicate a fault. First read Section 5.5.10.1, Board and Subrack Mounted Unit Exchange.
• Check whether the circuit board is activated in the data base.
• If all I/O boards indicate fault check that the system is not in CONFIGURATION mode.
• If all the boards with fault indications are in the same subrack, the fault is probably in the
bus extension to S100 I/O
– Check connections and cables.
– Check and replace the bus extender DSBC 174 located in the I/O subrack. Or replace
modems in an, if available, optical bus extension.
CAUTION
DSBC 174 or DSBC 176 can not be replaced while power supply is switched
on when used in single S100 I/O Bus Extension configuration.
NOTE ALSO!
If the supply to a subrack is switched on before the DSBC 174 or
DSBC 176 is in place, the process outputs in the subrack can set
themselves in optional states!
• If the fault indicating LEDs on several I/O boards illuminate, follow instructions in
Section 5.5.9.9, Fault Finding by Reducing the System.
• Check the process signal status.
The status of the digital signals (DSDI, DSDO) is indicated for each signal connection to
the process by a yellow LED. The values of analog signals can be measured at test points
on the front panel. Detailed information 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 and
connect to the measurement terminal on the terminal blocks.
• Check the signal values in the data base in accordance with the instructions in the
reference manual AMPL Configuration Advant Controller 400 Series.
• Check the signal values in the PC diagram in accordance with the instructions in the
manual AMPL Configuration Advant Controller 400 Series.
CAUTION
The I/O S100 bus extension board DBC174 or DSBC 176 can not be treated
that way while power supply is switched on when used in single S100 I/O Bus
Extension configuration.
NOTE ALSO!
If the supply to a subrack is switched on before the DSBC 174 or
DSBC 176 is in place, the process outputs in the subrack can set
themselves in optional states!
You should carefully follow general instructions and the information attached each board/unit
type in Section 5.5.10.1, Board and Subrack Mounted Unit Exchange.
The consequences to the process controlled must also be considered.
Proceed as follows:
1. Note the halt code on the processor module character display and the red LED indicators,
throughout the controller and its I/O, which illuminate
2. Perform a warm start that is an initialization with the start mode selector in position
1 (AUTO). If not successful continue at step 3.
3. Reduce the system until only the following modules remain
– 5 V Regulator SR511
– Processor Module PM511 including a program card
4. Perform a new warm start. If the system does not start continue 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 the module in which the fault appears.
d. Perform a warm start.
5. Perform a cold start i.e depress the ENTER button with the start mode selector in position
3 (CLEAR). Please note that the program card with the system program must be in its
position.
If the system does not start continue at step 6. If the system starts the fault is probably in
the data base or the PC program. Continue at step 7.
6. Replace the processor module and the submodule carrier with program card interface and
the program card, one at a time, until the controller starts in 3 (CLEAR) mode. Perform a
cold start after each replacement that is depress the ENTER button with the start mode
selector in position 3 (CLEAR).
7. Load in an available application program backup
8. Expand the system to full configuration.
General
In the following text, the word “board” also includes circuit board and rack mounted unit
(applicable). An example of such a unit is a voltage regulator or backup power supply.
It is important to understand the consequences of a board exchange on-line and how it affects
the current situation, for example:
• Replacement of an I/O board affects all channels on the board. It also sometimes indirectly
affects the outputs via an application function, for example, a closed loop control.
• Replacement of a communication board type CI531 affects both channels on the board.
Before output boards (both analog and digital) are replaced, it is preferable to separate the
different outputs from the process, that is, open terminal switches on the connection units (or
take other adequate measures). In some applications, this is an absolute requirement for safety
reasons.
The system software in Advant Controller 450 checks automatically that all I/O boards function
correctly. In the event of board fault, and board exchange, the 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 find general instructions for replacement of circuit
boards and information on the handling of individual circuit boards.
Practical Execution
Replace faulty or suspect circuit boards and units as described below.
1. Do not forget to read Section 5.5.6, Safety Regulations.
2. Look under the heading Additional Aspects of Individual Board Types, below, for other
useful information.
3. Special restrictions apply to the board type DSBC 174 or DSBC 176, bus repeater in the
S100 I/O bus extension.
CAUTION
You cannot replace DSBC 174 or DSBC 176 with the voltage switched on,
when used in single S100 I/O Bus Extension configuration.
4. If necessary, switch off the power supply to the Advant Controller. Then keep the start
mode switch on the front of the processor module in the AUTO position.
5. Provide access to the board/unit by loosening the locking mechanisms:
– The bar in front of the boards (I/O subrack).
– The screws in the handles (controller subrack). First disconnect all cables.
6. Grip the board firmly and extract the board quickly and decisively (I/O subrack).
Use both handles (controller subrack).
7. Check that the new board can replace the old:
– Ensure that the eventual jumpering is the same as the old board.
See Table 5-1 and Table 5-2.
– Check for lowest revision approved variant to be used for the equipment and use
replacement of the same or higher revision number.
8. Insert the new board carefully without reaching the rear plane contacts. Ensure that the
board slides in the guides in the subrack or carrier board.
9. Push in the new board/unit quickly and decisively.
10. Store extracted boards in envelopes of conductive 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 which can be replaced during operations are initialized automatically by the system
and the fault-indicating LED extinguishes automatically after approximately 10 s.
15. Perform a function test on the new board.
Table 5-1. Replacement Aspects of Individual Board Types (Controller Hardware) (Continued)
S1
S2
S3 S2 S1
Table 5-1. Replacement Aspects of Individual Board Types (Controller Hardware) (Continued)
Table 5-1. Replacement Aspects of Individual Board Types (Controller Hardware) (Continued)
S2 S1
S2 S1
S2 S1
S2 S1
Table 5-2. Replacement Aspects of Individual Board Types, S100 I/O (Continued)
S4 S1
S2
S5
S3
S1
S4
X4
Table 5-2. Replacement Aspects of Individual Board Types, S100 I/O (Continued)
Table 5-2. Replacement Aspects of Individual Board Types, S100 I/O (Continued)
S7
Table 5-2. Replacement Aspects of Individual Board Types, S100 I/O (Continued)
S1
S2
S1
S1
S2
S1
Table 5-2. Replacement Aspects of Individual Board Types, S100 I/O (Continued)
S1
R57
S4 R58
S2
S3
Table 5-2. Replacement Aspects of Individual Board Types, S100 I/O (Continued)
S104 S1
S110
X3
S109 S112
S10 S20
S9 S10 S1
S11
S12 S2
S13
S14
The replacement instruction focuses on the unregulated power supply units SA16x (a.c.) and
SD150 (d.c.). However the principles are valid for power switch and distribution unit
replacement as well.
Replacing a power supply unit shall always be carried out with highest safety possible.
Basically this means that voltage supply should always be switched off during repair and
installation work. Special provision is made for a system including redundancy where
replacement is urgently needed in a live system.
Before replacing a primary power supply unit, break its mains switch S1 in the power switch
unit (for the actual mains A or B). When the power supply unit is pluggable, unplug the power
cord. Where the power supply installation is fixed also switch off a safety breaker or remove the
actual fuse in the buildings mains installation before working in the power supply circuitry.
On Line Replacement
1. Switch off the actual mains supply branch in the cabinet and wait until the capacitors in
the power supply units have discharged. 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 (plugs or terminals).
5. Unscrew the screws which keep the unit in place and remove unit from the frame.
6. Install the new unit in the reverse order.
Reconnect all plug connectors (terminals).
7. Switch on the mains supply and test for the unit function.
LED LIVE on the 24 V distribution unit (SX554) should light. A volt meter connected to
the test terminal on the distribution unit should read 19 V - 32 V.
Single SR511
1. Switch off the mains supply.
Use the power switch S1 on the power switch unit.
2. Provide access to the unit by loosening the screws in the handles.
3. Grip the SR511 firmly and extract it 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 and mates properly with the contacts
in the rear plane.
6. Push the new unit in place by the handles.
7. Fasten the screws in the handles.
8. Switch on the mains supply voltage. With the processor module start mode selector in
position 1 (AUTO) the system will be automatically initialized and restarted.
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.
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 and mates properly with the contacts
in the rear plane.
