AADvance Comprehensive Training Manual (Rev 1.7 Oct 2012)

System Training Manual

Operation, System Build, Configuration, Programming, Troubleshooting, & Maintenance

For the AADvance Programmable Controller Revision 1.7 October 2012

Copyright Notice and Disclaimers Notice In no event will Rockwell Automation be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment. The examples given in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation does not assume responsibility or reliability for actual use based on the examples and diagrams. No patent liability is assumed by Rockwell Automation, with respect to use of information, circuits, equipment, or software described in this manual. Reproduction of this manual in whole who le or in part, without written permission of Rockwell Automation is prohibited. All trademarks are acknowledged.

Disclaimer It is not intended that the information in this publication covers every possible detail about the construction, operation, or maintenance of a control system installation. You should refer to your own (or supplied) system safety manual, installation instructions and operator/maintenance manuals.

Revision and Updating Policy This document is based on information available at the time of its publication; however, the document contents are subject to change from time to time. You should contact Rockwell Automation Technical Support by e-mail — [email protected] to check if you have the latest version of this publication. © Copyright Notice, Rockwell Automation 2012 This document contains proprietary information that is protected by copyright. All rights are reserved.

Documentation Feedback Your comments will help us to serve your documentation needs better. If you discover any errors or have any suggestions on how to improve this publication send your yo ur comments to our product support group: [email protected]

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AADvance System Training Manual, version 1.7

Warning Radio Frequency Interference Most electronic equipment is influenced by radio frequency interference (RFI). Caution should be exercised with regard to the use of portable communications equipment around such equipment. Signs should be posted in the vicinity of the equipment cautioning against the use of portable communications equipment.

Maintenance Maintenance must be performed only by qualified personnel. Otherwise personal injury or death, or damage to the system may result.

Company Background ICS Triplex has been manufacturing and supplying safety critical shutdown and control systems since 1969. The Regent Triple Modular Redundant (TMR) system was introduced in 1986. It incorporated Hardware-Implemented Fault Tolerance (HIFT). The Regent system has been field-proven in hundreds of installation world-wide. The Regent + Plus product family was introduced in 1995 and provided additional features and lower cost to the marketplace. The Trusted TMR system was introduced in 1997. The Trusted system is compatible with legacy Regent and Regent + Plus systems allowing a direct migration path for existing systems. AADvance was released in 2008. AADvance is a flexible and scalable system designed to enhance Trusted, not replace it. AADvance components can be configured as simplex, dual or triplicated. Systems may be small and standalone , or large and distributed.

Applicability This Training Manual applies to release 1.3.

Table of Contents

3

Issue Record Issue

Date

Comments

1.6

June 2011

Updated for Release 1.2

1.7

July 2012

Integrated with user manuals and updated for release 1.3

4


Table of Contents Chapter Chapter 1: Introd Introd uctio n Course Goals ..................................................................................... ............................... 1-1 Who This Course is Intended Intende d For ................................................................ .................... 1-2 Recommended Prerequisites .................................................... ............................................................................................ ........................................ 1-2 Course Length .............................................................................. .................................... 1-2

Chapter 2: System Overview Purpose ........................................................ ............................................................................................................... ..................................................................... .............. 2-1 Objectives.................................................... ........................................................................................................... ..................................................................... .............. 2-1 AADvance System Overview ......................................................................................... . 2-2 Features ............................................................................................ ............................. 2-2 General System Layout ............................................... .................................................. 2-3 Internal Bus Structure ............................................ ....................................................... 2-5 Flexible Configurations................................................. ................................................... 2-6 Non-Redundant, Fail Safe Architecture ............................................................ ............ 2-7 Dual Processor, Non-Redundant I/O ............................................................................ 2-8 Dual Architecture ................................................................................... ....................... 2-9 TMR Input & Processor, Fault Tolerant Output ........................................................ .......................................................... 2-10 Mixed Architecture ....................................................... .............................................. 2-11 Distributed Architecture .............................................................................................. 2-12 Test Your Knowledge .............................................. ...................................................... 2-13

Chapter Chapter 3: System Components Purpose ........................................................ ............................................................................................................... ..................................................................... .............. 3-1 Objectives.................................................... ........................................................................................................... ..................................................................... .............. 3-1 System Components Co mponents ............................................... .................................................... .......................................................... ...... 3-2 Hardware ........................................................................................................................ 3-2 Software ....................................................... .............................................................................................................. ................................................................... ............ 3-3 Processor Module .................................................................................................. ........... 3-4 Processor Base Unit ................................................................ ......................................... 3-8 3-8 Digital Input Modules ......................................................... ........................................... 3-10 Analog Input Modules ................................................................................................... 3-12 Digital Output Module .................................................. ................................................. 3-14 I/O Module Base Unit ............................................... ..................................................... 3-16 Field I/O Termination Assemblies ............................................. .................................... 3-18 Digital Input Termination Assemblies .................................. ....................................... 3-18 3-18 Analog Input Termination Assemblies .......................................... ............................... 3-22 Digital Output Termination Assemblies .............................................. ......................... 3-26 Test Your Knowledge .............................................. ...................................................... 3-29

Table of Contents

5

Chapter 4: System Build Purpose ............................................................................................................................. 4-1 Objectives......................................................................................................................... 4-1 System Build .................................................................................. .................................. 4-2 Environmental Limits .................................................. .................................................... 4-3 Component Sizes and Weights ........................................................................................ 4-4 Free Space ................................................................................ ........................................ 4-6 Mount a Processor Base Unit ............................................ ............................................... 4-7 Mount the I/O Base Units ................................................................ ................................ 4-8 Mount Termination Assemblies ................................................ ..................................... 4-10 Mount I/O Expansion Cables ......................................................................................... 4-12 Module Power ......................................................................... ....................................... 4-14 Module Power Supply Requirements.......................................................................... 4-15 Module Power Connections ........................................................................................ 4-16 Grounding ...................................................................................................................... 4-18 Security Dongle .............................................................................................................. 4-19 Processor Fault Alarm Contacts ................................................. .................................... 4-20 Serial Connections .............................................. ........................................................... 4-22 Field Power .................................................................... ................................................ 4-23 Wire the Field Connections............................................... ............................................. 4-24 Digital Inputs............................................................................................................... 4-25 Analog Inputs .............................................................................. ................................ 4-27 Digital Outputs .............................................................................................. .............. 4-30 Cable Management ........................................................................................................ 4-32 Module Polarization ..................................................................................... .................. 4-34 Installing Modules and Blanks ............................................... ........................................ 4-36 Heat Dissipation .................................................................................................... ......... 4-38 Parts List ........................................................................................................................ 4-40 Test Your Knowledge .............................................. ...................................................... 4-42

Chapter 5: Workbench Overview and Progr amming Purpose ............................................................................................................................. 5-1 Objectives......................................................................................................................... 5-1 Workbench .................................................................................................. ..................... 5-2 Workbench Overview ................................................................ ...................................... 5-4 Dictionary......................................................................................................................... 5-6 Data Types .................................................................................................................... 5-8 Import / Export Variables ........................................................................................... 5-19 Equipment Editor .................................................................................. ......................... 5-23 Inserting an I/O Module .............................................................................................. 5-30 Creating Programs.......................................................................................................... 5-36 Saving a Project ............................................................................................................. 5-46 Test Your Knowledge .............................................. ...................................................... 5-47

6


Chapter 6: Simulating and Testing Programs Purpose ............................................................................................................................. 6-1 Objectives......................................................................................................................... 6-1 Simulation ............................................. ........................................................................... 6-2 Changing Input Variables in a Program ................................................ ........................ 6-3 Changing Input Variables in the Equipment View .............................................. ......... 6-4 Changing Variables in the Dictionary ................................................. .......................... 6-5 Stopping Simulation ................................................... ................................................... 6-7 Test Your Knowledge .............................................. ........................................................ 6-8

Chapter 7: Downloading and Monitori ng Programs Purpose ............................................................................................................................. 7-1 Objectives......................................................................................................................... 7-1 Loading a Resource in a Controller ................................................................................. 7-2 Monitoring Programs ........................................................................ ............................... 7-6 Locking / Forcing ............................................................................................................. 7-9 Difference Between Locking Inputs and Outputs .................................. ...................... 7-11 Unlocking All Variables ............................................. .................................................. 7-13 Viewing Live Data in the Equipment View ............................................... .................... 7-14 Spying Variables ............................................................................... ............................. 7-15 Show Variable Comments ............................................................................................. 7-16 Going Offline ...................................................................................... ........................... 7-17 Test Your Knowledge .............................................. ...................................................... 7-18

Chapter 8: Creating and Using Function s and Function Block s Purpose ............................................................................................................................. 8-1 Objectives......................................................................................................................... 8-1 Functions/Function Blocks ................................................ .............................................. 8-2 Creating a Structured Text Function ................................................. ............................... 8-3 Define Your Variables in the Dictionary ...................................................................... 8-4 Using the Function ................................................. ....................................................... 8-6 Creating a Function Block Diagram Function ................................................................. 8-8 Using the Function ................................................. ..................................................... 8-10 Test Your Knowledge .............................................. ...................................................... 8-11

Chapter 9: Onlin e Changes Purpose ............................................................................................................................. 9-1 Objectives......................................................................................................................... 9-1 Modifying a Resource ................................................... ................................................... 9-2 Checking Version Resource Numbers ...................................................................... .... 9-2 Online Changes ....................................................................... ......................................... 9-3 Test Your Knowledge .............................................. ........................................................ 9-5

Table of Contents

7

Chapter 10: Bi ndings Between Resourc es Purpose ........................................................................................................................... 10-1 Objectives....................................................................................................................... 10-1 Variable Bindings........................................................................................................... 10-2 Plan Your Project .................................................. ......................................................... 10-3 Prepare Your Project ...................................................................................................... 10-4 Linking Resources................................................ .......................................................... 10-7 Simulate and Test Your Bindings .......................................................... ...................... 10-10 Test Your Knowledge .............................................. .................................................... 10-12 Chapter 11: Version Source Control Purpose ........................................................................................................................... 11-1 Objectives....................................................................................................................... 11-1 Version Source Control ................................................ .................................................. 11-2 Repository ..................................................................................................................... 11-2 Check In and Check Out ........................................................................... ..................... 11-4 Version Status Icons....................................................................................................... 11-5 Comparing Version .......................................................................................... .............. 11-6 Retrieving Earlier Versions .................................................. .......................................... 11-8 Test Your Knowledge .............................................. ...................................................... 11-9

Chapter 12: Miscellaneous Workbench Features Purpose ........................................................................................................................... 12-1 Objectives....................................................................................................................... 12-1 Cross Reference Browser ................................................. .............................................. 12-2 Printing .................................................. ......................................................................... 12-4 Passwords ....................................................................................................................... 12-7 POU Access Control ..................................................................................................... 12-8 Resource Access Control .............................................. ................................................ 12-9 Configuration (Controller) Access Control ............................................. ................... 12-10 Project Access Control ................................................. .............................................. 12-11 Export / Import Workbench Elements ......................................................................... 12-12 Export ........................................................................................................................ 12-12 Import ................................................ ................................................... ..................... 12-13 Archive / Restore Projects .................................................. .......................................... 12-16 Archive ...................................................................................................................... 12-16 Restore ...................................................................................................................... 12-18 Test Your Knowledge .............................................. .................................................... 12-22

8


Chapter 13: OPC Purpose ........................................................................................................................... 13-1 Objectives....................................................................................................................... 13-1 OPC Server .................................................................................................................... 13-2 Data Access vs. Alarm & Event ................................................................................... 13-3 Configuring the OPC Server ................................................... ....................................... 13-4 Configuring OPC Clients .................................................. ............................................. 13-7 Test Your Knowledge .............................................. .................................................... 13-10

Chapter 14: Troubleshootin g Purpose ........................................................................................................................... 14-1 Objectives....................................................................................................................... 14-1 Self Test Cycle Times ............................................ ................................................... ..... 14-2 Latching and Unlatching Faults ..................................................................................... 14-3 Fault Types ..................................................................................................................... 14-4 Viewing Variables Live .................................................. .............................................. 14-6 I/O State and LED Indications ................................................ ...................................... 14-7 Processor Event Log ...................................................................................................... 14-9 Test Your Knowledge .............................................. .................................................... 14-13

Chapter 15: Replacing Modules Purpose ........................................................................................................................... 15-1 Objectives....................................................................................................................... 15-1 Removing Modules ........................................................................... ............................. 15-2 Installing Modules............................................... ........................................................... 15-3 Test Your Knowledge .............................................. ...................................................... 15-5

Appendix 1: AADvance Discov er Util it y Purpose .......................................................................................................................... A1-1 Objectives...................................................................................................................... A1-1 Processor Base Unit Configuration ............................................................................... A1-2

Appendi x 2: Glossary Purpose .......................................................................................................................... A2-1 Objectives...................................................................................................................... A2-1 Glossary ........................................................................................................................ A2-2

Table of Contents

9

Appendi x 3: Puzzles and Exercise Purpose .......................................................................................................................... A3-1 Objectives...................................................................................................................... A3-1 Hardware Puzzle ........................................................................................................... A3-2 Software Puzzle............................................................................................................. A3-3 Programming Exercise ........................................................................................... ....... A3-4

Appendi x 4: Safety Manual Considerations Purpose .......................................................................................................................... A4-1 Objectives...................................................................................................................... A4-1 Please Read the Safety Manual! .................................................................................... A4-2 Rules vs. Recommendations ............................................... ....................................... A4-2 High Demand, SIL 3 and Energize to Action Applications ....................................... A4-3 Utilizing I/O Module Diagnostics .............................................................................. A4-3 Degraded Run Time Restrictions ................................................ ............................... A4-7 I/O Forcing ................................................. ................................................................ A4-8 Safety Manual Checklists......................................................................................... A4-10

10


Chapter 1

Introduction

Course Goals To teach users of the AADvance system: 









Introduction

How the AADvance system operates as a non-redundant and fault tolerant programmable logic controller. What modules and components are used in the AADvance system. How to put an AADvance system together. How to use the workbench to create, modify, test, download and update projects and programs to the system. How to create user defined functions and function blocks.



How to pass safety critical data between con trollers.



How to communicate with the system using OPC.



How to utilize the version control features.



How to troubleshoot a system and replace modules. 1-1

Who This Course Is Intended For 





Personnel responsible for designing, configuring and programming an AADvance system. Personnel responsible for installation, troubleshooting and maintenance of an AADvance system. Personnel designing a control system that needs to communicate with an AADvance system.

Recommended Prerequisites 





A general knowledge of programmable logic controllers (PLCs). A background in industrial electronic control principles and practices. A level of competence using Microsoft® Windows® operating systems and programs.

Course Length 4 days The majority of the course is hands-on. Students implement working solutions using actual hardware and software.

1-2


Chapter 2

System Overview

Purpose To provide an overview of the AADvance system and its components.

Objectives •

•

•

•

System Overview

To understand the different system components and configurations. To understand what module configurations meet what Safety Integrity Levels (SIL). To understand the types and names of modules used in the AADvance system. To understand the configuration limits of the system. 2-1

AADvance System Overview AADvance is an industrial controller that can be configured for non-redundant and fault tolerant control and safety applications. It is a scalable system consisting of different modules and interconnecting base units. AADvance can be used for a wide variety of applications such as: • • • • • • •

Critical process control Emergency shutdown Fire and gas detection/protection Rotating machinery control Burner management Boiler and furnace control Distributed monitoring and control

The system is designed for both high and low demand applications.

Features The main features of AADvance are: •

•

•

•

•

•

•

2-2

Flexible modular construction using individual modules to build a system. Operates as a stand alone system or part of a larger distributed network. Easily transforms from a non-redundant to a fault tolerant system. I/O module expansion/additions without system interruption. IEC 61508 certified system; reviewed and approved by TÜV. Handles the full range of IEC 61131 programming languages. Supports industry standard protocols such as HART, Ethernet, Modbus RTU, Open Modbus TCP, CIP and OPC.


General System Layout The AADvance system consists of: •

• •

•

A processor base unit (that can hold up to three processor modules) I/O base units (that can hold up to three I/O modules) I/O termination assemblies (that are inserted into the I/O base units) Processor and I/O modules (that are inserted into the base units)

Figure 2-1: System Components

System Overview

2-3

48 simplex modules, 24 dual, or 16 triplicated. There can be a mix within a system.

A processor base unit can support up to 8 I/O base units (up to 24 I/O modules) on its right side (Bus 1), and up to the same number on its left side (Bus 2), for a total of 48 modules. Module positions within the I/O base units are numbered from 01 to 24, the left most position being slot 01. Any individual module position within the system is uniquely identified by the combination of its bus and slot number, for example 1-01. Expansion cables may be used to connect base units, as shown in Figure 2-2.

I/O base units do not plug directly into the left connector of the processor base unit. Use an extension cable.

Figure 2-2: Example System Layout

2-4


Internal Bus Structure Internal communications between the processor and I/O modules are supported by command and response buses that are routed through the processor and I/O base units. The processor modules send commands to the I/O modules and process their returned responses. Each I/O module has a dedicated response line back to the processors. An interprocessor link (IPL) provides the communication links between dual or triple processor modules.

Figure 2-3: Internal Bus Structure

System Overview

2-5

Flexible Configurations The AADvance system is flexible and scalable. Configurations range from non-redundant fail safe to triplicated fault tolerant. Individual modules are designed as fail safe. Redundant modules are implemented for fault tolerance.

Processor Modules

A single processor module meets SIL 2 requirements. Redundant processor modules (two or more) meet SIL 3 requirements. High demand applications also require the use of redundant processor modules.

Input Modules

Individual input modules meet SIL 3 requirements. Redundant modules are implemented for fault tolerance.

Output Modules

Individual output modules meet SIL 2 requirements in a normally de-energized application and SIL 3 requirements in a normally energized application. Redundant (dual) modules meet SIL 3 requirements in a normally de-energized application and provide fault tolerance in a normally energized application. Triplicated output modules are not necessary and are not supported.

Output modules incorporate dual redundant circuitry internally. A dual module configuration provides a quad redundant output circuit arrangement. Typical system configurations are covered in the following pages.

2-6


Non-Redundant, Non-Redundant, Fail Safe Architecture Non-redundant modules will fail safe on the first detected fault and the process under control will shut down. This configuration meets SIL2 requirements (due to the single processor) and is suitable for low demand mode applications with either de-energise or energise to trip outputs. This configuration is also known as 1oo1D.

