Read this document and the documents listed in the additional resources section about installation, configuration, and
operation of this equipment before you install, configure, operate, or maintain this product. Users are required to
familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws,
and standards.
Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are
required to be carried out by suitably trained personnel in accordance with applicable code of practice.
If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may
be impaired.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from
the use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or
liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or
software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation,
Inc., is prohibited
Throughout this manual, when necessary, we use notes to make you aware of safety and other considerations.
WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous
environment, which may lead to personal injury or death, property damage, or economic loss.
ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property
damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.
CAUTION: Identifies information about practices or circumstances that can cause property damage or economic loss.
IMPORTANTIdentifies information that is critical for successful application and understanding of the product.
NOTEProvides key information about the product or service.
TIPTips give helpful information about using or setting up the equipment.
2Rockwell Automation Publication ICSTT-RM447M-EN-P - July 2019
Page 3
Labels may also be on or inside the equipment to provide specific precautions.
SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous
voltage may be present.
BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may
reach dangerous temperatures.
ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to
potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL
Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).
Rockwell Automation Publication ICSTT-RM447M-EN-P - July 20193
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4Rockwell Automation Publication ICSTT-RM447M-EN-P - July 2019
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Summary of Changes
This manual contains new and updated information as indicated in the
following table.
IssueDateComments
01Dec 2008First Issue
02Feb 2009
03Feb 2010
04Mar 2010Updates after peer review
05June 2010updates for release 1.1.1
06Oct 2010updates to meet UL requirements
07Nov 2010updates for ATEX and UL Certification and release 1.2
08July 2012Release 1.3 version
09June 2013Changes to TUV certification topic, add on-line update feature and module
10July 2014Release 1.33 updates
11March 2015Release 1.34 updates
12June 2015Correct Issue Record
LApril 2018Release 1.40 updates.
MJuly 2019Updated for Release 1.34 IEC 61508 Edition 2.0 certification
specification data.
Summary of changes in this Document Issue
Top icPa ge
Updated release number in Preface to 1.347
Updated Performance and Electrical Specifications section.23
Added references to ATEX and IECEx UL certificates in the Literature Library27
Updated module label27
Updated SIL 2 Architectures section.63
Updated Certified Configurations section.72
Updated Example Architectures with Approved Modules section.73
Rockwell Automation Publication ICSTT-RM447M-EN-P - July 20195
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Summary of Changes
6Rockwell Automation Publication ICSTT-RM447M-EN-P - July 2019
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Preface
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 related to 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.
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 also refer to your own local (or supplied) system safety
manual, installation and operator/maintenance manuals.
REVISION AND UPDATING POLICY
This document is based on information available at the time of its publication.
The document contents are subject to change from time to time. The latest
versions of the manuals are available at the Rockwell Automation Literature
Library under "Product Information" information "Critical Process Control &
Safety Systems".
In the Product Search field enter "AADvance" and the AADvance® option is
displayed.
Double click on the AADvance option and the latest version is shown.
Select the latest version and download the latest version.
AADVANCE RELEASE
This technical manual applies to AADvance Release: 1.34.
Rockwell Automation Publication ICSTT-RM447M-EN-P - July 20197
Page 8
Preface
LATEST PRODUCT INFORMATION
For the latest information about this product review the Product Notifications
and Technical Notes issued by technical support. Product Notifications and
product support are available at the Rockwell Automation Support Center at
http://rockwellautomation.custhelp.com
At the Search Knowledgebase tab select the option "By Product" then scroll
down and select the ICS Triplex® product AADvance.
Some of the Answer ID’s in the Knowledge Base require a TechConnect
SM
Support Contract. For more information about TechConnect Support
Contract Access Level and Features, click on the following link:
This will get you to the login page where you must enter your login details.
IMPORTANTA login is required to access the link. If you do not have an account then you
can create one using the "Sign Up" link at the top right of the web page.
PURPOSE OF THIS MANUAL
The AADvance controller is a logic solver. It uses processor modules and I/O
modules. An AADvance system is formed by one or more controllers, their
power sources, communications networks and workstations.
This technical manual describes the features, performance and functionality of
the AADvance controller and systems. It sets out some guidelines on how to
make a system that fits your application requirements.