6. Insert the SR511 slowly until it starts up (the green indicating LEDs / but not the red one /
on the SR511 front panel are lit), then push the SR511 fully into place.
7. Fasten the screws in the handles.
8. Check the regulator LED indications. F should be OFF while 2 V and 5 V should be ON.
9. Store extracted unit in envelope of conductive plastic.
DSSR 122
1. Switch off the mains supply.
Use the power switch S1 on the power switch unit.
2. Open the hinged frame to gain access to the unit and the connection terminals on the rear
side of the I/O subrack.
3. Disconnect the 24 V supply lead at the screw terminal.
4. Loosen the 5 V screw on the subrack 5 V terminal bar.
5. Loosen the 0 V screw on the subrack 0 V terminal bar.
6. Unscrew the screws which hold the regulator unit and remove it from the rack, lifting the
regulator upwards thus disengaging it from the 5 V, 0 V terminals.
7. 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.
8. Install new unit in the reverse order.
9. Switch on the mains supply voltage. With the processor module start mode selector in
position 1 (AUTO) the system will be automatically initialized and restarted.
10. Check 5 V (5.0 V - 5.25 V) on the test terminals using a volt meter.
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
replacement of the same or higher revision number.
5. Install the new regulator. Tighten the fixing screws firmly.
6. Check the LED indications. F should be OFF while LIVE should be ON.
7. Store extracted unit in envelope of conductive plastic.
Notes on DSSR 170:
• When replacing a voltage regulator, the substitute is to be placed in the same position as
the regulator to be exchanged.
• The upper fixing screw must be tightened to enable the 24 V/5 V conversion. If there is
any contact problem, adjust the position of the nut at the contact spring in the regulator.
• The fuse in the regulator is readily accessible at the rear of regulator printed circuit board
when the regulator has been removed from the rack.
• The correct function of a regulator can be checked only by individual testing of the
regulator. (In a separate test rig or by removing redundant regulators one at a time).
During the time of replacement the backup power supply will indicate F (Fail) and BF (Battery
Fail). This is observed in the system status display in the operator station too.
Possibly will, at low battery temperature, the red F LED on the backup power supply still be ON
under a few minutes after replacement.
NOTE
The battery includes cadmium and shall be treated as hazardous waste.
General
It is important to understand the consequences of a connection unit exchange on-line and how it
affects the current situation, for example:
Replacement of a connection unit affects all channels on the corresponding I/O board.
It also sometimes indirectly affects 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 cases, you can disconnect the signals/power
supply at a cross-coupling, in other cases, at process transducers and at the location where
the power supply is distributed.
2. Disconnect the internal cable which joins the connection unit and corresponding circuit
board.
3. Label the leads so that they can be connected to the new unit correctly.
4. Disconnect the leads. Unscrew the fixing screws. Remove.
5. Install the new unit in the reverse order. Ensure that the screws make contact with the
tinned surface of the earth plane of the circuit board for effective grounding.
6. Test the function.
Perform the adjustments in the order in which they are described (Z, B, G). If a certain
adjustment function is not available, the procedure is continued by setting the next parameter.
Potentiometers for adjusting the common section (A/D) are located on the lower part of the
front. The input voltage is measured at the test terminal X3. Make connections as shown in
Figure 5-21. Disconnect the process signal at the connection unit before the connections are
made.
DVM
G1 U
X- OV
G2 CMV
Z B G
Adjustment for Boards DSAI 130, DSAI 133 and DSAX 110
The A/D converter is adjusted in three operations:
• Adjustment of zero point Z (automatically adjusted on DSAI 133)
• Adjustment of full scale value G
• Adjustment of symmetry S (only DSAI 130, normally unnecessary).
The adjustments are performed in the same order as given here (zero point, full scale value and
symmetry, if relevant).
Adjust AI units which are intended for voltage or current signals with the help of a voltage
reference. If all inputs are jumpered for current, and none are unused so that the solder jumper
can be clipped, you can use a voltage reference which can give at least 20.5 mA for a channel
jumpered for a current shunt.
In this case, set CONV_PAR on the data base element to -20..20 mA, 0..20 mA or
-5..5 V, and half the reference voltage is used instead of the values specified below as an internal
gain multiplied by 2 is used.
An input and corresponding data base element are selected for the adjustment. If an unused
input is selected, 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 measured
value is read with an engineering station.
The potentiometers Z,G and S are located in the lower half of the front of the board.
Adjustment of the Zero Point on the A/D Converter
Adjust the reference voltage to the corresponding, a half step for the A/D converter:
DSAI 130 12 bits 1/2 bit = 1.25 mV
DSAI 133, DSAX 110 12 bits Automatic adjustment of zero.
Adjust the potentiometer Z on the board front, reading the unscaled value in the data base at the
same time.
Use the command GETAB on the engineering station to read the unscaled value continuously:
GETAB
IV= AIX.Y:16 Insert value, AI= Analog Input, X = board number, Y = signal number
(16 is the property number of the unscaled value).
GVD (Get Value Dynamically)
Example:
IV=AI1.1:16
will show unscaled value of first input of first board.
The zero point is correctly adjusted when the value varies between zero and a value
corresponding to an increment for the A/D converter, 128 for DSAI 110 and 8 for DSAI 130.
Resetting
Stop the GETAB command as described in the preceding chapter.
Reset the values for CONV_PAR, FILTER_P and DEADB.
Connect the process input or the jumper in the same way as the reference resistor is connected.
U
DVM
Z G L1 L2
Z G L1 L2
FS “U” FS 10 mA FS 20 mA
Number of Bits
U mV U mV (500 ohm) U mV (500 ohm)
8 bit
10 bit 10 000 5 000 10 000
12 bit
5.5.12.4 Adjustment of “Limit Low” L1 and “Limit High” L2, Channel by Channel
Limit the signal with the potentiometers L1 and L2 to optional values between -100% and
+100%.
If the limiting function is not used, its potentiometers must be screwed out
completely to + and -.
3. Check LED BC on the processor module. It should light indicating backup voltage for
RAM connected.
4. Switch on the mains supply.
5. The controller will be in OPERATION mode within a few minutes. This is indicated by P1
on the processor module character display. If any start program in the application program,
the controller operation will restart accordingly.
Cold Start
If for some reason the RAM content has been erased, or if severe software disturbances are
indicated, restoring of the system configuration and the application program is required.
A suitable backup must be available. The way of performing a loading of a backup depends on
the type of backup. See example and further information in Section 5.5.17, Loading of
Application Program.
DANGER
Reflect the personnel and machine safety, see Section 5.5.6, Safety
Regulations.
• The identity of the dump and the net and node number of the controller must be known.
In the example of procedure below the name ABCD and net 11, node 12 are used. Please
observe that the dump usually consists of different segments designated for example:
ABCD0001.AD, ABCD0002.AD and so on.
Example of Procedure
Action Response
1. Set the start mode selector on the
Processor Module PM511 front in 3 (CLEAR)
2. Check that the program card is in position.
The system software will be reloaded at the
cold start.
3. Depress the ENTER button The controller system configuration and the
application program are erased.
The processor module will indicate P2 after
about a minute.
4. Set the start mode selector in 1 (AUTO)
Do not press the ENTER button!
5. Connect the communication cable between
the engineering station and the Processor
Module PM511, port X10.
6. Switch on the power supply to the Successful Advant Station 100 Series ES
engineering 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 programming)
<CR>
12. In the node Setup window confirm or Contact with target.
select the correct Target System. Identity presented.
13. Type LDIR SRCE:*.AD<CR>to
check that your DUAP dump is available. In the example the following
ABCD0001.AD
ABCD0002.AD etc.
are listed.
14. Type LOAP <dump name>, SRCE <CR> The loading proceed. #
For example LOAP ABCD, SRCE<CR>
15. DICONFIG <CR> OK TO START UP THE TARGET, Y/N
16. Type Y <CR> After about one minute:
THE TARGET SYSTEM IS NOW IN
OPERATION MODE
The processor module will now indicate P1 (OPERATION mode) on the character display.
5.7 Backup
AdvaBuild On-line Builder supports the preparation of flash cards with application dumps,
DUAP. The AdvaBuild On-line Builder User’s Guide describes the different working
procedures in detail. Following is an overview.