Figure 2-4: 1oo1D Configuration

System Overview

2-7

Dual Processors, Non-Redundant I/O Non-redundant I/O modules will fail safe on the first detected fault and the process under control will shut down. The processor modules will degrade to 1oo1D on the first fault and must be replaced within the MTTR (Mean Time To Repair) assumed in the PFD (Probability of Failure on Demand) calculations in order to maintain the SIL 3 rating. This configuration is suitable for high as well as low demand mode applications and meets SIL3 requirements (SIL 2 for energize to trip outputs).

Figure 2-5: 1oo2D Processors, 1oo1D I/O Configuration

2-8


Dual Architecture Redundant I/O modules provide fault tolerance. Duplicated output modules also meet SIL3 requirements for energise to trip outputs. Input modules will degrade to 1oo1D (fail safe configuration) on the first detected fail danger fault with no time limit to repair. Processor modules will degrade to 1oo1D on a module fault and must be replaced within the MTTR (Mean Time To Repair) assumed in the PFD (Probability of Failure on Demand) calculations in order to maintain the SIL 3 rating. A failed output module used for a SIL3 energise to trip must be replaced within the MTTR assumed in the PFD calculations. There is no time limit in normally energized applications. This configuration is also known as 1oo2D.

Termination assemblies can span across I/O base units.

Figure 2-6: Dual Configuration

System Overview

2-9

TMR Input and Processor, Fault Tolerant Output Redundant I/O modules provide fault tolerance. Duplicated output modules also meet SIL3 requirements for energise to trip outputs. Input modules will degrade to 1oo2D on a first fault. They will degrade to 1oo1D on a second fault with no time limit to repair. Processor modules will degrade to 1oo2D on a first fault. They will degrade to 1oo1D on second module fault and a processor must be replaced within the (Mean Time To Repair) assumed in the PFD (Probability of Failure on Demand) calculations in order to maintain the SIL 3 rating. Output modules will degrade to 1oo1D on the first fault and must be replaced within the MTTR assumed in the PFD calculations (only for energize to trip outputs). There is no time limit for normally energized applications.

Figure 2-7: TMR (2oo3D) Inputs & Processors, Fault Tolerant Output Configuration

2-10


Mixed Architecture There can be a mixture of architectures and SILs within one system. Figure 2-7 shows non-redundant and dual I/O configurations with dual processors. Triplicated inputs and/or processors may also be included.

Figure 2-8: Mixed Architecture

System Overview

2-11

Distributed Architecture It is possible to locate I/O modules in separate systems and link the data using a network connection certified for safety applications. The systems share variables using bindings, as covered in Chapter 10.

Figure 2-9: Distributed Architecture

2-12


Test Your Knowledge 1. How many of each I/O module are required to meet SIL 3 in a normally energized application? 2. How many processor modules are required to meet SIL 3? 3. What is the minimum number of modules required for fault tolerance? 4. What is the total number of I/O modules that a processor can support? 5. Are triplicated output modules supported? 6. How many response buses does a processor have?

System Overview

2-13

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Chapter 3

System Components

Purpose To provide an overview of the AADvance system and its components.

Objectives

System Components

•

To understand the types and names of modules and components used in the AAdvance system.

•

To understand module and component features.

3-1

System Components Hardware The current release of AADvance consists of a 9110 processor module, 9401 & 9402 24V isolated digital input modules (8 & 16 channel), 9431 & 9432 4 – 20mA isolated analog input modules (8 & 16 channel), 9451 24V digital output module and 9481 & 9482 isolated analog output modules (3 & 8 channel). Other components required to complete the systems are a 9100 processor base unit, 9300 I/O base units for connecting the I/O modules to the processor, 9310 bus extension cable and termination assemblies for connecting the I/O modules to field devices. The hardware is modular. A processor base unit supports up to three processor modules. I/O base units support up to three I/O modules. I/O base units mate directly with the processor base unit and other I/O base units. I/O base units provide the intermodule communications buses and route power from the processor base unit to the I/O modules. The system becomes one interconnected mechanical and electrical assembly once assembled.

Figure 3-1: AADvance System 3-2


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4

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5

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Table 3-1: AADvance Components

Hardware may be mounted on a DIN rail or flat panel. The system does not require forced air cooling fans.

Software AADvance can be a distributed system where each node (referred to as a ‘configuration’) has at least a single processor module and its associated I/O. Each node is a stand alone system configured using IEC 61131-3 languages. Data may easily be transferred between nodes using ‘bindings’. Programs may be simulated offline for testing. AADvance runs a certified for safety operating system.

System Components

3-3

Processor Module The 9110 processor module communicates with the network, handles I/O scanning and solves application logic. It incorporates the following features: •

Rated for applications up to SIL 2 (non-redundant) and SIL 3 (dual & triple)

•

IEC 61508 certified

•

Handles full range of IEC 61131-3 languages

•

Application processor, communications co-processor and math co-processor

•

Two Ethernet and two serial ports (RS485) per processor

•

MODBUS, CIP and AADvance safety network protocols

•

Built in diagnostic testing and independent watchdog

•

Removal and replacement without system interruption in dual or triple configurations

•

System self-discovery at startup

Figure 3-2: AADvance Processor Module

3-4


Battery A replaceable battery is used to retain the following during a power loss:

Figure 3-3: Processor Battery The battery will last for approximately ten years under normal conditions (powered) and six months unpowered.

1)

system diagnostic logs

2)

keep the real time clock running

3)

variables flagged as ‘retained’

Resources and programs are stored in flash memory that does not need a battery.

The battery is a coin type BR2032 and is secured in a holder under the front cover of the module. The holder is provided with a ribbon to facilitate removal of the battery, as shown in Figure 3-3. You gain access to the battery by unscrewing the protective cover on the lower portion of the front panel.

Fault Reset Button There is a fault reset button on the front of each processor module. It is used to clear any fault indications and allow replaced I/O modules to come online. However, if a fault is still present, the diagnostic system will report a fault again so quickly there will be no visible change in the status indications.

Pressing the fault reset button does not impact scan time or the handling of I/O.

Module Locking Mechanism Modules will only run when the screw is in the locked position.

System Components

Each module (processor and I/O) has a locking mechanism that secures the module onto its base unit. The locking mechanism is a screw visible on the front panel of the module. It is engaged by a clockwise quarter turn of a flat blade screwdriver. The module incorporates an interlock which detects when a module is locked or unlocked.

3-5

LEDs There are 10 LEDs on the front of the module. The meaning of each LED is described in Table 3-2. ��

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Table 3-2: Processor LED Status

System Components

3-7

Processor Base Unit

Figure 3-4: AADvance Processor Base Unit

The 9100 processor base unit accepts up to three processor modules and incorporates the following features:

3-8


Module power is connected to the processor base unit and connects through the I/O base units to power all I/O modules.

•

Provides redundant connections for the system power

•

Provides the connection for ground

•

Provides the connections for the external redundant control network via two Ethernet connectors per processor

•

Provides the connections for two serial ports per processor

•

Provides the connection for a security dongle

Figure 3-5: AADvance Processor Base Unit Detail

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Table 3-3: Processor Base Unit Connection Information

System Components

3-9

Digital Input Modules The 9401 (8 channel) and 9402 (16 channel) are 24Vdc digital input modules. They accept galvanically isolated inputs and perform signal conditioning and conversion. The modules incorporate extensive diagnostics. Individual modules are non-redundant, fail-safe, and certified for use in SIL 3 applications. Redundancy and fault tolerance is achieved by grouping two or three modules together with common field connections. Modules can be removed and replaced online without system interruption when used in redundant (dual or triple) configurations. Sequence of events (SOE) resolution is 10 msec. The modules measure analog voltage in order to perform line monitoring and field fault detection (e.g., open / short circuits). Switching levels for each input channel are configurable in the workbench. The default parameters are:

Figure 3-6: AADvance Digital Input Module

3-10

•

Off: 0 to 5V dc

•

On: 15 to 30V dc

There are 11 LEDs on the front of the module. The meaning of each LED is described in Table 3-4.


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Table 3-4: Digital Input Module LED Status Indications

System Components

3-11

Analog Input Modules The 9431 (8 channel) and 9432 (16 channel) are 24Vdc analog input modules. They accept galvanically isolated 4 – 20mA inputs and perform signal conditioning and conversion. The modules incorporate extensive diagnostics. Individual modules are non-redundant, fail-safe, and certified for use in SIL 3 applications. Redundancy and fault tolerance is achieved by grouping two or three modules together with common field connections. Modules can be removed and replaced online without system interruption when used in redundant (dual or triple) configurations. Monitoring levels for each analog channel are configurable in the workbench. The default parameters are: •

Fault:

0 to 3.8mA

•

Normal: 3.8 to 22.0mA

•

Fault:

>22.0mA

The modules support HART (Highway Addressable Remote Transducer) communications.

Figure 3-7: AADvance Analog Input Module

3-12



��

��

��

��

��

��

��

��

��

��

��

��

��

�� (�)

��

��

��

��

��

��

��

��

��

��

��

��

A��

�� (�.�., �� ) ��

��

��

��

C��

A��

�� (�� , �� , �� )

��

C��

Table 3-5: Analog Input Module LED Status Indications

System Components

3-13

Digital Output Module The 9451 isolated digital output module connects to eight isolated circuits and incorporates the following features: •

Dual series output switches per channel (1oo2)

•

Built in overload protection per channel

•

1A continuous rating for each circuit

•

Voltage and current monitoring (feedback) per channel

•

Short circuit and open circuit line fault detection for on and off channels

•

Dual redundant field power without the need for external diodes

•

Output channel reverse current protection

The modules incorporate extensive diagnostics. Individual modules are fail-safe and certified for use in SIL 2 normally deenergized and SIL 3 normally energized applications. Triplicated output modules are not necessary and are not supported.

Figure 3-8: AADvance Digital Output Module

Redundancy and fault tolerance is achieved by grouping two modules together with common field connections. Two modules provide a quad output circuit arrangement and full fault tolerance. Modules can be removed and replaced online without system interruption when used in redundant (dual) configurations.

3-14



��

��

��

��

��

��

��

��

��

��

��

��

��

�� (�)

��

��

��

��

��

��

��

��

��

��

��

��

A��

�� (�.�., �� ) ��

��

C�� /��

��

C�� /��

A��

��

��

C��

Table 3-6: Digital Output Module LED Status Indications

System Components

3-15

I/O Module Base Unit

Figure 3-9: AADvance I/O Module Base Unit

The 9300 I/O module base unit connects the processor to I/O modules. You can install up to three modules on a base unit.

Termination assemblies can span across base units.

3-16

The base unit will also allow you to fit the same number of termination assemblies in different combinations. For, example, you can fit three simplex termination assemblies; or one dual and one simplex together, or one triple termination assembly. The combination will depend entirely on your required configuration.


The I/O base unit incorporates the following features:

System Components

•

Provides connection for one, two or three input/output modules depending on the redundancy requirements

•

Provides connections with termination assemblies that connect to the field input/outputs

•

Routes power to the I/O modules from the processor base unit

•

Routes common processor commands to the I/O modules

•

Routes responses between the I/O modules and processors

3-17

Field I/O Termination Assemblies Field wiring is connected to termination assemblies (TAs).

Digital Input Termination Assemblies A 9801 digital input termination assembly is a non-redundnat unit that provides connections for 16 non-isolated digital input channels and mates with a single 9401 or 9402 24Vdc digital input module.

Figure 3-10: AADvance DI Non-Redundant Termination Assembly

3-18


Figure 3-11 & 12: AADvance DI Non-Redundant Termination Assembly and Fuses

Fuse (shown in the figures above) will blow when an extreme over voltage is applied. Fuses can be replaced without removing a module using needle-nose pliers. The assembly incorporates the following features:

System Components

•

16 input channels for a simplex configuration

•

Industry standard field device connections at the terminal blocks

•

Fail safe design with individually fused channels and over voltage protection

3-19

The 9802 termination assembly is the dual version and mates with two 9401 or 9402 modules, as shown in Figure 3-13.

Figure 3-13: AADvance DI Dual Termination Assembly

3-20


The 9803 termination assembly is the triplicated version and mates with three 9401 or 9402 modules, as shown in Figure 3-14.

Figure 3-14: AADvance DI Triplicated Termination Assembly

System Components

3-21

Analog Input Termination Assemblies A 9831 termination assembly is a non-redundant assembly that provides connections for 16 non-isolated analog input channels and mates with a single 9431 or 9432 analog input module.

Figure 3-15: AADvance AI Non-Redundant Termination Assembly

Each channel has a 50mA fuse to prevent component damage in over-current situations. Fuses can be replaced without removing a module using needle-nose pliers

3-22


Figure 3-16: AADvance AI Simplex Termination Assembly

The assembly incorporates the following features:

System Components

•

16 input channels for a simplex configuration

•

Industry standard field device connections at the terminal blocks

•

Fail safe design with individually fused channels

3-23

The 9832 termination assembly is the dual version and mates with two 9431 or 9432 modules.

Figure 3-17: AADvance AI Dual Termination Assembly

3-24


The 9833 termination assembly is the triplicated version and mates with three 9431 or 9432 modules.

Figure 3-18: AADvance AI Triplicated Termination Assembly

System Components

3-25

Digital Output Termination Assemblies

Figure 3-19: AADvance DO Non-Redundant Termination Assembly

A 9851 termination assembly is a non-redundant assembly that provides termination for 8 digital outputs and mates with a single 9451 24Vdc digital output module. The termination assembly routes the module output channels via the mating connector to the field connection terminal blocks. The 24Vdc field voltages VFIELD 1 and VFIELD 2, used by the output module for the output field voltages, are connected at the terminal blocks and routed via two replaceable 10A fuses F1 and F2. These fuses, shown in Figures 3-19 through 21, give protection for the output module against field faults.

3-26


Figure 3-20 & 21: AADvance DO Termination Assembly and Field Power Fuses

System Components

3-27

Figure 3-22: AADvance DO Dual Termination Assembly

A 9852 termination assembly is a dual assembly that provides termination for 8 digital outputs and mates with two 9451 24Vdc digital output modules.

3-28


Analog Output Termination Assemblies

Figure 3-19: AADvance AO Non-Redundant Termination Assembly

A 9881 termination assembly is a non-redundant assembly that provides termination for 8 analog outputs and mates with a single 9481 or 9482 analog output module. The termination assembly routes the module output channels via the mating connector to the field connection terminal blocks. Although it has a fuse cover, there are no fuses. The visible components are capacitors for EMC suppression.

System Components

3-29

Figure 3-22: AADvance DO Dual Termination Assembly

A 9882 termination assembly is a dual assembly that provides termination for 8 analog outputs and mates with two 9481 or 9482 analog output modules.

3-30




Test Your Knowledge 1. A processor base unit can hold how many processor modules? 2. An I/O base unit can hold how many I/O modules? 3. How many Ethernet and serial connections are supported by a single processor module? 4. What does the battery retain during a power loss? 5. What does the battery not need to retain during a power loss, and why? 6. What two functions does the reset pushbutton have? 7. How is a field fault shown on the LEDs? 8. Can termination assemblies span across I/O base units?

System Components

3-31


Chapter 4

System Build

Purpose To summarize how to assemble an AADvance system.

Objectives

System Build

•

To understand the environmental limits of the system.

•

To understand module power requirements, heat dissipation and weight.

•

To be able to install base plates, termination assemblies, cables and modules.

•

To be able to wire field devices to the system.

4-1

System Build Note:

This chapter is a condensed version of the AADvance System Build Manual, which system integrators are highly encouraged to read.

AADvance is a modular system. Base units snap together using mating connectors and retaining clips. The base units provide the interconnections for module power, processor and I/O data. Once connected, the base units form a single mechanical assembly. The insertion and removal of modules will not disturb the electrical connections with field devices. AADvance modules are suitable for wall mounting or for installation within an enclosure. The system is designed to meet its electromagnetic compatibility criteria without further protection from an enclosure. AADvance can be panel or DIN rail mounted (using TS35 35mm x 7.5mm standard symmetric rails). Use the following steps to assemble a system. 1) Mount a processor base unit 2) Mount the I/O base units 3) Mount termination assemblies 4) Mount I/O expansion cables (optional) 5) Wire the field connections 6) Connect power and ground 7) Mount the processor and I/O modules 8) Ensure adequate power and heat dissipation

4-2


Environmental Limits The design of each installation must ensure that the operating environment is within the tolerances of the equipment. Consideration must be given to proper control of: •

Temperature

•

Humidity

•

Vibration and shock

•

EMI / RFI

Temperature Operating temperature: -20° to 70°C (-4° to 158°F) Note: Processors limited to 60°C (140°F) Storage & transport temperature: -40° to 70°C (-40° to 158°F)

Humidity The system is designed to operate in the range of 10 to 95% relative humidity, non-condensing. It is important to avoid changes of humidity and temperature that could produce condensation. Condensation on any type of electrical equipment can result in equipment failures or improper operation.

Vibration and shock The modules are designed to withstand a 15g peak shock and vibration to 0.5g sinusoidal sweep between 10Hz to 150Hz. Care must be taken to isolate the system from any sources of extreme mechanical shock or vibration.

EMI / RFI The modules have been designed to meet the requirements of EN500081/82 and EN55011/55022.

System Build

4-3

Component Size and Weights ��

�� (� � � � ��

��

233 � 126 � 18 �� (9�� 5 � � ��)

��

166 � 42 � 118 �� (6�� 1�⅝ � 4�⅝ ��)

Table 4-1: AADvance Component Sizes

The total depth of a base unit and module is 136 mm (5- ⅜in).

Figure 4-1: Component Dimensions (in mm)

4-4


Ensure that the mounting assembly can support the weight of the AADvance components using the Table 4-2. ��

�� (��

��

460 (16)

�/� ��

133 (5)

��

430 (15)

�� (8 ��)

280 (10)

�� (16 ��)

340 (12)

�� (8 ��)

280 (10)

�� (16 ��)

340 (12)

��

340 (12)

�� (8 ��)

290 (10.5)

��

133 (5)

��

260 (10)

��

360 (13)

��

40 (1)

�/� ��

50 (2)

�� (2 ��) ��

670 (24) ��

Table 4-2: AADvance Component Weights

System Build

4-5

Free Space The system requires a free space at least 140mm deep (from front to back) between the rear panel of an enclosure and the inside of an enclosure door. Allow sufficient free space around the base units. Every application needs space on at least three sides, as follows: •

Space above, to manipulate and install field wiring

•

Space below, to enable modules to fit and to be able to grasp a module during removal

•

Space to the right, to maneuver an I/O base unit during assembly or in the event of installing a new base unit.