WHO SHOULD USE MANUAL
This manual is intended primarily for system designers and technical sales
people who need to understand the capabilities of an AADvance controller.
This manual will help you to design a satisfactory system.
The information contained in this manual is intended to be used in
conjunction with (and not as an alternative for) expertise and knowledge about
safety-related systems. It is expected that the reader has an in depth
understanding of the intended application and can understand the generic
terms used inside this manual and the terminology used in the integrator's or
project's application area.
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Preface
Environmental compliance
Rockwell Automation maintains current product environmental information
on its website at:
Rockwell Automation Publication ICSTT-RM447M-EN-P - July 201915
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Table of Contents
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The AADvance System
Chapter 1
Introduction
An AADvance system consists of an AADvance controller, an external
operator's workstation, field connections, power sources and external network
connections. The flexibility of the design means that a system can meet a wide
variety of business needs. An AADvance system is assembled to a scale and
configuration that is applicable to your initial requirements and can be easily
changed to meet your changing business requirements in the future. A system is
built from an approved range of modules and assemblies.
This chapter introduces the primary components that can be used to assemble
an AADvance controller.
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Chapter 1The AADvance System
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Chapter 2
The AADvance Safety Controller
The AADvance controller is specifically designed for functional safety and
critical control applications; it gives a flexible solution for smaller scale
requirements. The system can also be used for safety implemented functions as
well as applications that are not related to safety but are nevertheless critical to
a business process. This AADvance controller offers the ability to make a costeffective system to a customer's specification for any of the following
applications:
• Emergency shutdown system
• Fire and gas installation protection system
• Critical process control
• Burner management
• Boiler and furnace control
• Distributed process monitoring and control
• Turbo-machinery governor control and over-speed protection (not yet
released)
An AADvance controller is particularly useful for emergency shut down and
fire and gas detection protection applications as it offers a system solution with
integrated and distributed fault tolerance. It is designed and validated to
international standards and is certified by independent certifying bodies for
functional safety control installations and UL for use in hazardous
environments.
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Chapter 2The AADvance Safety Controller
A controller is built from a range of compact plug-in modules (see illustration)
that are straightforward to assemble into a system. A system can have just one
or more controllers, a combination of I/O modules, power sources,
communications networks and user workstations. It can operate as a standalone system or as a distributed node of a larger control system.
NOTEThe printed circuit boards of all AADvance modules, termina-
tion assemblies and backplanes are coated during manufacture.
The coating meets defense and aerospace requirements, is approved to US MIL-1-46058C standard and meets IPC-CC-830.
The coating is also UL approved.
A Key benefit of the AADvance system is its flexibility. All of the
configurations are readily achieved by combining modules and assemblies
without using special cables or interface units. System architectures are user
configurable and can be changed without major system modifications.
I/O redundancy is configurable so you can make a decision between fail safe
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The AADvance Safety ControllerChapter 2
and fault tolerant solutions. There is no change to the complexity of operations
or programming that the controller can handle if you add redundant capacity
to create a fault tolerant solution.
They can be mounted onto DIN rails in a cabinet or directly mounted onto a
wall in a control room. Forced air cooling or special environmental control
equipment is not necessary. However, important consideration must be given
to the choice of cabinet or when the controller is installed in a hazardous
environment.
Specific guidelines are given in this user documentation to help you choose an
enclosure that will make sure that the system operates to its full capability and
reliability and that it also complies with the ATEX and UL certification
requirements for use in hazardous environments.
The Ethernet and serial ports are configurable for a number of protocols in
both simplex and redundant configurations for connection to other
AADvance controllers or external third party equipment. Communications
internally between the processors and I/O modules uses a proprietary
communications protocol over a custom wired harness. The AADvance system
supports transport layer communication protocols such as TCP and UDP for
MODBUS, CIP, IXL, Telnet and SNTP services.
A secure network communications protocol (SNCP), developed by Rockwell
Automation for the AADvance system, permits distributed control and safety
using new or existing network infrastructure while ensuring the security and
integrity of the data. Individual sensors and actuators can connect to a local
controller, minimizing the lengths of dedicated field cabling. There is no need
for a large central equipment room; rather, the complete distributed system can
be administered from one or more PC workstations placed at convenient
locations.