Considerations
• The system program backup and the application program backup can not be mixed in one
single flash card.
• Flash cards are available in three memory sizes (currently), 2 Mbytes, 4 Mbytes and
10 Mbytes. Select a type that takes the actual application program.
• The flash card for application backup must first be formatted using the AdvaBuild On-line
Builder.
• The application program dump (DUAP) to be used should be taken while the controller is
in the operation mode (P1). This will ensure that no manual intervention is needed to get
into full operation after a shut down and an automatic restart.
Step-by-step Instruction
1. An application program dump (DUAP) for the actual controller is assumed to be available
in the engineering station.
2. Insert a suitable flash card in the desired PCMCIA slot of the engineering station.
(Two slot available.)
3. Select 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 light.
A new item representing the added program card will be created automatically in the
system status display on the operator station.
Regarding appropriate hardware and software see Section 3.1.2.4, Backup of Application
Program.
7. The application program card is now ready for operation. However you are advised to
make a functional test of the backup in a non-critical situation. I.e. perform a cold start of
the controller when a possible shut down is accepted from a process control viewpoint.
Any checksum error of the original DUAP file will be detected in connection to the
downloading to the controller RAM.
Maintenance
During normal operation a program card is continuously supervised. The supervision is partly
based on checksum calculation. For the application backup the checksum is calculated in
connection to the program card insertion. (For the system software backup the checksum is
established during the system program generation, that is, part of the code.)
A red F LED on the MB510 module front indicates hardware error, checksum error or missing
program card. If the red F LED is turned on and if the application program card is removed and
after that reinstalled again and the red F LED turns off, then you must arrange for a functional
test of the backup. This should be performed in a non-critical situation.
In connection to the reinstallation of the hardware a new checksum calculation is made, possibly
hiding a memory error with respect to the 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.
$SSHQGL[$ +DUGZDUH0RGXOHV
$ /LVWRI+DUGZDUH0RGXOHV
By way of introduction, see below a complete list of all types of hardware modules related to
the Advant Controller 450. The list includes modules like circuit boards, power supply units and
connection units. They are listed in alphabetical order.
A reference is given telling you where to find a module description, including important
technical data:
$ &,56&&RPPXQLFDWLRQ,QWHUIDFH
)URQWYLHZ
7HFKQLFDO'DWD
,QGLFDWRUV
LED R (green) on module front. Indicates module running normally.
LED F, Fault (red) on module front.
-XPSHUV
The board contains one jumper for special purposes.
In normal operation, always keep jumper S1 in position 3 - 4 (“parking place”).
The component and position indications are found on the printed circuit board.
&RQQHFWRUV
Serial channels 1 and 2 connectors (X4 and X5):
- Connector type Nine-pole male DSUB (DE9P)
- Placement On module front
- Pin designation See Table A-2 below.
3RZHU6XSSO\
5V typical 400 mA
max. 670 mA
24 V max. 40 mA
Power loss (heat) typical 3W
0HFKDQLFDO'DWD
Module size: Occupying one submodule slot (H = 95 mm, L = 140 mm, connector not included)
Weight: 0.13 kg (0.29 lbs.)
$ '66%(QHUJ\5HVHUYRLU
'HVFULSWLRQ
The Energy Reservoir DSSB 170 is a capacitor unit intended for use with
24 V direct supply (without d.c./d.c. converter). In the event of mains
power failure, the unit provides the system with energy necessary for
storage of important data.
DSSB 170 is built up on a 19-inch apparatus plate.
The controller and the first 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 connected at the terminals X1:1 - 4. The output
X2:1 - 4 supplies the 5 V regulator units with 24 V.
A serial diode prevents the energy stored in the unit from leaking back to the
supply mains in the event of a power failure.
465 (18”)
7 x 13 (x4)
X2
37.5 (1.5”)
482 (19”)
20 (0.8”)
75 (3”)
7HFKQLFDO'DWD
,WHP 9DOXH
Voltage rating input 24 V d.c.
Output voltage 24 V d.c.
Backup time 5 ms
(in the range) 18.5 - 16 V with 25 A load
Voltage derivative with power failure 0.3 V/ms
with 25 A load
0HFKDQLFDO'DWD
Width 482 mm (19”)
Height 177 mm (7”), 4 U
Depth 75 mm (3”)
%ORFN'LDJUDP
'66%
X1 X2
1 1
2 2
3 3
4 4
$ 0%3URJUDP&DUG,QWHUIDFH
'HVFULSWLRQ
Utilizing an MB510 is one method of program card installation in an
Advant Controller 400 Series.
A program card is equipped 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 front indicates hardware error, check sum error or
missing program card.
MB
510 ABB
F RUN
Eject button
Arrow to indicate
top of program card
)URQWYLHZ
7HFKQLFDO'DWD
,QGLFDWRUV
LEDs on module front:
F (red) Module error
RUN (green) Module running normally
3RZHU6XSSO\
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
0%
Interface logic
Fault Control
Run
Control
Contact to
Contact carrier module
Data Data
$ 3093URFHVVRU0RGXOH
• Futurebus+ Board
• 25 MHz 68040 Processor
• 8 or 16 Mbyte Dynamic RAM with ECC
• Hardware support for redundant processors
• S100 I/O Interface PM
511V
ABB
• PCMCIA slot for flash memory card
• Service tool connector on front
• Boot PROM and SRAM RUN
F
HLT TO
BC DUAL
Description
PM511V is a processor module for Advant Controller 450. It is designed to fit
into RF533 series controller subracks.
The Motorola 68040 processor is a 32-bit virtual memory microprocessor with
an integrated floating point unit and with dual independent instruction and data
demand paged memory management units (MMUs). It also has two separate
4 kbyte caches, one for data and one for instructions.
The dynamic RAM memory is organized as a 64-bit memory with an 8-bit
cyclic redundancy check sum.
The module has a Futurebus+ type interface with 32-bit address/data lines 1
2 3
4
supporting compelled transfers.
ENTER
Distributed arbitration is used. Arbitration messages are supported .
X10
To support a configuration with two redundant processor modules with one SERV.
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-
X11
cessor. This makes it possible for the backup processor to resume the I/O
The module front has LED indicators for status information, a start mode selector
switch and an ENTER push button to manually initialize the controller.
You can find the operation description of these facilities in this manual.
A label on module side gives the full identification and information of actual
memory size. Available versions are designated PM511V08 or PM511V16. Front view
7HFKQLFDO'DWD
0HPRU\
8 or 16 Mbyte dynamic RAM for system software and application program.
,QGLFDWRUV
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
3RZHU6XSSO\
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.)
$ 5%[['XPP\0RGXOHV
'HVFULSWLRQ
Empty slots within a controller subrack should be equipped with dummy modules.
The reason is:
• Keeping air vented in a settled way
• Exterior appearance.
Available module types are:
7\SH 'HQRPLQDWLRQ$SSOLFDWLRQ'LPHQVLRQ
RB540 Dummy Module, half height double width6 SU, 12 mp (150 mm, 60 mm)
Substituting, for example, Regulator
ABB
)URQWYLHZ
$ 5&)DQ8QLW
'HVFULSWLRQ
Cassette model including three fans powered by 24 V d.c. Redundant power supply is possible.
For proper system function, 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 cables to and from the front connectors
of the modules in the subrack.
)URQ WYLHZ
X1 X2 X3
6LGHYLHZ
7RSYLHZ
X9X8X7
X6
X5
F uses X4
X1 X2 X3
Cable duct
7HFKQLFDO'DWD
3RZHU6XSSO\
24 V d.c., max. 0.7 A (for three fans)
Power loss (heat) typical 15 W
)XVHV
Each fan protected by a 0.8 A F Miniature Fuse Link.
$ODUP,QGLFDWLRQ
FANFAIL-signal Low level/0 V - Fan OK
High level/16.3 - 32 V - One or more fans have failed (<750 rpm)
Loadable <7.3 mA
0HFKDQLFDO'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.)