If an expansion cable is to connect to the left-most base unit, the controller also needs space to the left, to fit the expansion cable adaptor. Figure 4-2 shows the minimum recommended clearances for DIN rail mounting.

Figure 4-2: Required Free Space (in mm)

4-6


Mount a Processor Base Unit A processor base unit will support up to three processor modules.

Figure 4-3: Installing a Processor Base Unit

1) Place the processor base unit onto the DIN rail. 2) Secure the base unit by pushing the bottom retaining lever as far to the left as it will go until it latches in the locked position. Note:

System Build

Base plates may also be mounted flush on a panel wall using screws without a DIN rail.

4-7

Mount the I/O Module Base Units You can install up to three I/O modules on an I/O base unit.

Figure 4-4: Installing an I/O Base Unit

1) Mount a 9300 I/O base unit onto the DIN rail and slide it towards the 9100 processor base unit. 2) Ensure the joining connectors are fully mated. 3) Secure the base unit by pushing the bottom retaining lever as far to the left as it will go until it latches in the locked position. 4) Insert the plastic retaining clips into the top and the bottom slots. Note:

4-8

Base plates mounted flush on a panel wall will need to be connected before mounting. AADvance System Training Manual, version 1.7

This page is intentionally blank.

System Build

4-9

Mount Termination Assemblies Termination assemblies connect to I/O base units. You can fit three simplex assemblies, or one dual and one simplex, or a single triplicated termination assembly. The combination used will depend on your systems specific configuration requirements. Termination assemblies can span across base units.

1) Insert the termination assembly (TA) retaining clip (at the rear of the TA) into the slot on the plastic base unit, as shown in Figure 4-5. Press down and slide the assembly upwards as far as it will go. 2) Ensure the retaining tab clips over the circuit board to secure the TA in position, as shown in Figure 4-6.

Figure 4-5: Installing a Termination Assembly

4-10


Figure 4-6: Installing a Termination Assembly

System Build

4-11

Mount I/O Expansion Cables The I/O bus of base plates on separate DIN rails or mounted in different areas in a panel may be connected together using an expansion cable, as shown in Figure 4-7.

Figure 4-7: I/O Expansion Cable

The expansion cable assembly connects an I/O base unit to another I/O base unit or to the processor base unit. The assembly consists of a cable, terminated by multi-way plugs, and a pair of adaptors. The adaptors, shown in Figure 4-8, are 'handed' left and right. One adaptor connects to the right-hand bus connector of an I/O base unit or to bus 2 (the left hand connector) of a processor base unit. The other adapter connects to the left-hand bus connector of an I/O base unit.

4-12


Figure 4-8: I/O Expansion Cable Adapters

Terminators are not required at the end of the bus (last base unit).

System Build

Standard expansion cable assemblies are two meters long. (Custom lengths can be supplied.) The maximum possible length of an entire bus (the combination of I/O base units and expansion cables) is 8 meters.

4-13

Module Power Power supplies should be installed in a position where the 24V dc supply wiring can be kept reasonably short. Figure 4-9 shows an arrangement with one power supply unit for a nonredundant, fail safe controller.

Figure 4-9: Power Supply Mounting

It is recommended that the negative side of the field supply be grounded. This will avoid possible fail danger conditions that can be caused by some earth fault monitors used with floating power supplies. The power supply protection of the system is within the modules, not the base units. To protect the base units, the power distribution arrangement must provide a circuit breaker on the input side of each power source. The system can withstand a reverse polarity connection without permanent damage.

4-14


Module Power Supply Requirements

Field devices require an additional source of power.

AADvance requires 24Vdc power with a tolerance between 18Vdc and 32Vdc. The system has been designed to operate with most commercially available industrial uninterruptable power supplies (UPS). To select a suitable power supply, calculate the overall system load that must be powered (using Table 4-3), include any additional devices and add a contingency allowance between 25% and 50%. ��

9110 ��

High Availability I/O (1715) use the same hardware but ratings are different – these are calculated as worst case using different methods.

��

8�

9401 ��

3.3 �

9402 ��

4.0 �

9431 ��

3.3 �

9432 ��

4.0 �

9451 ��

3.0 �

9482 ��

3.6 �

��

��

Table 4-3: AADvance Module Power Requirements

System Build

4-15

Module Power Connections

Power is distributed to the I/O modules through the base units.

AADvance modules are designed to operate from two independent 24Vdc sources with a common return. Power is connected to the two plugs PWR-1 and PWR-2 on the processor base plate, as shown in Figures 4-10 and 4-11. The center terminals are normally left unconnected.

Figure 4-10: Processor Base Unit Power Connection

The terminal blocks can be removed for easy access.

Figure 4-11: Module Power Connection

4-16


The processor base unit links the +24V dc connections to the center terminal of each connector, as shown in Figure 4-12. This link may be used to connect the +24V dc supply to other processor base units.

Figure 4-12: Processor Base Unit Power Connection Detail

��

�� 2

�� , ��

2.5 �� (12 ��)

�� , ��

2.5 �� (12 ��)

��

7 �� (9/32 ��)

2

Table 4-4: Module Power Wiring Sizes

System Build

4-17

Grounding AADvance systems may have up to three separate ground systems: •

An AC safety ground (sometimes called the “dirty ground”) to protect people in the event of a fault. The ground stud on the processor base unit, shown in Figure 4-13, should be connected to the AC safety ground, along with all exposed metalwork such as DIN rails.

•

An instrument ground (sometimes called the “clean ground” or “0 Vdc ground”) to provide a good stable 0V reference for the system. Every signal return should be referenced to the instrument ground, which will be isolated from the AC safety ground.

•

Some field wiring will need shielded (screened) cable. There may be a shield ground in addition to the AC safety and instrument grounds to provide a common point to terminate cable shields.

Figure 4-13: AADvance Processor Base Unit Safety Ground Connection Detail

Systems may also be supplied with an IS (intrinsic safety) ground as required. Copper bus bars are normally used for grounding.

4-18


Security Dongle The system uses a dongle to control security. The dongle must be connected in order to download programs, make online changes, or perform locking (forcing). The dongle is supplied with the processor base unit.

Figure 4-14: Security Dongle

Processor Fault Alarm Contacts The terminal block marked 'FLT' is no longer used and does not work from release 1.1.

System Build

4-19

Serial Connections Each processor has two serial RS485 connections. The system supports both 2 wire (half duplex) and 4 wire (full duplex) configurations, with multi-drop supported in both configurations. The terminal blocks can be removed for easy access.

The pin-outs for the six serial connections on the processor base unit are shown in Figure 4-17 and Table 4-6.

Figure 4-17: Serial Connections

��

'Receive' and 'transmit') are with respect to the processor base unit.

�� (� ��

�� (� ��

��

�� (��)

��/�� (��)

��

�� (��)

��/�� (��)

0�

��

��

��

�� (��)

��

��

�� (��)

��

Table 4-6: Serial Connections

4-20


Field Power Field devices require an external source of power. This may be the power source used for the controller or a separate power source, depending on the application. Each input circuit should be fused. Each output module group (e.g., a module pair) should also have the field power fused. For a typical system, it is recommended that you provide a single breaker on the output of the field power source, followed by one or more fused terminals.

System Build

4-21

Wire the Field Connections Field wiring is connected direct to the terminal blocks of a termination assembly (TA). ��

�� 2

�� , ��

1.5 �� (16 ��)

�� , ��

1.5 �� (16 ��)

��

6 �� (� ��)

2

Table 4-7: Field Connection Wiring Sizes

Non-redundant termination assemblies have commoned power.

4-22


Digital Inputs

Figure 4-18: Simplex Digital Input Field Connections

Figure 4-19: Dual and Triplicated Digital Input Field Connections

System Build

4-23

Figure 4-20: Standard Digital Input Field Loop Circuit

Figure 4-21: Line Monitored Digital Input Field Loop Circuit

Note:

4-24

Please refer to the System Build manual for more details on normally de-energized inputs, recommended resistor values and input voltage threshold settings, etc.


Analog Inputs

Figure 4-22: Simplex Analog Input Field Connections

Figure 4-23: Dual and Triplicated Analog Input Field Connections

System Build

4-25

Figure 4-24: Two Wire Analog Input Field Loop Circuit

Figure 4-25: Three Wire Analog Input Loop Circuit

4-26


Figure 4-26: Four Wire Analog Input Loop Circuit

System Build

4-27

Digital Outputs

Figure 4-27: Simplex & Dual Digital Output Field Terminations

4-28


Figure 4-28: Digital Output Field Loop Circuit

For inductive loads, connect a diode at the actuator to protect the controller against back EMF.

System Build

4-29

Cable Management The field, power and other system wiring will be connected to terminals along the top of the base units. It is recommended a length of trunking be located above each set of base units for cable management.

Figure 4-29: Cable Management

4-30



System Build

4-31

Module Polarization Module polarization prevents the wrong module from being inserted into the wrong base unit. Modules are supplied with plugs already fitted, as shown in Figure 4-30.

Figure 4-30: Module Polarization

Termination assemblies are supplied with the pins already inserted.

Figure 4-31: Module Polarizing Pin Base Unit Positions

The legend for the polarization pins is shown in the lower left of the processor base unit and on each I/O termination assembly, as shown in Figure 4-31. The positions are numbered 1 through 6. The three pins are lettered A, B and C with A being on the top. Each pin, shown in Figure 4-32, is fitted in the base unit so that the index recess is next to the relevant numbered position shown in Table 4-8, as shown in Figures 4-32 and 33. ��

��

��

��

9110 ��

1

1

1

9401 ��

2

1

1

9402 ��

2

1

1

9431 ��

2

1

3

9432 ��

2

1

3

9451 ��

3

1

1

9481 ��

3

1

2

9482 ��

3

1

2

Table 4-8: Module Polarizing Pin Allocation 4-32


Figure 4-32: Polarizing Pin

Figure 4-33 shows the pins inserted for a 9401 digital input module and TAs.

T9801/2/3 TA

T9401

TA

Figure 4-33: Inserted Polarizing Pins

System Build

4-33

Installing Modules and Blanks Installing Modules Modules are installed by carefully pressing them onto the base unit, as shown in Figure 4-34, using the following procedure. 1. Inspect the connectors on the back of the module for bent or damaged pins. 2. Make sure the slot on the head of the module clamp screw is vertical. 3. Place the new module on to the dowel pins on the base unit. 4. Push the module home until the connectors are fully mated. 5. Turn the locking screw located on the front of the module ¼ turn clockwise using a broad flat bladed screwdriver.

Figure 4-34: Installing a Module

4-34


Fitting a New Processor Battery When installing a new processor module, fit its internal back-up battery as follows: 1. Use a small phillips screwdriver to release the battery cover. 2. Remove the cover. 3. Insert the battery supplied with the module, making sure its positive (+) side is facing to the right of the module. 4. Refit the cover.

Installing Module Blanks Blank plates should be installed over unused slot locations, as shown in Figure 4-35. Long blank plates are designed for I/O slot positions with no termination assembly.

Figure 4-35: Processor Blank Plate

System Build

4-35

Heat Dissipation AADvance is designed to operate without forced air cooling. Ensure that adequate ventilation is provided. Ambient temperature within an enclosure should not exceed 60°C (140°F), unless the enclosure does not contain the processors, in which case the limit is 70°C (158°F). Base plates and modules must be mounted vertically to allow proper air circulation through the modules.

The system dissipates all the power it uses as heat. Module power is connected to the processor base plate. Field power is connected to I/O termination assemblies and some of that power will also be dissipated as heat. Use Table 4-9 to estimate the maximum heat generated by the modules. ��

��

��

8�

�� (8 ��)

3.3 �

�� (16 ��)

4.0 �

��

0.11 �

�� (8 ��)

3.3 �

�� (16 ��)

4.0 �

�� (25��)

0.06 �

�� (1�)

3.0 � 0.5 �

�� (8 ��)

3.6 �

��

��

Table 4-9: AADvance Module Heat Dissipation

4-36



System Build

4-37

Parts List Note: Parts may be added to this list in future releases. Please consult Rockwell Automation for an updated list of available parts. Software Development Environment

9082 9083 9084 9085 9030

IEC61131 Workbench suite with single user, single controller license IEC61131 Workbench suite with single user, unlimited controller license IEC61131 Workbench suite with five user, unlimited controller license Five additional user license (for use with item 9084) OPC portal server

Processor Equipment

9100 9110 9193

Processor base unit Processor module Blanking cover (short), for unused position on processor base unit

Expansion Cable Assemblies

Expansion cable assembly, comprising expansion cable and two adaptors (handed): 9310-02 2 meter expansion cable (approximately 6 feet) 9310-xx Custom length expansion cable I/O Equipment

9300 9401 9402 9431 9432 9451 9481 9482 9191

I/O base unit Digital input module, 24V dc, 8 channel Digital input module, 24V dc, 16 channel Analog input module, 8 channel Analog input module, 16 channel Digital output module, 24V dc, 8 channel Analog output module, 3 channel Analog output module, 8 channel Blanking cover (tall), for unused position on I/O base unit The 9193 blanking cover may be used for positions on an I/O base unit with a termination assembly fitted.

4-38


Termination Assemblies

9801 9802 9803 9831 9832 9833 9851 9852 9881 9882

Digital input TA, 16 channel, simplex, non-isolated Digital input TA, 16 channel, dual Digital input TA, 16 channel, TMR Analog input TA, 16 channel, simplex, non-isolated Analog input TA, 16 channel, dual Analog input TA, 16 channel, TMR Digital output TA, 24V dc, 8 channel, simplex, nonisolated Digital output TA, 24V dc, 8 channel, dual, nonisolated Analog output TA, 8 channel, simplex Analog output TA, 8 channel, dual

Consumable Spares

9901 9902 9903 9904 9905 9906

System Build

Input fuse, 50mA (pack of 20) Output fuse, 10A (pack of 20) Coding peg / Polarizing Pins (pack of 20) Backplane clip (pack of 20) Battery, lithium, 3V 255mAh, coin pattern BR2032 or equivalent, for 9110 processor module (pack of 10) Replacement security dongle

4-39



Test Your Knowledge 1. What temperature range are the processors designed to operate within? 2. What are the two ways to mount base plates? 3. Where is I/O module field power connected? 4. How much power would a system with the following modules require? Assume all input modules are 16 channel. •

dual processors

•

two sets of triplicated analog input modules

•

five simplex analog input modules

•

four simplex digital input modules

•

two sets of dual digital output modules

•

three simplex digital output modules

5. How much would the system described in question 4 weigh? 6. How many I/O module base units would be required for the system described in question 4?

4-40


Chapter 5

Workbench Overview and Programming

Purpose To review the steps required to develop programs.

Objectives •

To be able to create projects.

•

To be able to add variable names to the dictionary.

•

To be able to build an I/O configuration and assign variable names.

•

To be able to configure the hardware: serial port settings, input module thresholds, watchdog timers, etc.

•

To be able to create, edit and compile programs.


5-1

Workbench The AADvance workbench is used to build control and safety programs. These programs can be distributed across several hardware platforms referred to as configurations. Configurations communicate with each other through networks. Configurations run resources which are groups of programs (up to 250) that are compiled and downloaded. This manual describes software functionality included in release 1.31 (Build 1.20.508).

The workbench is IEC 61131-3 compliant, offering all five languages (ladder, function block, structured text, instruction list and sequential function chart). Programs can be simulated and tested on the PC before downloading to actual hardware.

Starting the Workbench Please refer to the Configuration Guide for more information on the licensing options and the operation of the License Manager.

5-2

Start the workbench: Start All Programs AADvance AADvance Workbench. The workbench will run in demo mode for 30 days without a license. Full functionality requires a license (e.g., USB dongle). →

→

→


Start a New Project To start a new project, select File | New Project/Library, or use the New button. The following dialog box will appear.

Figure 5-1: New Project Dialog Box

The name is used as the project folder name. Project file names are always PRJLIBRARY.MDB.

The topics of the repository, version control and checkin/out are covered in Chapter 11.

The Workbench allows multiple people to work on a project at the same time. This requires locating certain files in a location that others can access (if you wish to utilize this capability). The Destination Folder is the location on your PC where various local files are stored. The Repository Path is the location folder where other centralized version information is stored. The default location for both folders is on the C drive of the PC that has the software loaded, but the Repository folder can be located on a central server.


5-3

Workbench Overview The link architecture view graphically displays the resources of a project and any links between them. This is the default view of the workbench providing a main entry point to all editors.

If you do not see the Project Tree on the left, click Window | Show Project Tree.

Figure 5-2: Link Architecture View

A configuration represents a hardware target (controller). AADvance configurations run a single resource. A resource consists of the dictionary of tag names, I/O configuration and POUs (Program Organization Units).

5-4


Some of the more common buttons in the workbench are summarized in Figure 5-3.

Figure 5-3: Common Workbench Buttons


5-5

Dictionary The typical first step is to define variable (tag) names in the dictionary. These names can then be connected to processor variables, I/O modules, I/O channels and then used in programs. However, it is not mandatory to define variables first. You can create programs first and enter variable names in the program editor. When doing so, the workbench will request basic information on the variable (i.e., type, scope, direction, attribute). While variables created this way will later appear in the dictionary, you may need to define them in more detail in the dictionary before compiling and running your program(s) (e.g., MODBUS address, SOE, initial value, retain, etc). Open the dictionary using the Project | Variables menu selection or the dictionary button. Expand the tree on the left to see the window displayed in Figure 5-4.

Figure 5-4: Workbench Dictionary View

5-6


The various components are sorted in a tree-like hierarchy. The tree name is displayed on the window title bar. The four dictionary tree views, as shown in Figure 5-5, are: variables, parameters, types and defined words.

Figure 5-5: Dictionary Views

In the All Variables workspace on the right, you can toggle between Grid Mode and Row Mode by right clicking in the workspace and making the appropriate selection in the pop-up menu, as shown in Figure 5-6.

Figure 5-6: Switching Between Grid and Row Mode


5-7

Data Types Variables are unique identifiers of data which can be used in the programs of a project. There are many different variables types, such as:

5-8

•

BOOL: Boolean (true / false)

•

SINT: Signed short integer (8 bit) from -128 to +127.

•

USINT: Unsigned short integer (8 bit) from 0 to 255.

•

BYTE: Byte (8 bit) from 0 to 255.

•

INT: Signed single integer (16 bit) from -32,768 to 32,767.

•

UINT: Unsigned single integer (16 bit) from 0 to 65,535.

•

WORD: Word (16 bit) from 0 to 65,535.

•

DINT: Signed double integer (32 bit) from -2,147,483,648 to +2,147,483,647.

•

UDINT: Unsigned double integer (32 bit) from 0 to 4,294,967,295.