The AADvance controller is developed and built for IEC 61131 compliance
and includes support for all five programming languages. (Instruction List (IL)
and Sequential Function Chart (SFC) languages are not supported by
AADvance® Workbench 2.0). Program access is secured by a "Program Enable"
key that you can remove. Simulation software lets you prove a new application
before reprogramming and downloading, again maximizing system uptime.
Additional security functions are also included to help prevent unauthorized
access.
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Chapter 2The AADvance Safety Controller
Safety Features
The AADvance controller meets non-safety business requirements and SIL 2
and SIL 3 safety related system requirements. The system has comprehensive
built-in redundant capabilities that improve system availability.
The AADvance safety system features are:
• Easily transformed from a simplex non-safety system to a fault tolerant
safety related system.
• An AADvance platform provides a set of components that can be
configured to meet a range of safety and fault tolerance user
requirements within a single system such as - fault tolerant topologies
1oo1, 1oo2D and 2oo3.
• IEC 61508 certified, reviewed and approved for safety systems up to SIL
3 by independent certifying bodies.
• The scalable characteristics of the system enables independent safety
functions within the same system to be configured with different
architectures to meet a user specific safety and availability requirements.
• The main components that provide the safety architecture are the
processor and I/O modules; the remaining components provide secure
external interfaces and connectivity between the field elements and the
main components and add to the safety functionality.
• AADvance processor modules are designed to meet the requirements
for SIL 2 and SIL 3 in a dual or triplicated configuration.
• Individual input modules are designed to meet the requirements for SIL
3 in simplex, dual or triple configurations.
• Individual output modules have been designed to meet the requirements
for SIL 3 in a simplex or dual configurations.
• Safe SIL 3 rated 'Black Channel' external communication over Ethernet.
Safety Configurations
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An AADvance system supports the following safety configurations:
Fai l-saf e
I/O modules fail-safe in the most basic simplex system.
SIL 2
SIL 2 architectures for fail-safe low demand applications. All SIL 2
architectures can be used for energize or de-energize to trip applications.
• SIL 2 low demand architectures
• SIL 2 fail safe architectures
• SIL 2 fault tolerant input architectures
• SIL 2 triplicated input architectures
• SIL 2 fault tolerant output architectures
• SIL 2 fault tolerant input/output architectures
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The AADvance Safety ControllerChapter 2
SIL 3
SIL 3 architectures:
• SIL 3 de-energize to trip applications.
• SIL 3 energize to action applications when fitted with dual digital
output modules.
• SIL 3 simplex or dual output module architectures
• SIL 3 fail safe I/O fault tolerant processor architecture
• SIL 3 fault tolerant architecture
• SIL 3 fault tolerant simplex, dual and triple input architectures
• SIL 3 dual or triple processor architectures
• SIL 3 high demand applications where the required safe state is greater
than 4 mA, when fitted with dual analogue output modules (A ‘safe
state’ is an output configured to go to a specific value, or configured to
hold last state)
Performance and Electrical
Specifications
Table 1 - Controller Performance and Electrical Specifications
AttributeValue
Performance Characteristics
Safety Integrity LevelIEC 61508 SIL 2
Safety level Degradation1oo1D, 1oo2D, 2oo3D
Processor Modules supportedThree
I/O Modules supported48 (8 or 16 channels modules)
Safety Accuracy Limit:
Digital inputs
Analogue inputs
Sequence of Event Resolution
Processor Module (for internal Variables):
Event Resolution
Time Stamp Accuracy
Digital Input Module:
Event Resolution
Time Stamp Accuracy
Electrical Characteristics
Supply voltageRedundant 24 Vdc nominal, 18 Vdc to 32 Vdc range
IEC 61508 SIL 3
(depending on processor and I/O module configuration)
(1)
1.0 Vdc
200 μA
1 ms
Application Scan
1 ms
10 ms
Channel isolation (channel to channel and channel to
chassis
Maximum withstanding
(1) When a controller's processor modules have degraded to 1oo1D, the system must be restored to at least 1oo2D by replacing the
faulty processor module(s) within the MTTR assumed in the PFD calculations; also, unless compensating measures are defined in
the Safety Requirements Specification (SRS) and documented in operating procedures, the application program must be designed
to shut down safety instrumented functions if a module failure due to dangerous fault has not been replaced within the MTTR.