0DLQWHQDQFH3DUWV
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
1 X1 Fuses Fan 1
+24VA
+24V X4 3 Power Supply
0V 2
1 0V
+24VB 1
X2
2 Sensor
0V 2
X5 Fan 2
X3 3 Power Supply
FANFAIL 1
0V 2 1 0V
2 Sensor
X6 Fan 3
3 Power Supply
Sensor Supervision 1 0V
2 Sensor
$ 5)&RQWUROOHU6XEUDFN68
'HVFULSWLRQ
Subrack for electronic modules with front connection of cables.
Mount the subrack close to the back wall in a cabinet. 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 unit provides a cable
duct to use for the cables connected to the modules.
)URQWYLHZ
.
B
l
i
n
d
X1 X2 X3
7HFKQLFDO'DWD
%DFNSODQH7HUPLQDOV(Panel layout, see below)
2.1 V and 3.3 V Test of termination voltages
5V Test of 5 V power supply of the controller subrack
5VBACK Test of the RAM backup voltage 5 V
(1.4”)
35
Back plane
(1.5”)
37.7
300 (11.8”), (7 U)
57.2
(2.3” )
222.25
(8.8”)
88.9
(3.5”)
(3.9”)
100
445 (17.5”) 330 (13”) y
482 (19”)
7HVWDQGFRQQHFWLRQIDFLOLWLHVSURYLGHGE\WKHUDLVHGEDFNSODQH
Connections
AUX1/A AUX1/B
24V/A 24V/B
Test AUX2/A AUX2/B
VBAT/A VBAT/B PFAIL/A PFAIL/A
0V 2.1V 3.3V 5V 5VBACK
$ 5)5)0RGHP6XEUDFN
'HVFULSWLRQ
RF540 and RF541 are subracks for assembly of auxiliary equipment like modems and certain
connection units for communication links.
RF541, the 19-inch variant is described below. RF540 for 24-inch standard differs 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 the power supply implies increased maintainability.
5) )URQWYLHZ 6LGHYLHZ
1 2 3 4 5 6 7 8 9
10
228.5
266 (10.5”) (6 U)
(9”)
171
(6.7”) 11
95
(3.7”)
38
(1.5”)
155 (6.1”)
465 (18”)
482 (19”)
Position: 1 2 3 4...
Position referred addressing is not used in S100 I/O All measurements in mm (in.)
7HFKQLFDO'DWD
0HFKDQLFDO'DWD
Dimension: Width measurement for 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”)
%ORFN'LDJUDP
$SSOLFDWLRQRIFRQWDFWJURXSV
24V
0V from cabinet supply
to first unit
to second unit
and so on
As above
$ 6$[[3RZHU6XSSO\8QLWV
'HVFULSWLRQ
SA1xx is a series of power 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.
Electric installation: Plug-in contacts. Primary connector EN 60 320, C20.
Mechanical installation: Rack or wall mounted, 19-inch width.
)URQWYLHZ 6LGHYLHZ
7HFKQLFDO'DWD
7DEOH $ 6$[[,QGLYLGXDO7HFKQLFDO'DWD
6DIHW\&ODVVLILFDWLRQ
Class I according to IEC 536 (earth protected).
3URWHFWLRQ5DWLQJ
IP20 according to IEC 529 (IEC 144).
,QVXODWLRQ
Rated insulation voltage 400 V a.c.
Dielectric test voltage 3250 V a.c., 50/60 Hz
)XVHV
0HFKDQLFDO'DWD
Dimension: width 482 mm (19”)
height 177 mm (7”), corresponds to 4 U height modules in a cabinet
depth 255 mm (10”)
0DLQWHQDQFH3DUWV
Midget Fuse, 10 * 38 mm 6 AF (fast), ABB part no.5672 827- 6
10AF 5672 827- 10
15AF 5672 827-15
%ORFN'LDJUDP
6$[[
SA167/168
only F2
X2
X1 +
F1 1
L1 (L) d.c.
output
a.c. -
mains 2
F1
L2 (N)
GND
PE
3
$ 6%%DFNXS3RZHU6XSSO\9DFGF
'HVFULSWLRQ F IP
SB510 is a battery charger which works together with one single battery BF BP
package, for example, SB522. Use these two modules for current
FC
supply of processor module RAM in the event of mains supply drop out.
F1
The capacity expressed in time of backup depends on the application. 2AF
Please refer to the actual Advant Controller documentation.
Use two sets (SB510 and SB522) to double the backup time.
SB510 is positioned in a controller subrack to interface with the backplane bus X11
and the battery.
Mains supply is connected via a module front connector.
The mains supply input provides fusing and other adequate protection.
The input energy is converted and used for 5 V internal unit supply and by a
controlled current generator for battery charging.
The current generator produces a current adapted to the mode of operation:
recharging, which takes approximately 10 hours after power-up or battery replacement,
or trickle charging.
During recharging, a LED FC on the module front lights up.
Diagnostic functions continuously supervise the operation. Error and other statuses are
indicated by module front LEDs. The information is available on the backplane
for further processing by the system status functions.
)URQWYLHZ
.At installation, insert the module in the subrack first. Then connect the power supply (X11)!
7HFKQLFDO'DWD
,QSXW'DWD
Mains supply: 110 - 230 V a.c.; variation -15 to +10%; ripple <15%
110 - 230 V d.c.; -20 to +20%; ripple <15% (no respect to polarity at d.c.)
Max. power: 25 VA
)XVHV
The mains supply input includes a fuse 2AF (fast)
(accessible from the module front).
3RZHU6XSSO\RI5$0
Output voltage at normal operation: 5.6 V ±0.2 V (zero load)
Output voltage at backup operation: 6.0 V ±0.2 V
Max. current: 2A
Notes:
- The output voltage level is raised during backup operation to compensate for voltage drops in voting circuitry.
- The output current is short-circuit proof.
- The physical output has a serial diode to provide two SB510s in parallel operation.
%DWWHU\&KDUJLQJ
Designed to NiCd battery 12 V, 4 Ah, for example, SB522.
Charging current:
Charging
175 mA
4 Ah 100%
175 mA
2.8 Ah 70%
A
0m
40
Time h
10 30
,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 or interruption in battery, cold battery at start
FC, Fast Charging (ylw) Indicates recharging after power-up or battery replacement (10 hours).
0DLQWHQDQFH3DUWV
Miniature Fuse Link, 5 x 20 mm, 2AF (fast) ABB part no. 5672 2011-17
0HFKDQLFDO'DWD
Module size: 6 SU, 12 mp (“half height, double width”)
Weight: 0.95 kg (2.1 lbs.)
Block Diagram
Normal Operation Backup Operation
Charging of Battery Discharging of Battery
6% 6%
X11 X11
Mains L 2AF Mains L 2AF
Supply Supply
a.c. or N a.c. or N
d.c. SB522 d.c. SB522
PE PE
Normal Normal
5V supply 5V supply
RAM RAM
$ 6%%DFNXS3RZHU6XSSO\9GF
'HVFULSWLRQ F IP
SB511 is a battery charger which works together with one single battery BF BP
package, for example, SB522. Use these two modules for current
FC
supply of processor module RAM in the event of mains supply drop out.
F1
The capacity expressed in time of backup depends on the application. 4AF
Please refer to the actual Advant Controller documentation.
Use two sets (SB511 and SB522) to double the backup time.
SB511 is positioned in a controller subrack to interface with the backplane bus X9
and the battery.
Mains supply is connected via a module front connector.
The mains supply input provides fusing and other adequate protection.
The input energy is converted and used for 5 V internal unit supply and by a
controlled current generator for battery charging.
The current generator produces a current adapted to the mode of operation:
recharging, which takes approximately 10 hours after power-up battery replacement,
or trickle charging.
During recharging, a LED FC on module front lights up.
Diagnostic functions continuously supervise the operation. Error and other statuses are
indicated by module front LEDs. The information is available on the backplane
for further processing by the system status functions.
)URQWYLHZ
.At installation, insert the module in the subrack first. Then connect the power supply (X9)!
Technical Data
,QSXW'DWD
Mains supply: 24-48 V d.c.; variation -20% to +20%; ripple < 15%
Max. power: 25 VA
3RZHU6XSSO\RI5$0
Output voltage at normal operation: 5.6 V ±0.2V (zero load)
Output voltage at backup operation: 6.0 V ±0.2V
Max. current: 2A
Notes:
- The output voltage level is raised during backup operation to compensate for voltage drops in voting circuitry.