•

DWORD: Double Word (32 bit) from 0 to 4,294,967,295.

•

LINT: Signed long integer (64 bit) from -9,223,372,036,854,775,808 to 9,223,372,036,854,775,807.

•

ULINT: Unsigned Long Integer (64 bit) from 0 to 18,446,744,073,709,551,615.

•

LWORD: Long Word (64 bit) from 0 to 18,446,744,073,709,551,615.

•

REAL: Real (floating, single precision) (32 bit), 1 sign bit + 23 mantissa bits + 8 exponent bits. The exponent value cannot be less than -37 or greater than +37. A real variable has six significant digits.

•

LREAL: Long Real (floating, double precision) (64 bit) 1 sign bit + 52 mantissa bits + 11 exponent bits. The value cannot be less than 1.7E -308 or greater than 1.7E +308. A long real variable has 15 significant digits.


•

TIME: Timer (32 bit) cannot be negative or exceed 1193h2m47s294ms.

•

DATE: Date (32 bit) from 1970-01-01 to 2038-01-18.

•

STRING: Character string with a defined size, up to 255 characters.

You can define arrays (a set of elements of the same type) and structures (a collection of elements of different types) using the above data types. AADvance I/O are available as pre-defined structures. To enter a variable, double-click the ellipsis (…) line in the right workspace area (shown in Figure 5-4). The dialog box shown in Figure 5-7 will then be displayed (when in Row Mode).

Figure 5-7: Dictionary Entry Dialog Box


5-9

Variable Data The variable data to be defined are shown in Table 5-1. Name Alias

Variable name A name, used in LD editor, limited to 16 characters

Group

Group name or "None"

Type

Data type (listed above)

()

If Type is STRING this represents the string length (max. 255 characters)

Dimension

The size (number of elements) of an array. For example: [1..3,1..10] - represents a two-dimensional array containing a total of 30 elements.

Attribute

Read-only, write-only, or free (read/write)

Scope

Global or local to a program or function

Direction

of I/O Wiring; Input, Output or Internal

Init. Value

Initial value when the resource is executed. Numeric or textual.

Wiring

Read-only cell, generated by the I/O wiring tool. Uses syntax of directly represented variable.

Comment

User comments, free format

Retain

Whether the value is retained if the resource stops and restarts. Yes or No

Address

Not applicable with AADvance

Table 5-1: Variable Data

Variable names: •

May be up to 128 characters

•

Must begin with a letter

•

The following characters can be letters, digits or the underscore character

Variables can have one of the following attributes:

5-10

•

Free: Variable which can be used for reading or writing

•

Read: Read-only variable

•

Write: Write-only variable


Variables have a direction: •

Internal: Internal variable updated by the program(s)

•

Input: Variable connected to an input device (refreshed by the system)

•

Output: Variable connected to an output device

I/O variables can be selected as structures. Make the selections shown in Figure 5-8 for a digital input.

Figure 5-8: Dictionary Entry Dialog Box

The full structure for a digital input is shown in Figure 5-9. You only need to assign one name for the structure (e.g., DI_1 in this example); the system automatically assigns full names and data types to all the variables within the structure.

Figure 5-9: Dictionary Showing Structures


5-11

True and False Labels True/False names are not used when monitoring a running program.

You can add optional names in the TRUE and FALSE message fields of Boolean variables, as shown in Figure 5-10. These names / messages will be used for Sequence of Events / OPC.

Figure 5-10: Boolean True & False Messages

5-12


Tagging Items for SOE Boolean variables can be tagged for SOE (sequence of events) recording, as shown in Figure 5-11.

Figure 5-11: Enabling SOE

All the SOE data is passed as Alarm and Events information via OPC (i.e., there is no stand-alone SOE collector).

The following items may be set on the SOE tab: •

•

•

•

•

Falling-edge: indication of the variable changing from TRUE to FALSE. Rising-edge: indication of the variable changing from FALSE to TRUE. Severity level: the level of importance of the rising-edge and falling-edge. Possible values range from 0 to 65535; the default value is 0. Filter Time: the minimum time lapse between two events for a variable, in milliseconds. Possible values range from 0 to 65535. Reference variable: on an event, the value of this variable is also sent with the event.


5-13

Modbus Addressing Variables can be assigned Modbus addresses using the Modbus tab, as shown in Figure 5-12.

Figure 5-12: Modbus Addressing

Refer to the Configuration Guide for more details on Modbus.

•

•

Read only/Write protected: Defines the variable direction and whether it can be written to. Available for coils and holding registers. Base Address: The Modbus base address of the variable. ―

Each Modbus Type has its own separate map

―

―

Hint: enter the Base Address first to make the Modbus Type field available

•

―

•

5-14

1 to 65,534 (two-registers wide) for DINT, UNIT and REAL variables (as shown in Figure 5-14) 1 to 65,532 (four-registers wide) for LINT, ULINT and LREAL variables.

Modbus Type: The type of Modbus variables. ―

•

1 to 65,535 (one register wide) for BOOL, INT and UINT variables (as shown in Figure 5-13)

For Boolean variables, the available types are discrete input or coil (as shown in Figure 5-13) For INT, UINT, DINT, UDINT and REAL variables, the available types are input registers and holding registers (as shown in Figure 5-14)

Modbus Functions: The available Modbus functions for use with the selected Modbus type. Data Type: The variable data type.


Figure 5-13: Modbus Addressing for a Boolean Type

Figure 5-14: Modbus Addressing for a UINT Type


5-15

The Base Address is the actual address of the variable sent over the protocol. Original Modbus implementations allocated 10,000 addresses to each Modbus type, e.g. Holding registers were 40,001-50,000. However, the address field that was actually sent by the protocol was based at zero, i.e. 1 to 10000. Later implementations, including AADvance, opened up the full 16-bit range to 65,535. If AADvance is communicating to a system using the original implementation, ensure that the addresses are in the range 1 to 10, 000.

5-16


Common Industrial Protocol (CIP)

Produce/consume variables are noninterfering. A failure of the Ethernet/IP stack will not interfere with the safe operation of the controller.

Common Industrial Protocol (CIP) over Ethernet/IP enables AADvance controllers to exchange data with ControlLogix controllers. The exchange of data uses the produce/consume method similar to the bindings mechanism used by the AADvance controller. You configure the exchange of data by defining a production variable (or structure) for one controller and a corresponding consumption variable (or structure) for the other, as shown in Figure 5-15.

Figure 5-15: CIP Configuration

At runtime, the controller with the consumption variable pulls data from the controller with the production variable. Refer to the Configuration Guide and the RSLogix online Help system for further information on CIP.

A production or consumption variable can contain up to 500 bytes (400 before release 1.31). You will need to create a CIP network in the Hardware Architecture view of the workbench. Notes:

You can only use the CIP network to exchange data using producers and consumers. The CIP network cannot be used for downloading to or monitoring a target. Do not use the CIP network to exchange data between AADvance controllers; use bindings over an SNCP network instead.


5-17

Complete the Dictionary Use the copy and paste features to create additional digital inputs. Change their name and comment fields. Make similar selections for analog inputs (type: T9K_AI_FULL, attribute: read, direction: input). Make similar selections for digital outputs (type: T9K_DO_FULL, attribute: free, direction: output). Add any other variable names you wish to use in your project (e.g., processor variables, such as the number of locked inputs or outputs, system health, battery health, etc.; I/O module variables such as a TA group status structure, etc). Save and close the dictionary.

5-18




5-19

Import / Export Variables You can import or export variable data using either a commaseparated (CSV) file in a text editor or a Microsoft Excel spreadsheet (if Excel 2007 or later is installed on your PC).

Exporting a Variable File Export the current dictionary in order to see the file format and what can be exported. The export variables selection is found in the File menu, as shown in Figure 5-16.

Figure 5-16: Exporting Variables

This will open the Export dialog box, as shown in Figure 5-17.

5-20


Figure 5-17: Export Dialog Boxes

From this dialog box, you may select the file location and name (using the Browse button), file type and what fields should be included. Click the Export button to create the actual file. An example of an exported variables file opened in Excel is shown in Figure 5-18.

Figure 5-18: Exported Variable File


5-21

Creating and Importing a Variable File When using a spreadsheet to enter information, enter each piece of information in a separate cell. Leave cells empty if an item is to be omitted. Refer to the program’s help system for a complete listing of the variable fields, default values, examples, etc.

Enter your data. Save the file in a CSV or XLS format. The import selection is found in the File menu, as shown in Figure 5-19.

Figure 5-19: Importing a Variable List

Select Variables, as shown in Figure 5-19. This will open the import dialog box shown in Figure 5-20. From here you can browse to open the particular file of interest.

Figure 5-20: Importing Variables

5-22


Equipment Editor I/O wiring enables you to define links between the variables defined in the dictionary and the I/O channels of your system(s). If the project tree view is not shown on the left of your screen (as in Figure 5-2) select Window | Show Project Tree View. Then select either the Equipment tab on the bottom of the project tree view, the I/O wiring button, or the Window | (your project name) Config1 view, to display the equipment view, as shown in the Figure 5-21.

Figure 5-21: Equipment Editor View

I/O Bus 1 extends to the right of the processor. Bus 2 extends to the left. Refer to the Configuration Guide for more details on the various processor settings.

The different tabbed sheets in the right workspace area (shown in Figure 5-21) are used to set the processor watchdog timer, serial ports, SNTP (Simple Network Time Protocol) clients and servers and more, as covered briefly in the following sections.


5-23

9110 Tab

Figure 5-22: 9110 Tab

The following settings can be made in the 9110 tab: •

•

5-24

Process Safety Time: The maximum time that the processor will allow the outputs to remain active in the event of serious internal faults. The system will go to its safe state if the process safety time is exceeded. Battery Alarm: This setting is normally enabled. It is provided as an option for systems which have no batteries, e.g. sub-sea modules.


Serial Ports Tab

Figure 5-23: Serial Ports Tab

The AADvance controller provides up to six serial communication ports, two for each 9110 processor module present. Each pair of serial ports is identified as SX-1 and SX-2 where 'X' is the processor module. The serial port settings define the protocol ('type') and the data characteristics of each of the serial ports.


5-25

SNTP Clients and Servers Tabs

Figure 5-24: SNTP Clients Tab

The AADvance controller supports a fault tolerant Simple Network Time Protocol (SNTP) service that can circulate an accurate time around the network. As an SNTP client the controller will accept the current time from external Network Time Protocol (NTP) and SNTP network time servers. The SNTP client’s settings tell the controller the IP address of the external server; the version of SNTP offered by the server; and the operating mode for the time synchronization signal that the processors will use for their real time clock. The AADvance controller can fulfill the role of one or more SNTP servers (one for each processor) to provide a network time signal throughout the network. Use the SNTP Servers tab to enter the necessary information.

5-26


Modbus Slaves Tab

Figure 5-25: Modbus Slaves Tab

Ethernet slaves can serve up to ten masters each.

AADvance can operate as a Modbus slave and support up to ten Modbus slaves per processor module. This gives a capacity of thirty Modbus slaves for a controller with three processor modules. As a Modbus slave, the controller supports Modbus RTU using a serial or Ethernet connection, and Modbus TCP using an Ethernet connection. You can configure a combination of connections for the Modbus slaves, subject to a limitation of no more than two Modbus RTU slaves using serial communications for each processor.


5-27

TCI Tab

Figure 5-26: TCI Tab

TCI stands for Transparent Communications Interface. This facility bridges communications between Ethernet and the serial ports. It only works when the application is stopped. An Ethernet connection to one of the six ports in the TCP column will open communications to that serial port. It is used in subsea modules as a serial gateway but is not available for live systems.

5-28


DiffServ

Figure 5-27: DiffServ Tab

DiffServ provides Ethernet protocol prioritization, again mainly for subsea systems. It allows individual ports and remote addresses to be given different ‘terms of service’ or priority, so that safety related communications can have precedence.


5-29

Variables Tab

Figure 5-28: Variables Tab

Status variables retrieve status information; control variables set status information.

5-30

There are many internal status and control variables available for use in your applications. There are seven variable types: •

Status Integers and Status Booleans provide information about the controller

•

Control Integers and Control Booleans enable the application to send specific information to the controller

•

RTC Status variables provide information about the controller real-time clock to the application

•

RTC Program variables specify parts of the date to be written to the real-time clock

•

RTC Control variables set and control updates to the real-time clock


Inserting an I/O Module Enter an I/O module by right clicking on an “Empty” tag in the tree view. Select the module type and configuration, as shown in Figure 5-29.

Figure 5-29: Inserting and I/O Module

Figure 5-30 shows a dual digital input module arrangement.

Figure 5-30: Equipment View for a Digital Input Module Workbench Overview and Programming

5-31

Connect an I/O Tag You can connect a variable to the diagnostic data to access all the point in one go. The variable must be of type “T9K_TA_GROUP_STATUS”. Click the ellipsis (…) button to the right of ‘Variable’ in the right pane to open a dialog box in order to select a dictionary variable name for that point. At the bottom of the right pane are connections for the channels. These can each be wired in three different ways: 1. Single element, e.g. a Bool for a digital input 2. Compact structure including Line Fault and Discrepancy 3. Full structure including all diagnostic points. Select a channel and click the ellipsis (…) button beside the table. Choose the type of variable. A full structure has been chosen in the example in Figure 5-31. Select the variable to connect to the channel.

Figure 5-31: Selecting a Dictionary Variable Name

5-32


Digital Input Voltage Thresholds Figure 5-32 shows the voltage thresholds for digital inputs. The module determines the channel state and the line fault status (e.g., open circuit, on, off, short circuit, etc.). by comparing the channel input voltage with defined threshold values . The default values are suitable for non-line monitored inputs. Customized values can be entered when inputs must be line monitored.

Figure 5-32: Digital Input Voltage Thresholds

The voltage pairs provide hysteresis for increasing and decreasing values to prevent chatter. For example, using the values shown in Figure 5-31, the voltage must increase above 5.509 volts to enter state 3, and must decrease below 4.990 to enter state 2.


5-33

Analog Input Current Thresholds Figure 5-33 shows a similar window for analog input current thresholds.

Figure 5-33: Analog Input Current Thresholds

5-34


HART Inputs Figure 5-34 shows how HART structure variable names may be assigned to analog inputs. This information can be utilized in your application programs and passed to other systems via OPC. HART pass-through is available in release 1.31. This allows a HART Asset Manager to access and maintain the field devices through AADvance.

Figure 5-34: HART Inputs


5-35

Scaling of Analog Inputs As shown in Figure 5-35, analog inputs are available as both integers (tagname.CNT) and reals (tagname.PV). Integers return values of 0 to 5120 for 0-20mA (1024 to 5120 for 4-20mA). Reals default as 0 to 100.00 for 4-20mA.

Figure 5-35: Analog Inputs

If you wish to change the scaling for a channel, go to the equipment view, expand the analog input module and select the channel you wish to modify. You can configure any linear conversion of either integer or real units by simply changing the numbers in the low and high text boxes (as shown in Figure 535). Non-linear conversion of the tagtname.cnt or tagname.pv variables can be accomplished using a user defined function or function block. Repeat the steps above to insert all the modules in your system and connect the variable names to each I/O channel. Save the hardware configuration. 5-36


Creating Programs Go to the link architecture view using the link architecture button, as shown Figure 5-36.

Figure 5-36: Link Architecture View


5-37

1) Select a Program Language Enter a new program by right clicking on “Programs” in the resource window in the right pane. Select “Add Program” and select a language – in this case FBD (Function Block Diagram) – as shown in Figure 5-37.

��

Both function block diagrams and ladder diagrams can be created using either the workbench ladder diagram (LD) or function block diagram (FBD) editors. The function block editor is more commonly used as it provides more drawing control and functionality. IEC61499 event driven function blocks are not available at the current releases. One language is chosen when creating a program. Languages cannot be changed or converted later. The available programming languages are described in Table 53.

5-38


Programming Language Ladder Diagram (LD)

Summary •

•

•

Function Block Diagram (FDB)

•

•

•

Structured Text (ST)

•

•

Sequential Function Charts (SFC) Instruction List (IL)

•

•

•

High level graphical language For Boolean operations Easy rules High level graphical language For mixed type of operations Large library of blocks High level text based language Can be used for functions or function blocks For sequential operations Can handle parallel processes Low level text based language

Safety Issues •

•

•

•

•

Commonly used for safety applications

Commonly used for safety applications

Used for safety applications with restrictions*

Can be used for safety applications Can be (but rarely is) used for safety applications, with restrictions*

Table 5-3: Programming Languages * From Safety Manual: Ensure logic has no infinite loops or logic which never executes. Test all branches of code and possible conditions.


5-39

2) Enter a Program Name Enter a name for the new program, as shown in Figure 5-38.

Figure 5-38: Naming a POU

A POU (Program Organization Unit) is a set of instructions written in one of the IEC 61131-3 languages. A POU can be a program, a function or function block.

5-40


3) Edit Your Program Double-click the new program name to open the editor window, as shown in Figure 5-39.

Figure 5-39: Program Window

Enter a variable on the page by first clicking on the variable button and then clicking within the window.


5-41

Assign Variable Names When a variable is placed on the page, a dialog box will open allowing you to select a variable name, in this case a Boolean input variable (the input element/variable within the structure, not the structure itself) as shown in Figure 5-40.

��

Note:

If you enter a variable name that does not exist in the dictionary, another dialog box will appear prompting you for the necessary information. That variable will then be added to the dictionary.

Enter another variable to the right of the first and select an output element/variable within one of your available output structures.

5-42


Connect Variables Connect the two variables using the connection button (F4). Mouse drag from one element to the other to connect them, as shown in Figure 5-41.

Figure 5-41: Simple Logic


5-43

Create the rest of your sample program. A simple example is shown in Figure 5-42.

Figure 5-42: Sample Program

5-44


Add Comments Comment fields can be entered using the Comment button. Comments make a program much easier to understand for others who may have to modify it in the future. Variable comments (from the dictionary) can be displayed using the Options | Show I/O Variable Comments menu selection, as shown in Figure 5-43.

Figure 5-43: Rung and Variable Comments

Save your program. Close the program window.


5-45

4) Build Your Program Build (compile) the program using the build button in the main workbench window, or the Project | Build Project menu selection. You can build individual programs, resources or entire projects using the different build buttons. Compiler messages will be shown in the output window toward the bottom of the workbench, as shown in Figure 5-44.