Rockwell Automation Publication ICSTT-RM447M-EN-P - July 201923
± 1.5 kVdc withstand for 1 minute.
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Chapter 2The AADvance Safety Controller
IMPORTANTOverall system power consumption, heat dissipation and weight can be
estimated using the values given in the heat dissipation and weight data
tables shown in this manual.
Scan Times
The controller processing scan times listed in the table are taken from a test
system which used only production modules. The tests which were used to
measure the scan times did not measure the effects of logic complexity and
communications loading.
Table 2 - Typical Module Scan Times
ModuleScan
9402Digital input module, 24 Vdc, 16 channel
9432Analogue input module 24 Vdc, 16 channel
9451Digital output module, 24 Vdc, 8 channel
9482Analogue output module, 24 Vdc, 8 channel
Simplex
Dual
Tri pl e
Simplex
Dual
Tri pl e
Simplex
Dual
Simplex
Dual
Minimum cycle time overhead
Scan overhead for each module0.04 ms
1
0.924 ms
1.676 ms
2.453 ms
1.170 ms
1.965 ms
2.656 ms
1.174 ms
2.202 ms
0.981 ms
1.761 ms
39.3 ms
1
The minimum overhead to the cycle time is a feature of the AADvance
Wo r k b e n c h .
The scan time is:
Scan time = 39.3 ms
+ Sync time
+ Total number of modules * 0.04 ms
+ Σ (Number of module groups x scan time shown above)
Where:
Sync time is a function of the total number of modules defined
according to the following table:
0..10 modules 20 ms
11..20 modules 22 ms
21..30 modules 24 ms
31..40 modules 27 ms
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The AADvance Safety ControllerChapter 2
41..48 modules 32 ms.
Though the average scan time will be within 1 ms of the scan time calculated
above the calculation does not take into account the effects of application logic
and network communication, and individual scans can vary by up to +/- 4 ms
around the average scan time.
Throughput time is the time from input change to output action. For
asynchronous inputs the throughput times can be derived from the Scan time
calculated above according to the following formulae:
• Minimum throughput time = Scan period + 7 ms
• Maximum throughput time = 2 x Scan time + 13 ms
An example configuration scan time:
System configuration includes T9432 Analogue input simplex modules x 30
and T9451 Digital output simplex modules x 18.
Total I/O modules = 48
Environmental Specification
Sync time = 32 ms
Scan time = 39.3 ms + 32 ms + (48 x 0.04) ms + (30 x 1.170) ms + (18 x
1.174) ms => 129.5 ms
Minimum throughput time = 129.5 ms + 7 ms => 136.5 ms
Maximum throughput time = (2 x 129.5) ms + 13 ms = 272.0 ms.
An AADvance system can be installed in a non-hazardous or a hazardous
environment. In a non-hazardous environment a system does not have to be
installed in an enclosure; however, the area where it is installed must maintain a
Pollution Degree 2 environment (IEC 60664-1).
The following environmental specification defines the minimum
environmental conditions for an AADvance controller installation. Additional
conditions apply to systems installed in a Hazardous environment.
Table 3 - Environmental Specification
AttributesValue
Operating Temperature Range:
For use in Hazardous Environments:
Processor Modules
I/O Modules and Termination Assemblies
For use in Non-hazardous Environments:
Processor Modules, I/O modules and Termination
Assemblies
Storage and Transport Temperature Range–40 °C to +70 °C (–40 °F to +158 °F)
Module Surface Temperature (during usual operation)43° C (109 °F) ± 2 °C
Humidity
–25 °C to +60 °C (–13 °F to +140 °F)
–25 °C to +70 °C (–13 °F to +158 °F)
–25 °C to +70 °C (–13 °F to +158 °F)
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Chapter 2The AADvance Safety Controller
AttributesValue
Operating10 % to 95 % RH, non-condensing
Storage and Transport10 % to 95 % RH, non-condensing
Vibration
Functional Stress5 Hz to 9 Hz
Continuous1.7 mm amplitude
Occasional 3.5 mm amplitude
Withstand10 Hz to 150 Hz
Acceleration0.1 g in 3 axes
Endurance10 Hz to 150 Hz
Acceleration0.5 g in 3 axes
Shock15 g peak, 11 ms duration, ½ sine
Altitude
Operating0 to 2,000 m (0 to 6,600 ft.)