- The output current is short-circuit proof.
- The physical output has a serial diode to provide two SB511s in parallel operation.
%DWWHU\&KDUJLQJ
Designed to NiCd battery 12 V, 4 Ah., for example, SB522.
Charging current:
Charging
175 mA
4 Ah 100%
175 m A
2.8 Ah 70%
A
0 m
40
Time h
10 30
,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 or interruption in battery, cold battery at start
FC, Fast Charging (ylw) Indicates recharging after power-up or battery replacement (10 hours)
0DLQWHQDQFH3DUWV
Miniature Fuse Link, 5 x 20 mm, 4AF (fast) ABB part no. 5672 2011-20
0HFKDQLFDO'DWD
Module size: 6 SU, 12 mp (“half height, double width”)
Weight: 0.95 kg (2.1 lbs.)
Block Diagram
Normal Operation Backup Operation
Charging of Battery Discharging of Battery
6% 6%
X9 X9
Mains 1 4AF Mains 1 4AF
Supply 2 Supply 2
d.c. d.c.
SB522 SB522
3 PE 3 PE
Normal Normal
5V supply 5V supply
RAM RAM
$ 6%%DWWHU\8QLW
'HVFULSWLRQ
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.
260 (10.2 “)
max. 40 (1 .6”)
6.4 (0.25”)
max. 71 (2.8”)
325 ±1 (12.8”)
Technical Data
(OHFWULFDO'DWD
Nominal battery voltage 12 V
Capacity 4 Ah (one-hour discharge)
Internal, non-replaceable 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”)
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]DUGRXVZDVWH.
0DLQWHQDQFH3DUWV
Battery Unit SB522
Block Diagram
6%
+12V X1:4
20AF
0V X1:1
$ 6&[6XEPRGXOH&DUULHUV
'HVFULSWLRQ F
RUN
Three variants of submodule carriers are available to fit into RF533 Series 1
controller subrack.
A submodule carrier has no complete function but two slots for submodules of
different kinds to define the desired function.
)URQWYLHZ
Technical Data
,QGLFDWRUV
LED RUN (green) on module front. Indicates module running normally.
LED F, Fault (red) on module front.
3RZHU6XSSO\ 6&6&
5 V d.c. typical 1.3 A1.5 A (excl. submodules)
max. 2.0 A2.0 A (excl. submodules)
$ 6'GFGF&RQYHUWHU
'HVFULSWLRQ
SD150 is a d.c. voltage converter for 24 V and 48 V d.c. networks.
It is intended to supply the voltage 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 located on the front of the unit.
480 (18.8”)
132 (5.2”)
89 (3.5”)
IN OUT
420 (16.5”)
21.5 (0.84”)
465 (18.2”)
)URQWYLHZ
6LGHYLHZ
M6 (4x)
316 (12.4”)
337 (13.2”)
50 (1.96”)
Technical Data
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
6DIHW\&ODVVLILFDWLRQ 0HFKDQLFDO'DWD
Class I according to IEC 536 (earth protected) Width 480 mm (18.8”)
3URWHFWLRQ5DWLQJ 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
6'
+ +
IN OUT
- -
PE
$ 655HJXODWRU99
'HVFULSWLRQ ABB SR
511
The regulator SR511 is a switch-mode power converter transforming
24 V d.c. to the stabilized voltages 5 V and 2.1 V d.c.
All of these voltages have a common negative terminal. F
Technical Data
,QGLFDWRUV
LED F (Fail, red) lights for undervoltage or overvoltage
LED 5 V (green) lights for normal voltage or overvoltage, but not for undervoltage
LED 2 V (green) lights for normal voltage or overvoltage, but not for undervoltage
,QSXW9GF
Dual 24 V d.c. inputs
Rated input power 310 W at full load; 5 V, 2.1 V
Maximum input power 350 W at current limit 46 A
Efficiency 70% typ.
Rated input voltage 24 V d.c.
Voltage variation ±8 V
External fuse 30 AF maxfor each 24 V terminal
2XWSXW9GF
Rated output voltage 5.15 V (adjustable)at 25 A load
Voltage variation 5.3 V max., 5.0 V min.at 0 A and 40 A, respectively
Ripple voltage 10 mV typ.at 40 A load
Load range 1 A - 35 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
2XWSXW9GF
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 output current at overtemperature
0HFKDQLFDO'DWD
Module size: 6 SU, 12 mp (“half height, double width”)
Weight: 1.6 kg (3.5 lbs.)
Block Diagram
65
24 V A Regulator 5 V
Power supply 24 V 5V
connected
via the back- 24 V B 5V
plane Regulator 2 V
5V 2V
Connection
2.1 V to the back-
plane
Fail
2V Supervisory logic
5V NORM-N
$ 3RZHU6ZLWFKDQG'LVWULEXWLRQ8QLWV
'HVFULSWLRQ
Power Switch and Distribution units (PSD units) are modular designs fitting 19-inch rails.
A rail houses up to three units.
Use PSD units to switch on/off the mains supply to an Advant Controller installation
and for internal power distribution.
Normally the modular box has three socket outlets. The internal connections are made
pluggable to the PSD unit.
Some PSD types have extra terminal blocks to permit series connection of additional units
and thus expand the number of socket outlets and matching miniature circuit breakers.
PSD units designed to be directly connected 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 “aux,” respectively, in Table A-7, under the heading below, 7HFKQLFDO'DWD.
Different types of PSD units are available to meet various requirements. See Table A-7.
The figure below represents the generalized appearance of the different types.
202 (8”)
Isolation transformer
130 mm (5”) deep behind apparatus plate
Example of equipment
SV-types only
Technical Data
Technical data for the individual variants available are given in Table A-7.
3DUDPHWHU 69 69 69 69 6; 6; 6; 6; 6; 6;
Category Supply main/aux aux aux aux aux main main aux main main main
Mains input Single Single Dual Dual Single Single Single Single Single Single
Mains Type of network any any any any any any TN any any any
PRI
Install. category III III III III III III II III III III
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
Primary fuse external, A ≤35 ≤35 ≤35 ≤35 ≤35 ≤35 ≤25 ≤80 ≤80 ≤100
1RWH: TN defined by standard EN 60 950. Install category II and III according to IEC 664.
$GYDQW&RQWUROOHU8VHU¶V*XLGH
$SSHQGL[$ +DUGZDUH0RGXOHV
6DIHW\&ODVVLILFDWLRQ
Class I according to IEC 536 (earth protected)
3URWHFWLRQ5DWLQJ
IP20 according to IEC 529 (IEC 144)
0HFKDQLFDO'DWD
SX-types SV-types (including isolation transformer)
Width 202 mm (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.)
%ORFN'LDJUDP
6969
X2
T1 PE
X1 F1 L
F3
L1
L2 X3
N L
PE
N
PE
X4 L
N
69 69 PE
120 V, 300 VA
T1 Isol. transf. 230 V, 300 VA
F1 MCB K 10A K 10A
X5 L
F3 MCB K 1.6A K 3A
2 10 mm2
N
X1, X2 Screw term. 10 mm
PE
X3 - X5 Outlet socket 10A 10A
6969
K1 T1 X1PE
F1 F1 L
F3
1
3 X3
N L
X1PE
N
PE
F2 F2
1 X4 L
3 N
X1PE PE
69 69
120 V, 300 VA X5
T1 Isol. transf. 230 V, 300 VA L
F1, F2 K 10A K 10A N
MCB
PE
F3 MCB K 1.6A K 3A
2 10 mm2
X1 Screw term. 10 mm
F1, F2 Screw term. 35 mm2 35 mm2
X3 - X5 Outlet socket 10A 10A
6;
X2
X1 PE
F1
L
N X3 L
PE
N
PE
X4 L
N
PE
6;
F1 K 10A
X5 L
N
X1 - X2 Screw term. 10 mm2
PE
X3 - X5 Outlet socket 10A
6;6;
X2 L1
X1 S1 L2
L1
PE
L2
PE
F1
X3 L1
L2
PE
6; 6;
X4 L1
L2
S1 Power switch
PE
F1, F2 MCB K 16A K 25A
2 35 mm2
X1, X2 Screw term. 16 mm
F2 X5 L1
X3 - X5 Outlet socket 16A 25A
L2
L1, L2 Design. as is L+, L- PE
6;6;
X2 L1
X1 L2
L1
PE
L2
PE
F1
X3 L1
L2
PE
6; 6; X4 L1
L2
PE
F1, F2 MCB K 16A K 25A
2 35 mm2
X1, X2 Screw term. 16 mm
F2 X5 L1
X3 - X5 Outlet socket 16A 25A
L2
L1, L2 Design. as is L+, L- PE
6;
S1
L+
S1
1
L-
3 F1
X1PE F1
L+
1
L-
3
6;
S1 Power switch
F1, F2 MCB K 50A
2 F2
X1PE Screw term. 35 mm F2 L+
S1, F1, F2 Screw rerm. 35 mm2 1
L-
3
$ 6;'LVWULEXWLRQ8QLW9GF
'HVFULSWLRQ
Use the power distribution panel SX554 unit for distribution
of 24 V or 48 V d.c. tension within an Advant Controller 410/450.