Figure 5-44: Compiler Output Messages

Once a project has been built, subsequent builds only recompile the parts of the project needing recompilation. You can choose to rebuild a project using the rebuild button or the Project | Rebuild Project menu selection. This recompiles the whole project and ensures that the complete compiled version is up-todate with the current workbench project. Notice the CVT Analysis at the end of the report. This is the Compiler Verification Tool, and it checks that the compiled code matches the logic that you built. Any problems are reported as mismatches, which must be investigated for safety system projects.

5-46


Saving a Project The project name is used to create a unique directory structure. Saving the project saves it in the MS-Access database of the project root directory. Other files related to the project are also updated in this directory structure.

To save a project From the File menu, choose Save Project, or use the save button.


5-47



Test Your Knowledge 1. How many resources can an AADvance controller run? 2. Inputs are defined in the dictionary with which choices of attribute (read, write, free)? 3. Outputs are defined in the dictionary with which choices of attribute (read, write, free)? 4. Which field in the dictionary is used to assign MODBUS addresses? 5. Which compiles everything – Build Project or Rebuild Project? 6. What formats can the Dictionary be exported to? 7. How many programming languages are available?

5-48


Chapter 6

Simulating and Testing Programs

Purpose To review the steps required to simulate and test programs.

Objectives •

To be able to simulate resources on your PC.

•

To be able to change variables and test your programs.


6-1

Simulation You can simulate (test) programs using the Debug | Simulation menu choice, or the simulate button. (Your project must be compiled before it can be simulated.) When simulating, the button bars will change slightly and the resource title bar will indicate that it is running code, as shown in Figure 6-1.

Figure 6-1: Debug/Simulate Window

6-2


Changing Input Variables in a Program You can change variables directly in a program. Double-click on a variable to bring up the write variable dialog box, as shown in Figure 6-2.

Figure 6-2: Write Variable Dialog Box in Program Window

Input variables in the simulator do not need to be locked (forced) in order to change their value. Booleans inputs can be toggled on and off using the TRUE and FALSE buttons. Analog input values can be changed by entering a value in the text field and clicking the Write button, as shown in Figure 6-3.

Figure 6-3: Entering an Analog Value

Verify that your program works as intended. Simulating and Testing Programs

6-3

Changing Input Variables in the Equipment View You can also change input variables in the Equipment view (without having to lock them), as shown in Figure 6-4.

Figure 6-4: Write Variable Dialog Box in Equipment View

After changing the state of an input, check that the corresponding output responds appropriately.

6-4


Changing Variables in the Dictionary Changing Input Variables You can also change input variables directly in the dictionary (without having to lock them), as shown in Figure 6-5.

Figure 6-5: Write Variable Dialog Box in the Dictionary


6-5

Changing Output Variables Trying to change the value of an output in the same manner will have no effect as the program is controlling the outputs. However, outputs may be locked and then their value may be changed (by opening the dialog box a second time), as shown in Figure 6-6.

Figure 6-4: Locking an Output Variable in the Dictionary

This is essentially the same way outputs are locked and controlled in a real system. The Locked column shows that the variable is locked. For an output, the variable is disconnected from the physical output, and the physical output is locked, not the variable. This has no use in the simulator because there is no physical output.

6-6


Stopping Simulation Stop the simulation using the Debug | Stop Simulation menu selection or using the stop debug button.


6-7



Test Your Knowledge 1. What is the point of simulating programs? 2. Must input variables be locked (forced) in order to change their value when simulating? 3. Must output variables be locked (forced) in order to change their value when simulating? 4. Does changing the value of a locked output change its logical value, or its physical value?

6-8


Chapter 7

Downloading and Monitoring Programs

Purpose To review the steps required to connect, download and control resources in the AADvance controller.

Objectives •

To be able to connect to AADvance.

•

To be able to download to AADvance.

•

To be able to monitor a program online.

•

To be able to lock / force variables.

•

To be able to disconnect from AADvance.


7-1

Loading a Resource in a Controller All programs in a project are compiled, downloaded and controlled (i.e., started and stopped) together. The compiled file is referred to as a resource.

Step 1: Set the IP Address of the Controller IP addresses and resource numbers in AADvance are read and set/programmed into chips in the processor base unit using the AADvance Discover utility. Refer to Appendix 1 for this procedure. You must then assign these addresses in the workbench. The IP addresses are set in the hardware architecture view, which is accessed using the button shown on the left, or using the Window | (Your Project Name) Hardware Architecture view menu choice. Select (left click) the vertical connecting link between the SNCP network line and the configuration, as shown in Figure 71. Right click and select Properties. Alternatively, you may also double-click the vertical connection.

Figure 7-1: Select and Right Click (or Double-Click) the Vertical Connector

7-2


Enter the IP address of the port(s) that have been configured for the system, as shown in Figure 7-2.

Figure 7-2: Setting the IP Address

Notes: 1) The IP addresses of the two ports of a processor need to be on different subnets.

2) If you change an IP address, you will need to recompile your project. 3) If you do not change an IP address, yet select the OK button, you will still need to recompile your project. Therefore, if you do not change an address, select the cancel button instead. 4) Your computer IP address will need to be on the same network in order to communicate with the system.


7-3

Step 2: Download to the Controller Download your resource to the controller using the Debug | Download menu choice, or the Download button. You will be presented with the dialog box shown in Figure 7-3.

Figure 7-3: Download Dialog Box

Select the configuration and resource of interest and click the Download button. The project will be checked into the repository automatically. A progress bar will display the download status. The Output window will also display a message upon completion of the download.

7-4


If a Resource is Already Running AADvance controllers can only run a single resource. If a resource is already running in the controller, you will be presented with the dialog box shown in Figure 7-4.

Figure 7-4: Resource Running Dialog Box

If you wish to download your resource, click the ‘stop and download’ button. Warning! Downloads stop the I/O modules. Do not perform a download on a system running an actual process or you will shut down your plant!

If you simply wish to ‘update’ or make changes to your running resource, perform an ‘on-line change’ instead of a download. On-line changes are covered in Chapter 9. Note:

You can successfully download to a controller that does not have any I/O modules. The system will simulate modules that are not connected. You can install the I/O modules later without having to reload the resource.


7-5

Monitoring Programs Step 1: Connect Using Debug After downloading a resource, you may then go online with the controller using the Debug | Debug Target menu selection or the Debug Target button. The toolbar will change slightly for the debug mode and the resource status will be shown (e.g., RUN), as shown in Figure 7-5.

Figure 7-5: Debug Window, Hardware Architecture View

7-6


Step 2: Gain Write Access From release 1.2, you cannot change or lock variables without gaining access. Click on the resource window for the system you want to work with, as shown in Figure 7-6.

Figure 7-7: Debug Window, Link Architecture View

Click on the yellow flash icon window or on the icon bar.

, either on the resource

Figure 7-8: Restricted Access Control

Click ‘Request’ to get access, and check the Status is Active. Click OK. The yellow flash icon on the Resource window is now a padlock icon.


7-7

Step 2: Open Your Program Go to the Link Architecture view (using the second button in the button bar) to see your program(s), as shown in Figure 7-9.

Figure 7-9: Debug Window, Link Architecture View

7-8


Double click on a program name to open and monitor it, as shown in Figure 7-10.

Figure 7-10: Monitoring a Program


7-9

Locking (Forcing) You can lock (force) I/O variables. Double click a variable to open the locking dialog box, as shown in Figure 7-11. If variables are being controlled (e.g., input sensors or a program writing to outputs) you must lock a variable before you can change its value.

Figure 7-11: Locking / Forcing

When you click the Lock button, the dialog box will automatically close. The variable will be locked in its last value. You will need to open the dialog box again to change the variable’s value. The Force LED on the processor(s) will turn amber when any variables are locked.

A locked variable will be shown with a * to the left of its variable name, as shown in Figure 7-12.

Figure 7-12: A Locked Variable

Notes: 1) Internal variables cannot be locked.

2) The asterisk is not shown when running in demo mode.

7-10


Viewing and locking a variable in a program window only shows its logic value. It does not show the variable’s physical (field) value. Variable can also be locked in the dictionary. This allows you to see both the logic and physical value, as shown in Figure 7-13.

Figure 7-13: Locking in the Dictionary

Viewing both the physical as well as logic values can be very helpful for troubleshooting, as covered in the following pages.


7-11

Differences Between Locking Inputs and Outputs There are subtle differences between the locking of inputs and outputs. Tip! Inputs are locked in logic, not at the input module. Outputs are locked at the output module, not in logic.

Figure 7-14 shows an example of a locked input. Imagine a technician is going to test an input by de-energizing the switch. The input is locked as shown by the * in the tag name and the Locked | Yes value in the dictionary. The field (physical) value of the input as shown in the dictionary is FALSE, while the logic value is TRUE. If the lock were turned off, the logic value would become FALSE and the corresponding output would trip.

Figure 7-14: A Locked Input

7-12


Figure 7-15 shows an example of a locked output. The output is locked as shown by the * in the tag name and the Locked | Yes value in the dictionary. The field (physical) value of the output as shown in the dictionary is FALSE, while the logic value is TRUE. If the lock were turned off, the physical value would become TRUE.

Figure 7-15: A Locked Output

Locking is normally only used for maintenance purposes.

Locking inputs allows you to test field devices (sensors) without shutting the plant down. Locking outputs allows you to test logic without shutting the plant down. Do not use locking to exclude a faulty field device long-term. Use a maintenance override.


7-13

Unlocking All Variables You can also view all locked variables and unlock them one at a time or all of them at once. Select the Debug | Diagnosis menu, as shown in Figure 7-16.

Figure 7-16: Locked Variables

This will pull up the resource diagnostics dialog box, as shown in Figure 7-17. From here, you can unlock one variable at a time, or all of them at once.

Figure 7-17: Locked Variables

Note: Locks are not retained during a power loss. 7-14


Viewing Live Data in the Equipment View Live data can be viewed in the equipment view, as shown in Figure 7-18.

Figure 7-18: Viewing Live Data in the Equipment View

Variables can also be locked in this view (by double clicking the variable name and following the same steps described above). The ‘Value’ field shown above is the logical value.


7-15

Spying Variables You can also view and lock variables using a spy window. This can be very useful when viewing variables that may not appear together in the dictionary, equipment view, or a program window. Highlight a variable and use the Debug | Spy menu selection, or the Spy button, to view the information shown in Figure 7-19.

Figure 7-19: Spy List

The locked column is not shown in a spy list, but variables may still be locked in the spy window.

Additional variables can be entered by double-clicking the ellipsis line at the bottom of the window. Note: Direct addresses can also be entered and viewed in a spy list even if you did not assign variable names to certain internal tags (e.g., module temperature, battery status, etc). This can be very useful for diagnostic purposes.

Spy lists can be saved by right clicking in the spy window.

7-16


Show Variable Comments You can view all variable comments (from the dictionary) using the Options | Show Variable Comments menu selection, as shown in Figure 7-20.

Figure 7-20: Displaying Variable Comments


7-17

Going Offline Go offline by using the Debug | Stop Debug Target menu selection, or the Stop Debug Target button. Warning! Do not stop the resource running in the controller that is controlling a process (i.e., do not use the Stop Resource button or command)! Stopping the resource will stop the running program(s) and shut down your plant! There is no confirmation prompt for the stop resource command on earlier workbenches.

7-18




Test Your Knowledge 1. Can a controller run more than one resource? 2. What is the command to monitor a system online? 3. What visual indication does the controller hardware provide that a variable is locked? 4. How can you tell looking at a variable whether it is locked or not? 5. Can internal variables be locked? 6. Can you view both the physical and logical values while looking at a variable in a program window only? 7. Where can you view both the physical and logic values of a variable? 8. Are locks retained during a power loss? 9. What command do you use to go offline while leaving the programs running in the controller?


7-19


Chapter 8

Creating and Using Functions and Function Blocks

Purpose To describe how to create and use functions and function blocks.

Objectives •

To understand the difference between functions and function blocks.

•

To be able to create and use functions and function blocks.


8-1

Functions and Function Blocks

Figure 8-1: Functions and Function Blocks

Functions and function blocks are reusable pieces of code. Functions have

only one output, may not contain internal variables and are not retained in memory. Function blocks can

have more than one output, may contain internal variables and are retained in memory. In other words, if a function is used 200 times, it will only be allocated space in memory once. If a function block is used 200 times, it will be allocated memory space 200 times, each one storing the value(s) it solves. There are many predefined functions and function blocks in the workbench. However, you may wish to create your own userdefined functions and function blocks (e.g., a two-out-of-three voter with discrepancy alarms and time delays). Most functions and function blocks are created using the function block, structured text or ladder diagram editors.

8-2


Creating a Structured Text Function In the link architecture view, right click on “Functions” in the resource box. Select a language type, as shown in Figure 8-2, in this case structured text.

Figure 8-2: Creating a Function

Enter a name for your function (e.g., “Vote_DI_2oo3”). Double-click on the function to open and edit it. Figure 8-2 shows an example of a very simple 2oo3 voter block without discrepancy alarms. Write the same code in your function. Note: The output variable name of a function is the same name as the function itself.

Figure 8-3: Creating a Simple 2oo3 Boolean Vote Function

Save and close your function.


8-3

Define Your Variables in the Dictionary The workbench must know what all the variable names are (Boolean, integer, input, output, etc.) in order to compile your program organization units properly. Variable names are defined in the parameters tab sheet of the dictionary. Open the nd dictionary and view the parameters tab (the 2 tab), as shown in Figure 8-4.

Figure 8-4: Parameters Tab in the Dictionary

Function and Function Block variables must be defined in the Parameters tab, not the Variables tab!

Double-click on the variable name to edit it, as shown in Figure 8-5. Change the variable type of the output to Boolean (instead of the default DINT). The “short name” is displayed within the image of the function itself when it is used in other programs (as the name may be too long to view within such a small area).

Figure 8-5: Defining Function Parameters

8-4


Add the remaining input variable names to your list. The remaining names will default with a direction of input. Add a short name and select the type as Boolean, as shown in Figure 8-6.

Figure 8-6: Defining Function Input Parameters

Figure 8-7 shows the four variables defined for this function.

Figure 8-7: Function Parameters

Save and close the dictionary.


8-5

Using the Function You may now reuse the function you created over and over in any of your programs. While in a program, open the function block list using the F3 key or the function block button in the editor window. Functions that you create will be shown in the ‘User Defined’ area of the function block dialog box, as shown in Figure 8-8.

Figure 8-8: Using a Function in a Program

8-6


Figure 8-9 shows an example of using the 2oo3 vote function in a program.

Figure 8-9: Using a Function in a Program

Save your changes, close the program window, and rebuild (recompile) the project. You can now simulate, download or update the resource in your controller. •

Simulation is covered in Chapter 6.

•

Downloading is covered in Chapter 7.

•

Updating is covered in Chapter 9.


8-7

Creating a Function Block Diagram Function Create another function, this time using the FBD (function block diagram) language editor. Name the function “AI_Mid”. Do not edit the function yet!

What you will create will eventually look like the example shown in Figure 8-10.

Figure 8-10: Mid Value Function

There are similar conversion blocks for converting any variable type to another.

8-8

The example above takes INT inputs, converts them to the type DINT, uses pre-defined max and min blocks (that only work with DINT variables) to select the middle of the three values, converts the result back to a type INT, and writes to an INT output.


Tip!

Create the parameter variables in the dictionary (in the parameters tab) before editing your function. If you edit your function first, the function block editor will ask you for the variable information, but it will create and save the variables in the variables tab sheet. You would then need to delete them there and recreate them on the correct tabbed sheet (i.e., parameters). nd

View the parameters tab (2 tab) in the dictionary and add the variables here (using the exact same names as you will use in your function). Make sure they are type INT and add a short name for each. Also, change the output to a type INT and add a short name. Figure 8-11 shows the four variables defined for this function.

Figure 8-11: Declaring Function Values

Note: The output variable name of a function must be the same name as the function itself.

Save and close the dictionary. Open the function and edit it to be similar to the example shown in Figure 8-10. Select the correct variable types from your dictionary.


8-9

Using the Function You can now use this function in any of your programs, as shown in Figure 8-12.

Figure 8-12: Example Using the Mid Value Function

Save your changes, close the program window, and rebuild (recompile) the project. You can now simulate, download or update the resource in your controller.

8-10

•

Simulation is covered in Chapter 6.

•

Downloading is covered in Chapter 7.

•

Updating is covered in Chapter 9.




Test Your Knowledge 1. A function can have how many outputs? 2. Which are retained in memory, functions or function blocks? 3. Where are function variable names defined? 4. What must a function output variable name be the same as? 5. What language can not be used to create functions or function blocks?


8-11


Chapter 9

Online Changes

Purpose To review how to change and update resources online.

Objectives •

Online Changes

To be able to modify resources and update them online.

9-1

Modifying a Resource Open an existing resource and make changes to it (e.g., change a program). Rebuild (recompile) the project.

Checking Resource Version Numbers This procedure assumes you already have your resource running in the controller.

If you connect to the system using ‘debug target’ without first loading your revised resource, a dialog box similar to Figure 9-1 will be displayed.

Figure 9-1: Version Mismatch Dialog Box

If you select ‘Yes’, the workbench will retrieve and display the earlier source code version from your repository. If you select ‘No’, the workbench will remain offline. Note:

9-2

1) The version numbers shown in Figure 9-1 represent the number of times the resource has been built/compiled; they do not represent local or repository version numbers (as covered in Chapter 11).


Online Changes You can update the resource running in a controller online without stopping the current resource or shutting your process down. Use the Debug | On-line Change: Download, or the Online Change: Download button. The dialog box shown in Figure 9-2 will appear.

Figure 9-2: Online Change Dialog Box

Select the configuration to be updated, go with the default first option (download, save on target and update) and click the Download/Update button.

Online Changes

9-3

When you are online, you can see the differences between the compiled resource versions in the workbench (your PC), running (in RAM) and stored (in flash memory) using the Debug | Diagnosis menu, Version Information tab, as shown in Figure 9-3.

Version numbers may differ if you select something other than the default option in Figure 9-2. Figure 9-3: Viewing Version Information

Note:

9-4

1) The version numbers shown in Figure 9-3 represent the number of times the resource has been built/compiled; they do not represent local or repository version numbers (as covered in Chapter 11).




Test Your Knowledge 1. Can a controller be updated online without shutting the system or your process down? 2. What is such a change called? 3. Can the workbench recognize different compiled resource versions between the workbench and the controller? 4. Is it possible to view the compiled version numbers of the workbench and online resources?

Online Changes

9-5


Chapter 10

Bindings Between Resources

Purpose To summarize how bindings are used to transfer variables between resources.

Objectives •

Bindings between Resources

To be able to link variables between resources.