Storage and Transport0 to 3,000 m (0 to 10,000 ft.)
This equipment must not be transported in
unpressurized aircraft flown above 10,000 ft.
Electromagnetic InterferenceTested to the following standards: EN 61326-1:2006,
Class A; EN 61326-3-1:2008, EN 54-4: 1997, A1; EN
61131-2:2007; EN 62061:2005.
Hazardous Location CapabilitySuitable for Class I Div 2 Groups A, B, C and D
1
There is no specific protection against liquids.
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The AADvance Safety ControllerChapter 2
Certifications for Safety
System Applications in
Hazardous Environments
Module Label
ATEX Certificate
Refer to AADvance Series T9000 Programmable Control and Safety System ATEX certificate, publication 9000-CT003
.
IECEx UL Certificate
Refer to AADvance Series T9000 Programmable Control and Safety System IECEx certificate, publication 9000-CT006
The following label information must be attached to each module.
.
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Chapter 2The AADvance Safety Controller
KCC-EMC Registration
Main Components
Physical Features
An AADvance controller is built from durable processor and I/O modules and
assemblies designed to IEC 61508 standards for safety systems and runs the
AADvance Workstation software. Field devices connect direct to a controller
and external communication links over Ethernet and serial links use a secure
protocol.
A new and innovative style characteristic of the AADvance controller is the
design of the hardware. All the modules and assemblies connect together easily
without the need for inter-module wiring.
CAUTION: The controller contains static sensitive
components. When the controller is installed attach a label
that is clearly visible to tell operators to follow anti-static
precautions when they touch or move modules. Failure to
follow these instructions can result in damage to the
equipment.
Compact Module Design
Each processor and I/O module has a flame-retardant and impact-resistant
plastic cover. The cover is designed to help ventilation and heat dissipation
occur naturally without the need for fan assisted cooling. Processor and I/O
modules fit onto standardized base units. Base units plug together by side
connectors and are securely held in position by specially designed plastic clips
which cannot corrode or seize up. Modules are retained by a locking screw
which is easy to access from the front.
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Figure 1 - An AADvance Module
The AADvance Safety ControllerChapter 2
NOTEStandard AADvance modules have a plastic casing and are rated IP20:
Protected against solid objects over 12 mm (1/2 in.) for example "fingers".
There is no specific protection against liquids.
Module Polarization Keying
For each I/O Module there is a matched termination assembly. The
controller incorporates module polarization keying to make sure that they
are correctly mated when installed. Sockets on the rear end plate align and
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Chapter 2The AADvance Safety Controller
mate with coding pins found on the termination assembly. The alignment
of the sockets and pins make sure that only the matched I/O modules and
termination assemblies can be mated.
Figure 2 - Coding Sockets
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Module Locking Mechanism
Figure 3 - Locking Screw
The AADvance Safety ControllerChapter 2
Each module carries a locking mechanism, which secures the module onto its
base unit. The locking mechanism is in the form of a clamp screw, which can be
seen on the front panel of the module and engaged by a quarter turn of a flat
blade screwdriver. The module senses the locking mechanism position and
notifies the controller accordingly. This acts as an interlock device and helps
prevent the module from going on-line when it is not in the locked position.
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Chapter 2The AADvance Safety Controller
Processor Base Unit
A processor base unit holds up to three processor modules:
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The AADvance Safety ControllerChapter 2
External Ethernet, Serial Data and Power Connections
The processor base unit external connections are:
•Earthing Stud
• Ethernet Ports (E1-1 to E3-2)
• Serial Ports (S1-1 to S3-2)
• Redundant +24 Vdc powers supply (PWR-1 and PWR-2)
• Program Enable security key (KEY)
• The FLT connector (currently not used).
Figure 4 - External Connectors on the Processor Base Unit
The power connections supply all three modules with redundant power, each
processor module each have two Serial ports and two Ethernet port
connectors. The KEY connector supports all three processor modules and
helps prevent access to the application unless the Program Enable key is
inserted.