It mounts right below an SA1xx power supply unit and may be utilized
as a support during replacement of a heavy-weight power supply unit.
SX554 is a connector printed circuit board mounted in a steel frame.
It has two screw terminals for 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 power inlet,
one outlet X12 which can be used for remote sensing/measuring
the input terminal voltage, and a dual fast-on tab outlet fused 1A.
465 (18”)
Label X14
X1 X2 X3 X4 X5 X15 F2 F1 X21 X22 X10 X11 Live X12 X23 32 43
(1.3”) (1.7”)
4
420 (16.5”)
482 (19”)
)URQWYLHZ
7HFKQLFDO'DWD
,QGLFDWRUV
LED LIVE (green) on module front. Indicates a voltage at the power inlet.
(OHFWULFDO'DWD
Input voltage: 24 V or 48 V d.c.; variation -20 to +20%
Rated input current: 30 A
External fuse 30AT (slow) max. Short-circuit protection for the equipment.
Installation Category: II according to IEC 664
Rated insulation voltage: 60 V (Dielectric test voltage 1000 V a.c.)
)XVHV
F1 - Thermal overload 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
%ORFN'LDJUDP
6;
+ X10a
- b
+ X11a
- b
R2
+ X12
F1 X14
X21 + F2
LIVE + X15
10AT 1AF
X22 -
Terminal Description + X1
1
X21, X22 screw term. 10 mm2 power inlet -
2
X23 GND X23 tab 6.3 x 0.8 mm RFI ground conn.
X2 - X4
X10, X11 tabs 6.3 x 0.8 mm non fused power outlets
X1 - X5 male conn. 2-pole fused 10A power outlets + X5
1
X14, X15 tabs 6.3 x 0.8 mm fused 1A aux. pow. outlets -
X12 tabs 6.3 x 0.8 mm R = 3.3 k aux. sign. outlet 2
$ 7&6\VWHP6WDWXV&ROOHFWRU
Two relay outputs controlled by RUN signal (Processor Modules A and B).
RUN
'HVFULSWLRQ A1
A2
TC520 is positioned in a controller subrack to interface with the backplane bus. AG
The module collects status information from around the system. Inputs from the backplane B1
bus of the Advant Controller as well as the module front connector are treated. B2
The information is then distributed on a transmit-only serial link. BG
This serial link is available on the backplane to all main CPUs for listening only. RA
RA
To achieve external synchronization of the Advant Controller system calendar clock, RB
the “minute pulse” is connected to TC520. The signal is separately distributed RB
on the bus backplane to the processor module(s). FN
S
The module also makes a RUN-signal controlled relay contact externally available. SG
As long as the RUN-signal is active, the relay contact is closed.
Inputs, except the SYNC input, are filtered digitally by software.
TC520 is totally autonomous, that is, it cannot be affected by an outside user. The status
of all inputs is reported, regardless of whether the inputs are connected or not.
The application of the inputs A1, A2, B1, B2 is configured in the controller data base.
Error state with respect to electrical signal level is defined by the application. )URQWYLHZ
See the controller configuration/installation chapters.
For the input FN (FANFAIL), the logic high level 24 V is applied as the error state.
7HFKQLFDO'DWD
,QGLFDWRUV
LED RUN (green) on module front indicates module running normally.
1, A1 STATUSA1 IO24VA or “F1” -50 to +2 V +12 to Opto 1ms/100ms > 100ms Positive
+60 V
2, A2 STATUSA2 IO24VB or “F2”
4, B1 STATUSB1 “F3”
5, B2 STATUSB2 “F4”
11, FN FANFAIL -50 to +2 V +12 to Ref. chassis 1ms/100ms > 100 ms Positive
+60 V
12, S SYNCIN Opto 1 ms/ -- ms > 10 ms Positive
13, SG COMM.SYNC
3RZHU6XSSO\ 0HFKDQLFDO'DWD
5 V d.c. typical 5 0 mA Module size: 6 SU, 6 mp (“half height”)
Power loss (heat) typical 0.25 W Weight: 0.23 kg (0.5 lbs.)
Block Diagram
7&
Register X2
X3 Register
Backplane
SYNC-N
Relay
Relay
CPU
PROM
SIO
Cabinet Type
Figure B-4. Position of the Holes for fixing the Cabinet(s) to the Floor
Symbol in
RM500V1 RM500V2
Figure B-4
X 69 mm (2.7”) 69 mm (2.7”)
W3 702 mm (27.6”) 602 mm (23.7)
W 800 mm (31.5”) 700 mm (27.6”)
Y 56 mm (2.2”) 56 mm (2.2”)
Symbol in
RM500V1 RM500V2
Figure B-4
D3 419 mm (16.5”) 544 mm (21.4”)
Dtot 531 mm (20.9”) 655 mm (25.8”)
The CPU subrack is provided with a fan unit to equalize the temperature difference in the
subrack.
D.1 General
To use the documents provided at delivery, you must be familiar with the item designation
system used in Advant Controller cabinets.
Each component in the system has a unique designation which indicates exactly the location of
the component in the cabinet. This designation consists of a letter 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..
When there are several cabinets, they are designated 1 and 2 from the left.
The mounting planes are for example 1B, 2B and so on.
All mounting planes A, B, C, D, E, H, V (hinged frame) and U (hinged frame) are divided
vertically into 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 figures. The + sign prefix
indicates that the designation is location-oriented.
102
156
108
1 56 85
. 1
6
7
12
756
Please note!
The given location-oriented item designation
should not be mixed up with the module
item designation in the computer infrastructure (address)
where the positions are designated from the left 1, 2, 3, and so on.
See Figure D-5
1 26 85
1
102
6
7
726
18
Address
.
1 B Voltage Voltage
l Reg. Reg.
Sub- i
positions n 1 2
d
2 Backup Backup S
Power Power u
Supply Supply p
e
1 2 r
v.
Address/Position 1 2 3 4 5 6 7 8
1 5 9 25 81
1
2
4
5
6
1 4 9
Item design. 4 10
11
1 4 12
Item design. 4 13
14
Numbering of
circuit boards
1 2 3
2
1 (Slot)
1 (Slot)
(Slot) X1
X1 X1
X31
X2 2 X21
(Slot)
X22
Module front Module front with Front of unit with several contacts
with contacts slots for submodules and slots for submodules
Jumper group
S2 S1
X1
X2
Connection Units
The item designation code for the contacts of the connection unit are shown in Figure D-12.
The connector for internal connections in the cabinet is always designated X80.
The terminal block group or connector for external connections is designated X90.
If there are more connectors, these are designated X81, X82, or X91, X92, and so on.
X91
X92
1 - - - - - - - - - - - - - - - - - 46 1 - - - -5
X90 X90
X80 X80
When more than one connection unit is mounted on the same mounting 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.
B4.1 B4.13
1 13 24
Level B4
19” design
Figure D-14 shows a typical connection between connection unit B1.1 and I/O board U4.125.
The item designation of the board gives its location in the subrack.