10-1

Variable Bindings Bindings are directional links between variables located in different resources running in different configurations (controllers). One variable is referred to as the producing variable and the other as the consuming variable . The value stored in the producing variable is transferred to the consuming variable. Bindings are shared over Ethernet using a proprietary protocol certified for safety. A separate network is not necessary for bindings, but is recommended (especially if there is high network traffic). Redundant networks are also not necessary, but are recommended, as shown in Figure 10-1.

Figure 10-1: Bindings Between Configurations

The workbench enables bindings between resources within the same project (contained within different configurations). These are referred to as internal bindings . Note:

10-2

You will need to be running a workbench license capable of multiple configurations in order to add additional configurations to your project. It is not possible to add a second configuration when running in demo mode.


Plan Your Project It may be helpful to draw a diagram of what you want to accomplish, as shown in Figure 10-2. As shown in the top half of the figure, you could have an element of an input variable structure write to an internal Boolean variable (using application logic). That internal variable could then be passed to an internal Boolean variable in a second system (using bindings). The second system could then write that internal Boolean variable to an element in an output variable structure (using application logic). This is done because variable types must match; an input structure differs from an output structure and you cannot select an element within a structure for bindings.

Figure 10-2: Bindings Between Configurations

Alternatively, as shown in the bottom half of Figure 10-2, you could have an input Boolean variable (not a structure) in one system write directly to an output Boolean variable (not a structure) in the second system, passing the I/O Boolean variables directly using bindings. This would not require the use of internal variables or writing any application logic in either system! However, defining the input and output as Booleans (instead of structures) means that you lose potentially valuable diagnostic information (e.g., voltage, state, line fault, etc.). Note:

Binding variable types must match.


10-3

Prepare Your Project You must be running a workbench license capable of multiple configurations in order to add additional configurations.

The following example is based on a single project with two configurations (1 & 2), each with a single resource, with data passing from Config1 to Config2 as shown in Figure 10-2. One set of bindings will use internal variables, the other will pass an I/O variable directly without using internal variables. In the Hardware Architecture view, right click in the workspace area on the right and select Insert Configuration, as shown in Figure 10-3.

Figure 10-3: Inserting a Configuration

A Configuration Properties dialog box will open. Set the target as a 9000 series controller, as shown in Figure 10-4.

Figure 10-4: Selecting the Target Hardware 10-4


Right click in the workspace area on the right and select Insert Network. In the dialog box that appears, select an SNCP (Safety Network Control Protocol) network, and give the network a name, as shown in Figure 10-5.

Figure 10-5: Adding a Network for Bindings

Connect the configurations to the SNCP network by leftclicking and dragging from the network line up to the configuration. Double-click the vertical line to open the connection properties dialog box. Enter IP Addresses for each configuration. Your project may now look similar to Figure 106.


10-5

Figure 10-6: Entering IP Addresses for Bindings

Complete the dictionary for each configuration. Refer to Figure 10-2 as an example. For example: a) Change one digital input from a structure to a Boolean in both the dictionary and the equipment view. b) Add an internal Boolean variable that you will write to from one of your existing digital input structures. c) Add I/O modules to the second configuration and assign appropriate variable names and types. Write simple application logic in both resources that will utilize information from the other (i.e., write the input variable structure Boolean element to the internal Boolean in the first resource, and write the internal Boolean to an output structure Boolean element in the second resource). Again, refer to Figure 10-2 as an example.

10-6


Linking Resources You need to first link resources before binding variables belonging to them. Data links between resources are directional. When in the Link Architecture view, use the Project | Internal Binding List menu selection or the Internal Binding List button to open the Binding List window shown in Figure 10-7.

Figure 10-7: Binding List Window

You create links between resources in the left side of the Binding List window. The following example consists of two variables produced in resource 1 and consumed in resource 2, as shown in Figure 10-2. Think of it as the row number writing to the column number. The small curved arrow is the key.

Double-click in the upper right quadrant 1 2. An icon will appear in that quadrant as shown in Figure 10-8. →

Figure 10-8: Binding Selection

Double-click on the ellipsis (…) in the right pane to open the dialog box shown in Figure 10-9.


10-7

Figure 10-9: Binding Details Dialog Box

Select the producing and consuming variables. You can only define bindings between variables of a same type. Produced and consumed variable names do not have to match. Producing variables can have any direction attribute (input, output, and internal). Consuming variables can only have the output or internal attribute and must also have the Free attribute. The consuming error variable (the use of which is optional) must be a DINT type and would contain an error code in the event of a network error. The error behavior defines the variable value to be used in the event of a network error. The update behavior defines the variable value to be used when a controller producing a variable is going through an online change. 10-8


The example in Figure 10-10 shows produced and consumed variables.

Figure 10-10: Populated Binding List Window

Close the Binding List window. The link architecture view will indicate bindings with a line (or two lines for bi-directional bindings) shown between resources, as shown in Figure 10-11.

Figure 10-11: Project With Two Configurations And Bindings

Rebuild (recompile) the project.


10-9

Simulate and Test Your Bindings Simulate the project and test the bindings. In this case, turning on either input in config1 will turn on the corresponding output in config2. If your workbench is only physically connected to one resource (not both), the workbench will produce communication error messages in the output window, as shown in Figure 10-12.

Figure 10-12: Communication Error Messages

You can disable communications to a configuration using the Debug | Manage Configurations to debug menu selection (when offline). This will bring up the dialog box shown in Figure 1013, where you can de-select configurations to debug.

Figure 10-13: Managing Configurations to Debug

10-10


If you have two actual controllers, you will need to change the resource number of the second controller using the AADvance Discover utility (as configurations require unique resource numbers). Use the utility to also set the IP addresses.


10-11



Test Your Knowledge 1. An AADvance controller (configuration) can run how many resources? 2. What are the names of bindings used within the same project? 3. Can bindings be defined between variables of different types? 4. Must producing and consuming variable names match (i.e., be the same)? 5. Is a separate network for bindings required?

10-12


Chapter 11

Version Source Control

Purpose To review version control, the repository, check in and check out of program organization units, and file comparison features.

Objectives


•

To be able to set the repository path where files are stored.

•

To be able to check in and check out program organization units.

•

To understand the different status of program units.

•

To be able to compare different version files.

•

To be able to open earlier version files. 11-1

Version Source Control Different versions of workbench elements ─ including projects, configurations, resources, and POUs (program organization units) ─ are managed by saving them to a version source control repository. This enables you to retrieve older versions of the elements at a later time.

Repository Source files are stored in a repository. The repository path is set when creating a project. The default location of the repository will be on the C drive of the computer the workbench is installed on, as shown in Figure 11-1.

The destination folder is where your local files are kept.

Figure 11-1: Repository Path

The full default destination path in Windows XP is: C:\Document and Settings\All Users\ Application Data\AADvance\AADvance\Repos. In Windows 7 it is: C:\Users\Public\ Application Data\AADvance\AADvance\Repos.

11-2


Viewing the Repository Path of an Existing Project Once you are in a project, you can view the repository path using the File | Project Properties menu selection, the Version Control tab and its browse button, as shown in Figure 11-2.

Figure 11-2: Viewing the Repository Path of an Existing Project


11-3

Check In and Check Out When creating a project, the workbench automatically checks the project into the repository. The project remains checked out after the check in. All POUs are automatically checked in when you perform a download or an online change.

Recursive means that item and all of its sub-elements.

Program Organization Units (POUs) that you create are not automatically checked-in. They will be shown in the workbench as “new” (as described on the following page). You decide when you wish to check things into the repository and perform this step manually. When checking items in, you can choose to set a recursive check in that includes all sub-elements. For example, when you check in a configuration with the recursive option set, its resource and all of its POUs are checked-in (i.e., everything in the project tree view). Keeping the item checked out allows you to continue editing it, as shown in Figure 11-3.

Figure 11-3: Checking In a Configuration

When you check out an item from the repository, that item’s version number is incremented. The output window will generate messages reminding you of this.

11-4

Note:

Items must be checked in before they can be deleted.


Version Status Icons The version control status of an element is indicated in the workbench using the following small symbols in the upper left corner of the icons used for projects, configurations, resources and program organization units. Checked-in. The workbench element is available for checkout from the version source control repository. Checked-out locally. The current workbench element version is checked out of the repository and is not available to other users. Old version. The version source control repository holds a more recent version of the workbench element. Checked-out remotely. The workbench element is checked out by another user and is not available. New element. The workbench element is added to the project but not yet checked in. Unknown status. The workbench is unable to retrieve the status of the element. This is normally due to a broken repository connection. You can obtain version control status information by holding the mouse cursor on the control status icons of workbench elements. This information (e.g., version control status, modification owner, last modified date and time of the element, the user having checked out the element) is displayed in a tooltip, as shown in Figure 11-4.

Figure 11-4: Version Control Tooltip Version Source Control

11-5

Comparing Earlier Versions You can view the history of a project, configuration, resource, or program organization unit using the Tools | View History menu selection or the View History button. A dialog box, as shown in Figure 11-5, will appear.

Figure 11-5: Program History

When viewing the history of a project, configuration, resource, or program organization unit, you can choose to compare a previously checked in version of the element with the current version (by selecting another version) or with another checkedin version (by selecting two versions while pressing the Ctrl key). Click the Diff (Differences) button (in Figure 11-5) to show the file differences window, as shown in Figure 11-6.

Figure 11-6: File Differences Window

11-6


Click the View Sources button to view the difference between file versions, as shown in Figure 11-7.

Figure 11-7: Viewing Different Source Versions

The workbench will graphically show you what has been removed, modified or inserted.


11-7

Retrieving Earlier Versions Select the version you are interested in (in the history window shown in Figure 11-5) and click the Get button. That version will be retrieved from the repository. The local version in your workbench will now have the same version number as the item you just retrieved, although the tool tip will still show the highest version number available for that item in the repository. Checking the item in will increment the version number.

11-8




Test Your Knowledge 1. Does the workbench save previous versions of configurations, resources and programs? 2. Where are previous files stored? 3. Can items that are checked out be deleted? 4. Can the workbench graphically compare different file versions?


11-9


Chapter 12

Miscellaneous Workbench Features

Purpose To review miscellaneous workbench features.

Objectives •

To be able to use the cross reference browser.

•

To be able to print projects.

•

To be able to set up password protection schemes.

•

To be able to export and import workbench elements.

•

To be able to archive and restore projects.


12-1

Cross Reference Browser The cross references browser lists the variables in your project and where they are used. Open the cross reference browser using the Tool | Browser menu selection or the Browser button. When the browser window opens, click on the identical Browse button to generate the browse file. The cross reference browser, shown in Figure 12-1, is divided into five sections: A The list of global objects declared in a project. B The search field where you can enter a name to search in the list of objects. C The description of the object selected in the list. Double-clicking on a program line in area D will open that program editor and highlight that element.

D The locations of the object selected in the list in the project program organization units. E The output window where messages and error messages are displayed.

Figure 12-1: Cross Reference Browser

A broken link symbol indicates an object is not used in any program organization units.

12-2


The information displayed in the browser can be a bit confusing to understand initially, especially when structures are used. The browser shows not only the variable name, but the direct address of all of the elements in the structure using the following designations: I Q X B W R

Input Output Boolean 8-bit unsigned short integer 16-bit integer (signed or unsigned) 32-bit real

The number associated with the I/O configuration address indicates the processor bus number, module number and channel number.

Viewing Dependencies Right click on a variable in the cross reference browser (in area A of Figure 12-1) and select View Dependencies. The example shown in Figure 12-2 indicates the dependencies used in the earlier binding exercise.

Figure 12-2: Variable Dependencies


12-3

Printing You can print complete or partial documentation for your project using the document generator. You can access the document generator from the hardware architecture view, link architecture view, dictionary view, or any of the language editors using the File | Print menu selection or the print button. The document generator window has three tabs, as shown in Figure 12-3: •

•

•

Table, showing a table (or tree) representing all items that can be printed for the current project, shown in Figure 12-3. Options, showing a list of printing options, shown in Figure 12-4. Preview , displaying a preview of the project to print, shown in Figure 12-5. This window is resizable.

Figure 12-3: Document Generator Window, Table View 12-4


Figure 12-4: Document Generator Window, Options View


12-5

Different fonts, sizes, colors, etc. can be selected using the Options -> Customize menu choice in any editor window.

Figure 12-5: Document Generator Window, Preview View

Clicking the Print button will bring up the standard Windows print dialog box, as shown in Figure 12-6.

Figure 12-6: Print Dialog Box 12-6


Passwords The password access control described in the following pages is relevant for release 1.3. Access control is expected to change in a future release.


12-7

POU Access Control You can control access to user-defined POUs (program organization units) using a password. Right click the POU and select Properties to open the dialog box shown in Figure 12-7. Select the Security tab.

Figure 12-7: POU Properties Dialog Box

Users that do not have the password may still be able to open the POU in read only mode depending upon how the resource in which it is contained has its access control configured. The security state of a POU is indicated by its icon color in the resource, as shown in Table 12-1. Icon

Security State Yellow. The POU has no access control. All users have read and write access in the POU. In the dictionary view, local variables and parameters are visible and editable. Red. The POU is locked. Users not having the POU password cannot access the POU; these users do not have read or write capabilities. In the dictionary view, local variables and parameters are visible but not editable. Blue. The POU is in read-only mode. Users not having the resource password can view the POU; these users do not have write capabilities. The read-only mode for the POU is inherited from the resource to which it belongs. In the dictionary view, local variables and parameters are visible but not editable. Green. The POU is unlocked. User can access the POU; this user has read and write capabilities. In the dictionary view, local variables and parameters are visible and editable.

Table 12-1: POU Icon and Security States

12-8


Resource Access Control You can control access to resources using a password. You can also choose to apply the read-only mode to a resource. You set access control for a resource in its properties' security tab. Right click on a resource window title bar and select Properties to open the dialog box shown in Figure 12-8.

In read-only mode, users not having the password will have read-only access. Figure 12-8: Resource Properties Dialog Box

The security state of a resource is indicated by the color of the lower triangle in the resource title bar icon, as shown in Table 12-2. Icon

Security State Gray. The resource has no access control. All users have read and write access in the resource. POUs in the resource may have individual access control. Red. The resource is locked. Users not having the resource password cannot access the resource or its POUs; these users do not have read or write capabilities. These users can change resource properties, wire and bind variables, modify the memory for retain, and add devices to wired variables. Cyan. The resource is in read-only mode. Users not having the resource password can view the resource and its POUs; these users only have read capabilities. These users can change resource properties, wire and bind variables, modify the memory for retain, and add devices to wired variables. POUs in the resource may have individual access control. Green. The resource is unlocked. User can access the resource and its POUs; this user has read and write capabilities. However, POUs in the resource may have individual access control.

Table 12-2: Resource Icon and Security States Miscellaneous Workbench Features

12-9

Configuration (Controller) Access Control You can control access to a configuration (controller) with a password. The configuration access control prevents the connection of all clients not having the target's password. Note:

The password is embedded on the target controller and can only be set or changed while in debug mode (i.e., online).

While debugging a target, right click on the configuration’s title bar in the hardware architecture view, select Properties and the security tab, as shown in Figure 12-9.

Figure 12-9: Configuration Properties Dialog Box

Enter and confirm the password. Acknowledge the confirmation prompt. At run time, the security state of a configuration is indicated by its title bar icon as shown in Table 12-3. Icon

Security State The configuration has no access c ontrol. All clients can access the target. The configuration is not accessible; the target does not recognize the password. IXL clients not having the target password cannot access the target. The configuration is accessible; the target recognizes the password. IXL clients having the target password c an access the target.

Table 12-3: Configuration Icon and Security States

12-10


Project Access Control You can control access to the entire project using a password. You have the option of applying read-only mode to the project. In read-only mode, users not having the password will have read-only access to the project. When opening a project in readonly mode, all resources and POUs making up the project are set to read-only mode. Resources and program organization units making up projects can have their own access control. A resource having its own password without the read-only option remains locked and cannot be viewed without its password. While in read-only mode, you cannot build (compile) a project. You open the project security dialog box from the File | Project Properties menu selection. The project properties dialog box will be displayed, as shown in Figure 12-10.

Figure 12-10: Project Properties Dialog Box


12-11

Export / Import Workbench Elements Export You cannot export entire projects; use the archive feature instead.

You can export and import workbench elements (i.e., configurations, resources, program organization units, variables (dictionary)) from one project to another. Exporting saves files with out their history (earlier file versions). To export a workbench element, use the File | Export menu and select the element type of interest. An Export dialog box will be displayed, as shown in Figure 12-11.

Figure 12-11: Exporting a Configuration

You do not select a destination location for the exported files; they are saved in their respective folders.

12-12


Import Import files using the File | Import | Exchange file menu selection to bring up the dialog box shown in Figure 12-12.

Figure 12-12: Importing a File, Step 1

Notes:

Password definitions are retained when exporting and importing elements having access control. It is not possible to ‘upload from the target’.

Click the Next button to bring up the dialog box shown in Figure 12-13.



12-13

Select the Browse button to bring up the dialog box shown in Figure 12-14.


Select the file name of interest and click the Open button. You can then select the items of interest to import, as shown in Figure 12-15.


Click the Next button to be presented with the final dialog box, as shown in Figure12-16.

12-14



Export/Import Types Configuration: The entire configuration, resource, programs etc. Entire Resource : Overwrites existing resource of same name with resource, programs, variables etc. Resource Properties : Cycle time, retain settings, compiler options etc. Resource I/O Device Instances : Module definitions Resource Wired Variables : Variables wired to module definitions (you must import the I/O Device Instances first so the right boards are there to wire to) Resource External Bindings : CIP setup – NOT bindings between resources within one project POU: Program Variables : Excel (2007 or later) or .csv of variable parameters


12-15

Archive / Restore Projects Archive A project can be archived and restored complete with its history (earlier file versions), although you can select “latest version only” in the archive type drop down list. Note:

Your project must be checked-in in order to archive it. Use the Tools | Check in | Project menu selection.

Use the File | Archive/Restore Project menu selection to display and use the dialog box shown in Figure 12-17.

Figure 12-17: Archive / Restore Dialog Box

Select a destination archive file name and location using the ellipsis button in the Destination section shown above, which will open the dialog box shown in Figure 12-18.

12-16


Figure 12-18: Archive Save As Dialog Box

The Archive button will now be enabled in the archive dialog box shown in Figure 12-17. Click the Archive button to create the archive file. A dialog box will confirm the success of the archive operation, as shown in Figure 12-19.

Figure 12-19: Archive Completed Successfully

You may then copy the .vsc file to another computer for restoring.


12-17

Restore Use the File | Archive/Restore Project menu selection to display the dialog box shown in Figure 12-20.