S2 S1 X90
X80
X1
Flat
Cable
X2
The poles of the connection terminal block on the connection unit are numbered from left to
right, see Figure D-15. The code for a process connection to pole 3 becomes B1.1.X90:3.
B1.1.X90:3
+QA1
B1.1
1 2 3 4 5 Etc
Connection
X90 Unit
X80
1 2 1 2 3
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.
An extract from a wiring table, Table D-1, shows the corresponding item designations,
Connection point A
No. Instar.
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) X1
7 2H15 13 X80
8 1H35 2 F1X3
(1) x stands for 1, 2, 3 and so on.
E.1 General
The tables below present the current consumption and power dissipation of all relevant
hardware modules included in Advant Controller 450 and its I/O.
Use this information:
• When dimensioning the supply to the system
• When calculating the heat generated in RM500 cabinet.
The values given in the tables are typical and adapted to these kind of applications.
It is assumed that 70 percent of the channels on a board are active simultaneously.
Use the tables as forms in your own calculation.
Table E-2. Current Consumption and Power Dissipation, S100 I/O Boards
Table E-2. Current Consumption and Power Dissipation, S100 I/O Boards (Continued)
Table E-3. Current Consumption and Power Dissipation, Power Supply and Sundry
(1)
SA1xx - - 100 Approx. for all types of
power supply 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
TC625 - 0.13 3
TC630 - 0.1 2.4
Sum
(1) Redundant power supply units should not be included in the calculation of number of boards/units.
AI A) B) C)
_______ ms F) G)
_______ E+H
____ 0.60
H)=A*G*F/10
_______%
H) ________%
DIC A) B) C) _______ ms F) G) _______ E+H
AO A) B) C)
_______ ms F) G)
_______ E+H
C)
A) B) C)=A*100/B D) C*D)
C)
A) B) C)=A*100/B D) C*D)
C)
A) B) C)=A*100/B D) C*D)
C)
A) B) C)=A*100/B D) C*D)
C)
A) B) C)=A*100/B D) C*D)
C)
A) B) C)=A*100/B D) C*D)
C)
A) B) C)=A*100/B D) C*D)
C)
A) B) C)=A*100/B D) C*D)
C)
A) B) C)=A*100/B D) C*D)
C)
A) B) C)=A*100/B D) C*D)
C)
A) B) C)=A*100/B D) C*D)
C)
A) B) C)=A*100/B D) C*D)
C)
A) B) C)=A*100/B D) C*D)
C)
A) B) C)=A*100/B D) C*D)
C)
A) B) C)=A*100/B D) C*D)
C)
Total ________ %
Factor
Object type Remark Total RAM req.
(kbytes)
AI/AO signals S100 I/O x 0.30
S400 I/O (MP 51 not included) x 0.30
S800 I/O x 0.27
DI/DO signals S100 I/O x 0.26
S400 I/O (MP 51 not included) x 0.26
S800 I/O x 0.14
S800 I/O station No. of S800 I/O stations on AF 100 x 0.40
Calculated signals For presentation and event handling in x 0.30
AS 500 Series operator stations (includ-
ing signals via Advant Fieldbus 100)
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 signals x 0.50
VALVECON Excluding I/O signals x 0.60
MOTCON Excluding I/O signals x 0.80
GROUP Excluding I/O signals(1) 1 x 3.00
SEQ Excluding I/O signals x 1.00
DAT No. of DB elements x 0.02
TEXT No. of DB elements x 0.14
Table handling No. of tables(2) x 4.90
Factor
Object type Remark Total RAM req.
(kbytes)
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 Basic requirement for QC07-OPF41 1 x 799.00
operator station
and IMS Station or No. of trend data storage logs(5) x 12.00
MV800/1 Group alarm, No. of group objects x 0.13
No. of group members x 0.09
MasterBatch 200/1 Basic requirement for QC07-BAT41 1 x 418.00
No. of SECCONx1.7+OPCONx6.0+ x 1.00
TANKCONx1.8
No. of processes(6) x 25.00
PROFIBUS DP No. of Profibuses x 1.20
Number of PROFIBUS slaves x 0.80
LONWORKS No. of LONWORKS Communication x 65
Network modules (CI572/CI573)
No. of LONWORKS devices x 0.2
No. of LONWORKS variables x0.06
(input and outputs)
No. of LONWORKS multiple network x 0.33
variable
No. of LONWORKS Event Treat x 0.14
No. of MasterBus 300/300E, RCOM/RCOM+, GCOM and x 8.00
MultiVendor Interface
User Defined Basic requirements for QC07-UDP41 1 x 132.00
PC elements (7)
Storage of user defined PC elements 1 x 150.00
Space for storage of User Diskette contents(7) x 100.00
Basic requirements for QC07-LIB41 1 x 32.00
Basic requirements for QC07-LIB42 1 x479.00
Basic requirements for QC07-FUZ41 1 x 40.00
Basic requirements for QC07-COM41 1 x 33.00
Basic requirements for QC07-BAS41 1 x 2207.00
Spare RAM area(8) 1 x 40.00 40.00
(9)
Approximative total RAM requirement in kbytes
(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) 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 is known.
(8) Recommended value for most systems.
(9) Must be less than the RAM size of the processor module (8 or 16 Mbyte).
‘*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’0000FFFF
D4 H’00000172 D5 H’000003E5 D6 H’00002544 D7 H’000182D8
AO H’00480128 A1 H’00480128 A2 H’0048545E A3 H’0001C9F6
A4 H’00052886 A5 H’0048246E A6 H’00480100 A7 H’0048246A
System stack
H’004800DA H’2704 H’0000 H’5244 H’002C
H’004800E2 H’0165 H’C20A H’FFFC H’3A79
H’004800EA H’2400 H’0000 H’ODEE H’0048
H’004800F2 H’246E H’0048 H’0100 H’0000
H’004800FA H’0000 H’760A H’0070
System halt code = 05
Bus time-out error in system or kernel mode
DANGER
You should carefully follow general safety instructions given in Chapter 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.
Halt
Significance Corrective Actions
Code
-3. Backup CPU in a redundant pair stopped when 1. Check the mode switches on primary and backup
restarted CPU boards. Restart the backup CPU with the
mode switch in the same position as the primary
CPU had when it was last restarted.
NOTE
If position “AUTO” does not work then
switch to “CLEAR” or vice versa.
Halt
Significance Corrective Actions
Code
09 Overload, STALL ALARM Note the error code and the red LED indicators which
have illuminated. LSYSHI gives the level of the
overload and indicates the type of overload which
has occurred.
S§LOSTAL = 0:
Hardware fault but not memory board fault. Replace
the faulty hardware.
S§LOSTAL = -1:
Overload on PC level.
Extend cycle times on PC.
Hardware fault is possible; I/O board or
communication board.
Replace the faulty hardware.
0A Memory error. The address to the incorrect Replace the processor module.
position is in the address register A0. The error
code appears during the test of the RAM which
is only performed on initialization of the system.
0b System program check sum test error. RAM test. Replace 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. Follow instructions in Section 5.5.9.5, Check of
Power up after power fail in a system that has no Power Supply.
power fail handling, neither warm start up nor
power fail restart.
16 Serious program error. Follow instructions in Section 5.5.16, System
Restart, INIT.
17 Wrong processor module type in the system. Replace the processor module.
24 System with redundant processor modules only. Restart the backup module which was stopped.
Indication on the backup module.
Error at changeover. Probably the system was
not fully synchronized when an attempt to
changeover was made.
Halt
Significance Corrective Actions
Code
2C System with redundant processor modules only. Replace the backup processor module.
Indication on the backup module.
Internal error.
32 System with redundant processor modules only. This means a serious shut down of a redundant
Indication on the “new” primary at changeover. system. Further detailed information of the possible
Error in changeover. Unexpected status. reason of the halt is stored in the system. This
information is accessible by ABB experts only.
36 System with redundant processor modules only. This means a serious shut down of a redundant
Indication on the “new” primary at changeover. system. Further detailed information of the possible
Error in changeover. Unexpected status reason of the halt is stored in the system. This
information is accessible by ABB experts only.
38 System with redundant processor modules only. Restart with the same system program in both
Indication on the backup module. processor modules.
Internal error. System program in backup and
primary is not equal.
40 System with redundant processor modules only. Try again by depressing the ENTER button. If the
Error when initializing the backup module. same error occurs, replace the backup module.
41 System with redundant processor modules only. Replace the backup module.
Indication on the backup module.
Error detected in the initial diagnostic test.
The RCU-chip on the backup module may be
malfunctioning.
42 System with redundant processor modules only. Replace the backup module.
Indication on the backup module.
Internal error in the task-scheduler for the
backup module.
43 System with redundant processor modules only. Replace the backup module.
Indication on the backup module.
Hardware error on the RCU-chip.
44 System with redundant processor modules only. Replace the backup module.
Indication on the backup module.
Error in the communication between the backup
and primary modules.
Halt
Significance Corrective Actions
Code
45 System with redundant processor modules only. Replace the backup module.
Indication on the backup module.
Internal error concerning interrupts in the
backup module. Possibly malfunctioning RCU-
chip.
46 System with redundant processor modules only. This means a serious shut down of a redundant
Indication on the “new” primary at changeover. system. Further detailed information of the possible
Error in changeover. Floating-point exception reason of the halt is stored in the system. This
pending. information is accessible by ABB experts only
47 System with redundant processor modules only. This means a serious shut down of a redundant
Indication on the “new” primary at changeover. system. Further detailed information of the possible
Error in changeover. MOVEM instruction to/from reason of the halt is stored in the system.
I/O during changeover. This information is accessible by ABB experts only
48 System with redundant processor modules only. This means a serious shut down of a redundant
Indication on the “new” primary at changeover. system. Further detailed information of the possible
Error in changeover. Status channel interrupt not reason of the halt is stored in the system.
pending during changeover. This information is accessible by ABB experts only
80 System with redundant processor and S100 I/O This means a serious S100 I/O bus cable or Bus
bus redundancy. Extender (DSBC 174/DSBC 176) error. Bus cable
Error in S100 I/O bus cable or Bus Extender broken or faulty DSBC 174 or DSBC 176.
(DSBC 174/DSBC 176). The halt can also occur if the Bus Extender
connected to the primary CPU is stopped by using
the switch on the front of the Bus Extender.
Network Node Time Type Code Task Interrupted Address Data 1 Data 2
Significance
Network Specifies within which communication network in the installation the message has been
generated.
Node Specifies the node in which the message was generated. If Network and Node are not
specified, the message is from an engineering station.
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.
Data 1 Optional extra information, expressed in decimal or hexadecimal (H’) form.
Data 2 If data 2 contains no information, Data 1 only is presented. Data 2 can also be in decimal or
hexadecimal (H’) form.
DANGER
You should carefully follow general safety instructions given in Chapter 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.
Type 2 Overload
11 1 12:16:30 2 46 CXKK220
Type 17 MasterNet
11 1 12:23:44 17 1 CXNM540 A H’00000000 21 11
Type 22 PC interpreter
11 1 12:23:45 22 9 DAYIP30 109 34392
Continue
Type 26 Other Faults (System Messages from Printer and operator station)
11 1 16:23:54 26 12 DCCA910 H’04900010 1 2
Data 1 contains concepts and instance numbers which can be used to locate incorrect data base
elements with the help of the command MDB. Do MDB “Concept”. Instance.
Example:
A system message includes Data 1 = H’ 01400001. The most significant word 0140 represents
the concept while the least significant word 0001 represents the instance number. Convert with
the help of Table I-11 to decimal form. Apply the decimal form and do MDB 333.1 to see the
corresponding data base.
From a more general viewpoint the command LCT is used to list all types of data base elements
in the system and all its concepts (LOF FILE). 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.
In the Advant Controller 400 Series, numbers in hexadecimal notation are identified by an
introductory H’. Decimal notation is used otherwise.
Examples: H’0000357A Hexadecimal
00003578 Decimal
The following shows a table for rapid conversion of up to four-figure hexadecimal numbers.
If the number contains more figures, the value can be calculated in accordance with the
examples above.
For example: H’257E = 8192 + 1280 + 112 + 14
INDEX
A D
Address D-4 Data and text handling 1-97
Advant Station 500 Series 1-105 Data entry 2-57
AI810 1-75 Data Set 1-92
AI820 1-75 Delivered Version Specification C-1
AI830 1-75 to 1-76 Delivery Specification C-1
AI835 1-75 DI810 1-73
AO810 1-75 DI811 1-73
AO820 1-75 DI820 1-73
Application Program Backup DI821 1-73 to 1-74
Appropriate Hardware and Software 3-4 Dimensioning 2-57
Overview 1-26 Distributed connection units 2-36
Working procedures 5-87 DO810 1-73 to 1-74
Arithmetic 1-97 DO820 1-74
B E
Backup power supply for RAM and system clock 1-44 Enter
Backup processor module 4-1 Safety aspects 5-1 to 5-2
Battery backup time 3-58 Environmental Adaptation 1-118
Block 1-22 Environmental Considerations 2-2
Event Handling
C Technical Data 3-60
Calendar time functions 1-97 Extended MTUs 1-77
CI810V1 1-72 External clock synchronization
CI820 1-72 Description 1-35
Compact MTUs 1-77 Electrical data A-46
Configuration mode 4-1 Installation 2-31
Configuration/Application Building 3-72
Connection Unit 1-49 F
Controller Feedback control 1-101
Block diagram 1-22 Frequency measurement 1-98
Functional interfaces 1-23 Functional units 1-96
Functional modularization 1-23 Fusing in distribution board 3-7
Controller system configuration 3-72 Fusing within the system 1-44
CPU-load
Base-Load 3-45 G
Calculation principles 3-41 Group start 1-102
Data Set 3-51
Logging 3-53 H
Masterview 320 3-52 Hardware structure 1-20
Others 3-54 HART Interface 1-52 to 1-53
PC and Process I/O 3-46 Heating element 2-18
Performance-General 3-44
Subscription, Command, Event 3-49
I
Creating 2-57
Inspection and Test Record C-1
Current consumption 3-6
Intrinsic Safety Barriers 1-52
J R
Jumpering - Overview 5-54 Release Notes C-1
Reports 1-99
L Run/Alarm relay
License Certificate C-1 Description 1-108
Lifting instructions 2-18 Electrical data A-46
Location of components D-1 Installation 2-31
Location-Oriented Item Designations D-3
Logic and Time Delays 1-97 S
Safety switch 2-10
M Safety system aspects 1-108
Masterview 320 1-104 SD811 1-78 to 1-79
MasterView 800 Series 1-105 SD812 1-78 to 1-79
MasterView 800/1 1-105 Selection of primary/backup processor module 4-3
Measuring 1-100 Sequence control 1-97
Memory Shut-down
Application Program Backup 1-26 Automatic 2-52
Power Supply Backup 1-26 Emergency 2-50
Size 3-58 Manual 2-51
System Program Backup 1-25 Safety 2-50
Mimic panel 1-104 Software structure 4-15
Module Termination Units 1-76 SU-modules D-3
Modulebus 1-71 Supervision 1-100
Motor control 1-102 Supervisory inputs 1-110
Mounting planes D-1 Electrical data A-46
MTUs 1-70, 1-76 Installation 2-31
Support and Problem Reporting C-1
N Swing frame D-1
Naming 3-74 System definition 3-72
System Log C-1
O
Object oriented connection 1-49 T
Offline mode 4-1 TB815 1-72
Operation mode 4-1 Terminal Diagram C-1
Order Reference Sheet C-1 Termination Units 1-70
Outputs behavior at interrupts 1-107 TU810 1-77
TU811 1-77
TU830 1-77
P
TU831 1-77
P1, P2, -3, -4 4-1
TU835 1-77
PC element 1-92
TU836 1-78
Positioning 1-97
TU837 1-78
Primary processor module 4-1
Type circuits 3-75
Priority system 3-39
Product variants 1-24
Protective earth 2-8 U
Pulse counting 1-98 UPS, Uninterrupted Power Supply 3-10
User Defined PC Elements
Application 1-94
Program module 1-34
V
Valve control 1-102
VT100 terminal 1-105