Figure 12-20: Restoring a Project

Select the Restore option. Click the ellipsis button in the Source Archive File section to use the open dialog box, as shown in Figure 12-21.

12-18


Figure 12-21: Selecting an Archive File to Restore

Find and select the .vsc file name of interest. Click the Open button. This will take you back to the dialog box shown in Figure 12-20. It is not necessary to make a selection in the Repository Projects pull down menu (shown in Figure 12-20). Click the Restore button (shown in Figure 12-20). A dialog box will confirm the success of the restore operation.


12-19

Opening the Restored Project Restoring a project does not ‘open’ it. To open the project select the File | Open menu selection or use the Open button. The Open Dialog box will be displayed, as shown in Figure 12-14.

Figure 12-14: Open Dialog Box

The project file of interest will not be shown yet as you must first open the project from the repository. Click the Open from repository button, to display the dialog box shown in Figure 1215.

12-20


Select the desired project in the drop-down list, as shown in Figure 12-15, and click the OK button.

Figure 12-15: Open from Repository Dialog Box

Note:

As an alternative to archiving/restoring a project, you can zip the entire project folder, but this will not include repository information.


12-21



Test Your Knowledge 1. What is the purpose of the cross reference browser? 2. Is print preview available in the workbench? 3. How many passwords can be set at the resource level? 4. If a user does not have the resource level password, and read-only access has not been enabled, are users able to view the files in read-only mode? 5. How many passwords may be set in the controller? 6. What are some of differences between Archive and Export?

12-22


Chapter 13

OPC

Purpose To review the steps to implement OPC.

Objectives

OPC

•

To understand the fundamentals of OPC.

•

To be able to implement the AADvance OPC server.

•

To be able to configure sample OPC clients and collect data from the OPC server.

13-1

OPC Server The AADvance OPC Server is a Windows-based application that allows OPC compatible clients, such as HMIs and SCADA systems, to connect to one or more AADvance controllers to access data, as shown in Figure 13-1.

Figure 13-1: Services Window

The AADvance OPC server runs as a Windows service. A service is an application type that runs in the background. Service applications typically provide features such as client/server applications, web servers, database servers, and other server-based applications, both locally and across a network. You can start, stop, pause, resume, or disable a service on remote and local computers (with the appropriate permissions). You can also set up recovery actions to take place if a service fails (e.g., restarting the service automatically).

13-2


Data Access vs. Alarm & Event OPC data access clients are the most common and are used by many HMI (Human Machine Interface) packages to monitor specific process variables originating from an AADvance system. OPC data access clients query the OPC server by variable name. The OPC server allows data access clients to access any variable defined in a configuration. The OPC server only generates events for variables configured for SOE in the workbench dictionary.

OPC alarm & event clients are used primarily in event historian or event log type applications. OPC alarm & event clients query the OPC server by controller name. Instead of being able to query by variable name, the alarm & event clients receive all events originating from subscribed controllers.

Installation The AADvance OPC server is installed from a separate CD.

OPC

13-3

Configuring the OPC Server The following information describes: •

The OPC server (build 153) supplied as version 1.20.508.

•

Using the server and clients on the same PC.

Note:

More detailed information is available in the OPC Portal Server Manual (e.g., how to configure DCOM when the server and client are running on different PCs, synchronizing clocks between the controller and PC, etc.).

A wizard is used to create an XML file used by the OPC server. When you build or rebuild a project, the workbench will open a dialog box asking if you wish to create the XML file, as shown in Figure 13-2.

Figure 13-2: Start ConfigGen Tool Dialog Box

Click Yes. The Wizard will open, as shown in Figure 13-3.

13-4


Figure 13-3: OPC Configuration Wizard

Select Next. Check or browse for the project folder and the project database PrjLibrary.mdb, as shown in Figure 13-4. The password is the Project password, if one is set (see chapter 12).

Figure 13-4: Project Path

Continue through the Wizard steps. You do not need to check the requested options (although you may). Go with the default file location shown in the final screen, as shown in Figure 13-5. OPC

13-5

Figure 13-5: Default File Location

Click the Next> button. The Wizard will automatically create the configuration file, as shown in Figure 13-6.

Figure 13-6: Wizard Configuration File

Click the Restart OPC Service Now button. This will restart the service and direct it to the new XML file. Click the Finish button once that process is completed.

13-6


Configuring OPC Clients Connecting to the OPC server is implemented differently for each OPC client. For OPC data access clients that allow browsing of the available OPC servers, the OPC server is identified as ICSTriplexOPCServer.

Sample Data Access Client 1.

OPC | Connect… menu

selection.

2. Select the appropriate server (ICSTriplexOPCServer in this case), as shown in Figure 13.7. Click the OK button.

Figure 13-7: Select OPC Server Dialog Box

OPC

13-7

3.

OPC | Add item… menu

selection.

Expand the configuration and resource and select the tags that you wish to view, as shown in Figure 13-8. Data Access clients constantly poll for selected variables.

Figure 13-8: OPC Add Item Dialog Box

Figure 13-9 shows an example of a simple OPC Data Access client running and monitoring digital and analog values.

Figure 13-9: Sample OPC Data Access Client

13-8


Sample Alarm & Event Client 1.

OPC | Connect… menu

selection.

2. Select the appropriate server (ICSTriplexOPCServer in this case) as shown in Figure 13.10. Click the OK button. Alarm & Events clients receive information pushed out by the server. Specific variables do not need to be selected.

Figure 13-10: Select OPC Alarm Server Dialog Box 1,000 events are stored in the controller SOE buffer. The buffer is not retained on a power loss.

Figure 13-11 shows an example of a simple OPC Alarm & Event client running and monitoring sequence of events information.

Figure 13-11: Sample OPC Alarm & Event Client

OPC

13-9



Test Your Knowledge 1. Which OPC client type requests data? 2. Which OPC client type automatically receives data? 3. Is the OPC configuration file created by the workbench? 4. True or false: the OPC server will generate alarm and events for all tags defined in the dictionary.

13-10


Chapter 14

Troubleshooting

Purpose To review basic troubleshooting of the AADvance system.

Objectives

Troubleshooting

•

To be familiar with the fault detection capabilities of the AADvance system.

•

To be able to analyze the LED fault indicators and identify faulty modules.

•

To be able to view diagnostic information online.

•

To be able to upload the processor log.

14-1

Self Test Cycle Times AADvance diagnostics occur at different intervals. Some faults are reported on their first detection. Others can take hours before being reported. Most faults are filtered by requiring a number of successive faults before being reported (i.e., turning on a red LED). As shown in Figure 14-1, if an error is present, a fault counter increments. If the error is not present during the next test interval, the fault counter decrements (by a lower value). If the counter exceeds a threshold, the fault is reported as permanent. At that point, one or more LEDs will turn red, fault information will be available in the system, and entries will be placed in the processor log.

Figure 14-1: Fault Filtering

14-2


Latching and Unlatching Faults Some system faults are latching. In order to clear them, you must remedy the source of the fault (usually by replacing a module) and then press the Fault Reset button on a processor module. Note:

During the reset operation, the system continues to run at its normal scan rate. There is no change in system performance and no additional vulnerability to faults.

Some system faults are non-latching. The system will attempt to recover automatically and the fault indication will clear once the fault condition has been remedied. Indications of field faults (e.g., open or short circuits, which are indicated by amber channel status indicators) are non-latching. You may therefore not see some short term problems. The fault indication clears as soon you remedy the source of the problem.

Figure 14-2: Indication of a Latching Channel Fault

Troubleshooting

14-3

Fault Types Note:

Please refer to the Troubleshooting and Maintenance Manual for more detailed troubleshooting information and tips.

Faults are classified as follows: • • • •

System faults Module faults Channel faults Field faults

System Faults A system fault is indicated when a detected fault cannot be isolated to a single module (e.g., a bus failure or backplane fault) or the fault is not the result of a hardware failure that needs a module replacement (e.g. a software fault, calibration drift). When this type of fault occurs in the system, only the System Healthy LED on the processor(s) will turn red.

Module Faults A module fault is indicated when a fault is isolated to the hardware of a specific module. The Healthy LED turns red on the faulty module and the System Healthy LED on the processor(s) also turns red.

Channel Faults A channel fault is indicated when a faulty channel is isolated to a specific channel of an I/O module. Channel faults are also reported as module faults. The Channel LED will turn red, the I/O module Healthy LED will turn red and the System Healthy LED on the processor(s) will turn red.

14-4


Field Faults A field fault is indicated when a fault condition is isolated to a field condition or field device and not an I/O module itself (e.g., open or short circuit field connection, no field power, out-ofrange signal, etc). These faults are indicated by a Channel LED turning amber and are not indicated as a channel, module or system fault.

Figure 14-3: Module Fault Types

Troubleshooting

14-5

Viewing Variables Live When online (debugging), live values of all variables can be viewed in the dictionary, as shown in Figures 14-4 and 14-5.

Figure 14-4: Viewing Variables Online in the Dictionary

Figure 14-5: Viewing I/O Variables Online in the Dictionary

Variables can also be viewed in programs and spy lists.

14-6


I/O State and LED Indications

Current, voltage and other information can also be read live.

Viewing the state of an I/O variable structure (tagname.STA), as shown in Figure 14-5, can be useful for troubleshooting. The state variable reports a numeric value (from 1 to 7) which reflects the current state of the channel. The following figures indicate the state values and the corresponding I/O LED indications for various I/O types.

Figure 14-6: Digital Input Conditions and Indications

Figure 14-7: Analog Input Conditions and Indications Troubleshooting

14-7

Figure 14-8: Digital Output Conditions and Indications

Figure 14-9: Analog Output Conditions and Indications

14-8


Diagnostic Collection The processor keeps a system event log of 500 entries in a rotating buffer. This covers several weeks of history in a quiet system but it can fill rapidly with a chronic issue. In a future release, the events will be added to the OPC Alarm and Events output, so that the events may be collected by a HMI. It is not usually necessary to read the processor’s event log. The most likely system faults are also provided on diagnostic variables. A module that consistently shows a red Healthy LED almost certainly needs repair or replacement. However, a second opinion is sometimes desirable. A diagnostic collection tool is available that will collect the processor’s event log as well as all diagnostic system data. This is available in the Rockwell Automation knowledgebase as article 68174. Within Rockwell Automation, it is on the ICS Triplex product support website techsupport.icstriplex.com, linked from the RAIN page A-Z as SSB Technology Support.

Installation Run the installation program. You can leave the options at their defaults. The installer offers to run the collection tool.

Communications Setup

Figure 14-10: Communications Setup

You can connect to the system by serial cable or Ethernet. For a serial connection, unscrew the cover on the front of a processor. The cover hides a round serial port as well as the battery. Use a TC-304-01 maintenance cable and connect the processor to a computer serial port. If a computer has no serial ports, the Rockwell Automation 9300-USBS adapter is Troubleshooting

14-9

recommended. Choose the appropriate serial port from the dropdown list. For an Ethernet connection, ensure the computer is on the same subnet as the system’s Ethernet port that you are connected to. Type the system’s IP address into the setup window. After successfully connecting, that IP address will be available for next time by clicking the drop-down arrow. Click OK. The program will start collecting diagnostic data. As it receives data on module serial numbers and versions, it displays these in the window.

Figure 14-11: Data Collection

When the program has finished collecting, it asks for details of the log.

Figure 14-12: File name details

These details will help identify the system – the log only contains the name of the application that is running, which may not be enough information to identify the system. Click OK. Two files are now saved. One file contains all the diagnostic data and is encrypted, but it can be opened by 14-10


support personnel. The other is a comma separated variable (.csv) file that can be opened in Excel. This provides all the serial numbers and firmware versions of the modules in the system. The encrypted file contains the state of the system as it was when the log was taken, with a certain amount of history in the processor logs. It provides detailed diagnostics on many different functions of the system. It does not include the application logic, SOE events and variable states and cannot be used to diagnose a problem with the application.

Troubleshooting

14-11



Test Your Knowledge 1. What LED color indicates an I/O channel fault? 2. What LED color indicates an I/O field fault (e.g., short circuit)? 3. If an I/O channel is indicated as faulty, what other LEDs will indicate a fault? 4. If a field fault disappears, will LEDs change state (color)? 5. What does state 3 mean for a digital output and what is the expected channel LED color?

14-12


Chapter 15

Replacing Modules

Purpose To review the procedure for replacing modules in an AADvance system.

Objectives •

Replacing Modules

To be able to replace faulty modules.

15-1

Removing Modules Modules can be removed on line without shutting anything down or upsetting the process in redundant configurations only. Pulling out a non-redundant module will most likely impact your process. Modules are removed by carefully pulling them out of the base unit using the following procedure. The module Run LED will turn red when the module is unlocked.

1. Turn the locking screw located on the front of the module ¼ turn counter clockwise. The screw slot will be vertical when the module is unlocked. 2. Carefully remove the module from the base unit. Contact Rockwell Automation in order to obtain a return material authorization and return the module.

15-2


Installing Modules Modules are installed by carefully pressing them onto the base unit, as shown in Figure 15-1, using the following procedure. 1. Inspect the connectors on the back of the module for bent or damaged pins. 2. Make sure the slot of the module locking screw is vertical. 3. Place the new module on to the dowel pins on the base unit. 4. Push the module until the connectors are fully mated. 5. Turn the locking screw located on the front of the module ¼ turn clockwise. When replacing a processor, press its Fault Reset button once its Run LED turns amber.

6. Wait for the module Run LED to turn amber. Press the Reset button on a processor to enable the module to run.

Figure 15-1: Inserting a Module

Replacing Modules

15-3

Inserting a New Processor Battery When installing a new processor module, Insert its internal back-up battery as follows: 1. Use a small Phillips screwdriver to release the battery cover. 2. Remove the cover. Take care to retain the screw and grommet. 3. Insert the battery (a BR2032 coin cell) into the slot with the ribbon on its left and its “+” positive side to the right. The front plastic has “+” marks to indicate the positive side. 4. Refit the cover.

Figure 15-2: Removing the Processor Battery Cover

15-4




Test Your Knowledge 1. What tool is required to replace modules? 2. Can non-redundant modules be replaced online without impacting the process? 3. Can redundant modules be replaced online without impacting the process? 4. What must you do after replacing a module to enable it to run? 5. What must you also do when installing a new processor module besides just plugging it into the base unit?

Replacing Modules

15-5


Appendix 1

AADvance Discover Utility

Purpose To review how to configure the IP addresses of the six Ethernet ports and set the resource number of the processor base unit.

Objectives


•

To be able to configure the IP addresses of the six Ethernet ports using the AADvance Discover utility

•

To be able to set the resource number of the processor base unit using the AADvance Discover utility.

A1-1

Processor Base Unit Configuration Before a group of programs making up a resource can be downloaded to a system, the system must have a valid IP address and resource number. The following material describes how to view and configure IP addresses and resource numbers. A resource number uniquely identifies the system (configuration) when there are multiple systems (configurations) in a distributed project. A configuration can only run one resource. The processor base unit has a unique MAC (Media Access Control) address range configured at the factory. The AADvance Discover utility will detect and report the MAC addresses that are connected to a network and allow you to configure a new - or modify an existing - IP address, as well as read and set the resource number. The processor base unit holds the two IP addresses of each processor slot, six addresses in all. Notes:

1) Each Ethernet port of the pair on a processor slot must be configured on a different subnet. 2) IP Addresses cannot be changed on a running system.

Having the IP addresses set in the base unit means that you can remove a faulty processor module and install a new one without needing to set or load anything in the module. A processor module must be connected in order to configure the chip in the base unit for that slot, as shown in Figure A1-1. Setting the addresses for one slot does not change the settings for the other two slots. However, when a second or third processor is added to a running system, it will copy the settings to its own base unit chip.

A1-2


Figure A1-1: Process Base Unit


A1-3

Configuring or Viewing the Resource Number and IP Address of a Processor Base Unit You need to configure the IP addresses for each processor slot of a new processor base unit. Make a note of the MAC address range for the base unit shown on the label on the 9100 processor base unit. Decide on an IP address for each Ethernet port. Each Ethernet port of the pair for a processor slot must be configured on a different subnet. Configuring the IP Addresses and Resource Number:

1) Connect an Ethernet cable between your PC and a port on the controller base unit connected to a processor. 2) Insert the Program Enable key into the KEY socket on the processor base unit. The settings cannot be changed if the key is not fitted. 3) Start the AADvance Discover utility (Start > All Programs > AADvance > AADvance Discover). 4) Find the MAC Address listed on the screen, as shown in Figure A1-2.

Figure A1-2: AADvance Discover Screen

A1-4


Note:

The AADvance Discover utility will find any AADvance system and allow configuration on the same “broadcast domain” as the PC that the utility is running on. Systems connected by routers, firewalls, VPN connections cannot be seen. AADvance Discover broadcasts to all devices, and the controllers will respond. However, Windows may misdirect the replies and firewalls/shields may block them. You may get better visibility of systems by disabling wireless, unplugging other networks and disabling firewalls. 5) Verify that the system status is “Configurable”. A processor showing a status of “Locked” means it is running a resource and cannot be changed. Stop the resource. Check the Program Enable key is fitted. 6) Double click on the MAC Address for your system. The Resource/IP Address dialog box will be displayed, as shown in Figure A1-2.

Figure A1-2: Resource/IP Address Dialog Box


A1-5

7) Enter the IP Address values into the fields for each Ethernet port E1-1/2 to E3-1/2. Click Apply. The controller status will show “In Progress” and then “Configurable” when the IP Addresses are updated. 8) Change the resource number if you will have multiple resources (controllers) in a distributed system. Each system must have a unique resource number. 9) Cycle power to the controller to complete a change to the resource number. 10)Refresh the screen to confirm that the resource number is correct.

A1-6


Appendix 2

Glossary

Purpose To summarize common AADvance, workbench and industry terms.

Objectives •

Glossary

To be familiar with and understand common AADvance, workbench and industry terms.

A2-1

�� - Devices which cause an action (electrical, mechanical, pneumatic, etc.) to

occur when required within a plant component. Examples would be valves and pumps. �� - American Institute of Chemical Engineers �� - Type of variable. These are continuous integer or real variables. �� - American National Standards Institute �� - Application Program Interface, and also American Petroleum Institute �� - Organizational structure of a computing system which describes the

functional relationship between board level, device level and system level components. �� - The American Standard Code for Information Interchange. Uses seven bits to

represent 128 characters. Both upper and lower case letters, numbers, special symbols and a wide range of control codes are included. �� - A data communications term describing the method by which signals

between computers are timed. Although the number of characters to be sent per second is undefined, the rate at which a character’s bits are sent is pre-determined. Each character is preceded by a start bit and terminated by a stop bit. �� - The probability that a system will be able to perform its designated function

when required for use, normally expressed as a percentage. �� - A printed circuit board which supports bussed functions to connectors

mounted on a printed circuit board. Plug-in components and modules are then able to connect to the bus pins. �� - Type of variable. Such variables can only take true or false values. �� - Basic Process Control System �� - A type of memory in which information is stored temporarily during transfer

from one device to another, or one process to another. Normally used to accommodate the difference in the rate or time at which the devices can handle the data. �� - A group of conductors which carry related data. Micro-based systems have an

Address Bus, Data Bus and a Control Bus. �� - Center for Chemical Process Safety �� - Graphic component of an LD program used to represent the assignment of an output

variable. A2-2


�� - Text included in a program that has no impact on the execution of that

program. �� – A software object made up of one or more resources. �� - Graphic component of an LD program. It represents the status of an input

variable. �� - Commercial Off The Shelf �� - The percentage of faults that will be detected by automatic system diagnostics. �� - Information calculated by the workbench relating to the dictionary of

variables, and where those variables are used in a project. �� - Distributed Control System �� - Tests performed on equipment to detect faults. �� - Set of internal, input, output variables and defined words used in programs. �� - Deutsche Industrie-Norm (German Industrial Standard) �� - A difference exists between one or more elements of a redundant system. �/�/�� - Electrical (Relay) / Electronic (Solid State) / Programmable Electronic System �� - Electromagnetic Compatibility �� - Electromagnetic Interference �� - Erasable Programmable Read Only Memory. A non-volatile storage medium

which is electronically programmed. The EPROM device may be erased by strong ultraviolet light. �� – Electrically Erasable Programmable Read Only Memory. �� - Electrostatic Discharge, also Emergency Shutdown �� - Equipment Under Control �&� - Fire and Gas

Glossary

A2-3

�� - The capability to go to a pre-determined safe state in the event of a specific

malfunction. �� - Built-in capability of a system to provide continued correct execution of

its assigned function in the presence of a limited number of hardware and software faults. �� - Function Block �� - Functional Block Diagram. One of the graphical IEC 61131-3 languages. �� - Equipment connected to the field side of the I/O terminals. Such

equipment includes field wiring, sensors, final control elements and those operator interface devices hard-wired to I/O terminals. �� - Special purpose memory units containing software embedded in protected

memory required for the operation of programmable electronics. �� - Graphic component of the FBD language which represents a standard

elementary function from the IEC 61131 TOOLSET libraries. �� - Range of variables or defined words. Such variables or words may be used in any

program of one project. �� - Graphical User Interface. �� - Human Machine Interface �� - The ability to remove and replace modules without removing power

or stopping system operation. �� - Industrial Control System, also Industrial Control Services (the original name of the

company). �� – International Electrotechnical Commission �� 61131 - International standard defining programming languages, electrical parameters

and environmental conditions for programmable electrical systems. �� 61508 - An international standard that covers functional safety, encompassing

electrical, electronic and programmable electronic systems; hardware and software aspects. This standard is focused for vendors. �� 61511 - An international standard that covers functional safety and Safety

Instrumented Systems for the process industry, encompassing electrical, electronic and

A2-4


programmable electronic systems, hardware and software aspects. This standard is focused for users, contractors and system integrators. �� - Institute of Electrical and Electronics Engineers �� - Instruction List. A low level IEC 61131 language, similar to the simple textual PLC’s

language. �� - Attribute of a variable. Such variables are linked to an input device. �� - Interface that converts input signals from external devices into signals that

the control system can utilize. �� - Class of analogue variables stored in a signed integer 32-bit format. �� - Attribute of a variable which is not linked to an input or output device. �/� – Input / Output. �/� �� - Single connection point of an I/O module. An I/O channel may receive an

I/O variable. �� – International Society of Automation.

Ladder Diagram - Graphic language mixing contacts and coils for the design of Boolean equations. �� – Light Emitting Diode �� - Ladder Diagram An IEC 61131-3 language composed of contact symbols

representing logical equations and simple actions. The main function of the ladder diagram is to control outputs based on input conditions. �� - Range of variables or defined words. Such variables and words may be used in

only one program of one project. �� /� - Input or output variable disconnected logically from the corresponding I/O

module by a Lock (force) command sent by the user from the workbench. Locking is typically used during testing and maintenance of field devices. �� - Man Machine Interface. The operator’s window to monitoring and keys, knobs,

switches, Graphical User Interface of the Operator Workstation, etc. for making adjustments in the process.

Glossary

A2-5

�� - An industry standard communications protocol developed by Modicon. Used to

communicate with external devices such as distributed control systems (DCSs) or operator interfaces. �� - m-out-of-n. See Voting System. �� - An electronic (generally pluggable) sub-system. �� - Mean Time Between Failure �� - Mean Time To Failure �� - Mean Time to Repair �� - Optional address defined for each variable. This address is used by the

Modbus protocol when the target system is connected to other systems. �� - OLE (Object Linking and Embedding) for Process Control �� - Occupational Safety and Health Administration �� - Attribute of a variable. Such variables are linked to an output device of the target

system. �� - Interface that converts output signals from the control system into

signals that can actuate external devices. �� - Operator Workstation – see HMI and MMI. �� - Programmable Electronic Systems �� - Probability of Failure on Demand �� - Process Hazards Analysis �� - Programmable Logic Controller �� - Main left and right vertical rails at the extremities of a ladder diagram. �� – Program Organization Unit. A POU can be a program, a function or function

block. �� - Basic programming unit in a project. A program is described with one

language, and is placed in the hierarchy architecture of the project.

A2-6


�� - Programming area which groups all the information (configurations, resources,

programs, variables, target code etc.). �� - A set of rules governing data flow in a communication system. The protocol

governs such matters as the way a messages are is addressed and routed, how often it is sent, how to recover from transmission errors and how much information is to be sent. �� - Process Safety Time �� - Random Access Memory. A volatile (unless battery backed) form of read/write

memory. The time to access different locations is the same. It may be static (SRAM - data held in a flip- flop) or dynamic (DRAM – data held as a capacitive charge). �� - Class of analog variables stored in a floating IEEE single precision 32-bit format. �� - The employment of two or more devices, each performing the same

function, in order to improve reliability and/or availability. �� – The POUs and definitions making up a virtual machine. �� - Radio Frequency Interference �� - Regent Interface Module. Development term for

Trusted TMR

Interface Module.

�� - Reduced Instruction Set Computer. �� - Risk Reduction Factor. 1/PFD ��232�, ��422, ��485 - Standard interfaces introduced by the Energy Industries

Association covering the electrical connection between data communication equipment. RS-232C is the most commonly used interface. RS-422 allows for high transmission rates over longer distances. �� - Remote Telemetry Unit �� - Sequential Function Chart. A IEC 61131-3 language that divides the process cycle

into a number of well-defined steps separated by transitions. �� - Safety Instrumented Function �� - Safety Integrity Level. One of four possible discrete levels for specifying the safety

integrity requirements of the safety functions to be allocated to the safety-related systems. SIL4 has the highest level of safety integrity; SIL1 has the lowest. �� - Safety Instrumented System Glossary

A2-7

��: One portion of a redundant system. �� - Sequence of Events �� (�� ) - Software specific to the user application. Generally, it

contains logic sequences, permissives, limits, expressions, etc. that control the appropriate input, output, calculations and decisions necessary to meet system safety functional requirements. �� - Structured Text. A high level IEC 61131-3 language with a syntax similar to Pascal.

Used mainly to implement complex procedures that cannot be expressed easily with graphical languages. �� - An empty hinged metal surround, designed to contain 483mm (19 inch)

standard equipment. �� - A data-communication term describing the method by which signals

between computers are timed. In synchronous communications, a prearranged number of bits is expected to be sent across a line per second. To synchronise the sending and receiving machines, a clocking signal is sent on the same line by the transmitting computer. There are no start or stop bits in synchronous communications. �� – The hardware platform on which virtual machines run resources of a project.

You download configurations onto a target. ��/�� - Transfer Control Protocol/Internet Protocol �� - Triple Modular Redundancy. �� - Technischer Überwachungs-Verein �� - Independent third party certification against a defined range of

International standards including DIN V VDE 0801, IEC 61508, IEC 801. � - Units of electronic module size (1¾ inches). �� - Uninteruptible Power Supply �� – (IsaVM.exe) The instantiation of a resource on a target. �� - Redundant system, e.g. m out of n, 1-oo-2, 2-oo-3 etc. which requires at

least m of the n channels to be in agreement before the system can take action.

A2-8


�� - Watchdog circuitry (timer) provides dynamic and/or static monitoring of

processor operation and is used to annunciate processor or processor related failures (such as an endless loop). �� - Watch Dog Timer

Glossary

A2-9


Appendix 3

Puzzles and Exercise

Purpose To review and reinforce the material.

Objectives


•

To remember the names of AADvance hardware and software components.

•

To be able to build a project from scratch.

A3-1

Hardware Crossword Puzzle for AADvance 1

2

3

4

6

7 9

5

8

10

11 12

13 14 15

16

17

18

19 20 21

www.CrosswordWeaver.com

ACROSS 1

DOWN

Power is distributed to the I/O modules through the ____ Units. 8 Fuses can be replaced without _____ a module. 9 A _____ base unit can support 16 I/O base units. 11 Simplex Termination Assemblies have ______ power. 12 Modules can be replaced _____ without system interruption. 13 The 8401 Digital Input Module accepts ____ inputs. 14 Base Units snap together using mating connectors and retaining ____. 16 Resources and programs are stored i n ____ memory. 18 Each module is designed as fail ____. 20 Module ______ prevents the wrong module from being inserted. 21 AADvance has been approved by ____

A3-2

2

To replace a module, you must use a _________. 3 A single processor module meets SIL ___ requirements. 4 The Processor Base Unit has a connection for the security _____. 5 AADvance can be panel or ___ rail mounted. 6 A _____ is used to help remove the coin-type battery from the processor. 7 An internal circuit is used to detect impending module ______. 10 Digital Output Modules have _____ current protection. 15 Analog Input Modules accept ____ signals. 17 Two Digital Output Modules provide a ____ circuit arrangement. 19 The maximum possible Expansion Cable length is ____ meters.


Software Crossword Puzzle for AADvance 1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

www.CrosswordWeaver.com

ACROSS 1

Programs may be ______ offline for testing. 3 Data is transferred between nodes using ____. 6 Internal variables cannot be ______. 8 _______ are groups of programs. 10 A POU is a set of ______ in logic. 12 ____ names for a function can be viewed in the dictionary. 13 Your project must be ______ before it can be simulated. 14 AADvance configurations can only run a single ______. 15 You must first link resources before ______ variables. 18 The Cross Reference Browser is divided into _____ sections. 19 I/O bus one (1) extends to the ____ of the processor. 20 On-line _____ can be done without stopping the current resource. 22 Boolean variables can be tagged for ___.


DOWN 1

You can only define bindings between variables of the _____ type. 2 The software components are sorted in a ____-like hierarchy. 4 Configurations communicate with each other through ______. 5 The opposite of a producing variable is a ________ variable. 6 _____ are not retained during a power loss. 7 You can view both logic and field values in the ________. 9 You can control access to resources using a _______. There are _____ classifications of faults. 11 The Project must be _____ out to make any changes. 16 Each ___ is a stand alone system with at least 1 processor & it's associated I/O. 17 Bindings are directional _____ between variables in different resources. 21 There are _____ programming languages available. A3-3

AADvance Programming Training Exercise

PSV 1001 o Flare

HH PI 1001

LI 1001 ESS

ESS SDC 1001 ESS

SDC 1003

HH ESS

SDV 1003

L LL

SDC 1002 SDV 1001

ESS

SDV 1002

PS 1001A

PS 1001B

PS 1001C

Gas To Injection Compression

LIT 1001

SDC 1004 ESS

SDV 1004

From Manifold

V-1000 High Pressure Separator

Oil To LP Separator SDC 1005 ESS

SDV 1005

Water To Hydrocyclone

Tag

Description

PI1001 HH

Separator High Pressure (2oo3)

LI1001 HH

Separator High Level

> 90%

LI 1001 L

Separator Low Level

< 50%

LI1001 LL

Separator Low Low Level

< 10%

A3-4

Setpoint

n o i t p i r c s e D

1 e v l a v t e l n I

2 e v l a v t e l n I

e v l a v s a G

e v e l v a l a v V r e l i t O a W

g a T

1 0 0 1 V D S

2 0 0 1 V D S

3 0 0 1 V D S

4 0 0 1 V D S

X

X

5 0 0 1 V D S

X X X


Notes: 1. Use the tag names shown in the P&ID (‘balloons’) for your actual I/O variable names. If you do not understand the P&ID, please ask your instructor for clarification. 2. Develop a function for two-out-of-three voting of the digital inputs. 3.

Use a 5 second time delay for all three level trips.

4. Test your project in the simulator before loading it into the controller. 5. If you have time, add a second configuration to your project with a digital input and output module. Create bindings between the configurations so that when the separator shuts down due to high pressure, an action takes place in the second configuration. Test this modified project in the simulator (as we do not have a second controller to use in class) and show it to your instructor.


A3-5


Appendix 4

Safety Manual Considerations

Purpose To summarize product specific safety issues related to system implementation.

Objectives •

To understand the product specific implementation issues in order for the system to comply with international functional safety standards.


A4-1

Please Read the Safety Manual! This appendix is intended primarily for system integrators. The information presented here is an abbreviated version of a more detailed safety manual (document # 553630). This information is intended to be used in conjunction with – and not as a substitute for – expertise and experience in safety-related systems. It is expected that the reader has a thorough understanding of the intended application, an understanding of the terms used within this manual, and the terminology specific to the integrator’s or project’s application area. It is assumed that the integrator is familiar with the IEC 61511 standard, the safety life cycle, and has a safety management system in place. This appendix does not summarize the standard (e.g., personnel must be competent), the life cycle (e.g., how to develop the safety requirements specification), nor does it describe a suitable safety management system. This appendix does not repeat topics covered elsewhere in this manual (e.g., install the modules vertically, consider the processor and I/O watchdog timer settings, etc.), or cover topics that apply to all safety systems (e.g., thoroughly test software, ensure against radio interference, etc.).

Rules vs. Recommendations The safety manual contains rules and recommendations. •

Rules are mandatory and must be followed if the

resulting system is to be SIL3 compliant. These are identified by the term ‘shall’. •

Recommendations are not mandatory, but if they are

not followed, extra safety precautions must be taken in order for the system to be compliant. Recommendations are identified by the term ‘it is highly recommended’ .

A4-2


High Demand, SIL 3 and Energize to Action Applications For high demand applications, a minimum of dual processors are required. For SIL3 applications, a minimum of dual processors are required. For de-energize to action (normally energized) operation, one digital output module is sufficient for SIL3 requirements. However, for energize to action operation, dual digital output modules are required.

Utilizing I/O Module Diagnostics Input Modules

The analog .cnt variable will be 0; the .pv variable will be calculated (scaled) based on a count of 0.

When an input channel is not capable of reporting a value within specification of the full scale measurement (1% for analog inputs, 4% for digital inputs) ‘safe’ values are reported by the variables (0 for analog, FALSE for digital).

Figure A4-1: I/O Structure Variables


A4-3

When the accuracy between channels in a redundant input module configuration exceeds limits (2% for analog inputs, 8% for digital inputs) then a discrepancy alarm (.dis variable) is set for the input channel. The discrepancy alarms shall be monitored for safety critical applications by an application program and used to provide an alarm to the plant operations personnel (so they may replace the module within the repair time assumed in performance calculations). All I/O modules include line-monitoring facilities. These facilities shall be utilized for normally de-energized I/O. Refer to the safety manual for recommended end of line resistor values and digital input voltage threshold value settings.

Figure A4-2: Digital Input Voltage Thresholds

A4-4


Digital Output Modules

The shut down state for digital outputs can be configured for the following settings: •

Off, de-energize (fail-safe, the default)

•

Hold last state

Careful consideration should be given to the affect on the process of using the ‘hold last state’ setting.

Figure A4-3: Digital Output Shutdown States


A4-5

The digital output module incorporates line test functionality that can report and indicate ‘no load’ field faults. This functionality can be enabled or disabled. The settings are: •

•

Yes - disables reporting and indication of ‘no load’ field faults No – ‘No load’ field faults are reported and indicated

Figure A4-4: Disabling Digital Output Testing

A4-6


Degraded Run Time Restrictions The maximum duration for single-channel operation of modules depends on the specific process and must be specified individually for each application. •

•

•

•

Input modules can operate in a simplex arrangement without time limit for SIL3 and lower applications. Output modules can operate in a simplex arrangement without time limit for SIL3 de-energize to action (normally energized) applications. Output modules can operate in a simplex arrangement without time limit for SIL2 energize to action applications, or for up to the MTTR when used in SIL3 energize to action applications. An application program must be designed to shut down energize to action SIL3 safety instrumented functions if a faulty output module has not been replaced within the MTTR. Processor modules can operate in a simplex arrangement without time limit for SIL2 applications, or for up to the MTTR when used in high demand mode applications, or for up to the MTTR when used in SIL3 applications. An application program must be designed to shut down the system if a faulty processor module has not been replaced within the MTTR.


A4-7

I/O Forcing The AADvance Workbench supports forcing of individual inputs and outputs. The Workbench uses the term ‘locking’ to describe forcing. Forcing requires the program enable key to be fitted to the 9100 Processor Base Unit. Forcing is intended only for the purposes of engineering, installation and commissioning activities. When the system is in-service, maintenance overrides for safetyrelated inputs and outputs should be implemented using an application program instead of forcing (e.g., external hard-wired switches connected to conventional system inputs). The Force LED on the front of the T9110 Processor Module indicates when one or more I/O points are forced. The application program can determine how many points are currently forced. It is highly recommended that this information be used to control an additional status display and/or for logging purposes.

Figure A4-5: Processor Integer Status Variables

A4-8


If the forcing facility is used when the system is in-service, a safety-related input connected to an operator accessible switch shall be implemented to initiate the removal of the force condition.

Figure A4-6: Processor Boolean Control Variables

In order to accommodate maintenance overrides safely, TÜV has documented a set of principles that shall be followed. These principles are published in the document "Maintenance Override" by TÜV Süddeutschland / TÜV Product Service GmbH and TÜV Rheinland.


A4-9

AADvance Comprehensive Training Manual (Rev 1.7 Oct 2012)

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