Serial Communications Ports
The serial ports (S1-1 and S1-2; S2-1 and S2-2; S3-1 and S3-2) support the
following signal modes depending on use:
• RS485fd: A four-wire full duplex connection that features different
busses for transmit and receive. This selection must also be used when
the controller is acting as a MODBUS master using the optional fourwire definition specified in Section 3.3.3 of the MODBUS-over-serial
standard.
• RS485fdmux: A four-wire full-duplex connection with tri-state outputs
on the transmit connections. This must be used when the controller is
acting as a MODBUS Slave on a four-wire bus.
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Chapter 2The AADvance Safety Controller
• RS485hdmux: A two-wire half duplex connection applicable for master
slave or slave use. This is shown in the MODBUS-over-serial standard.
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The AADvance Safety ControllerChapter 2
I/O Base Unit
An I/O base unit holds up to three I/O modules:
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Chapter 2The AADvance Safety Controller
Termination Assemblies
The AADvance system provides a range of termination assemblies to connect
field wiring to the I/O modules. A termination assembly is a printed circuit
equipped with screw terminal blocks for the field wiring (and in some cases
fuses) and connectors for the plug-in I/O modules. Termination assemblies
give the system designer flexibility when configuring redundant and fault
tolerant systems.
Termination assemblies come in three types: simplex, dual or triple to
accommodate one two or three I/O modules. Each termination assembly
provides connections for up to 16 channels but can accommodate 8 or 16
channel modules.
The version illustrated is a simplex termination assembly for a digital input
module. The field wiring connectors are located to the left, the fuses have a
cover (shown open) and the module sockets are to the right. Each fuse cover
has a label that identifies the fuse numbers.
Figure 5 - Single Termination Assembly
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Figure 6 - Top View
The AADvance Safety ControllerChapter 2
T9892 Digital Output Termination Assembly
The T9892 Terminal Assembly module operates in conjunction with the
T9451 Digital Output Module and provides 8 dual configuration output
channels. It shares the same pin-out as the standard AADvance T9852 Digital
Output Terminal Assembly and has the same coding peg configuration. The
difference is that the T9892 has a separate connector for the field power input
voltage connections (the left most terminal block shown below). It also has
additional fusing to give extra protection against field faults.
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Chapter 2The AADvance Safety Controller
Figure 7 - T9892 Dual Termination Assembly
Field Wiring
Field device wiring connections are made to industry-standard screw terminal
blocks on the termination assemblies. Terminals are easy to access without
needing to dismantle assemblies. The specification for the field wiring sizes is
given in the topic "Power and External Connector Wiring Requirements".
This illustration shows field wiring connections at the termination assemblies.
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Figure 8 - Field Wiring Connections
The AADvance Safety ControllerChapter 2
NOTEThe recommended torque for termination assembly screw connectors is 5
Nm.
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Chapter 2The AADvance Safety Controller
Product Dimensions
A typical controller arrangement is shown with processor modules installed on
the processor base unit and an I/O base unit mated with the processor base
unit. I/O modules are installed on the base unit and a termination assembly
plugged into the I/O base unit.
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The AADvance Safety ControllerChapter 2
Table 4 - Summary of Dimensions
AttributeValue
Base unit dimensions (H × W × D), approx.233 mm × 126 mm × 18 mm (see text)
Module dimensions (H × W × D), approx.166 mm × 42 mm × 118 mm
(9-¼ in. × 5 in. × ¾ in.)
(6-½ in. × 1-⅝ in. × 4-⅝ in.)
The depth of the base unit (18 mm) excludes the parts of the backplane
connectors that mate inside the module connectors. Adding the depth of a
module (118 mm) to the depth of the base unit gives the overall depth of the
controller assembly at 136 mm.
Module Dimensions
All modules have the same dimensions.
Figure 9 - Module Dimensions
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Corrective Maintenance and Module Replacement
Scheduled maintenance consists of checking the I/O Module calibrations and
proof tests. Detailed scheduled and corrective maintenance information is
given in the AADvance Troubleshooting and Maintenance Manual Doc No:
ICSTT-RM406. Corrective maintenance is by module replacement and where
required fuse replacement in Termination Assemblies. In dual and triple
modular redundant configurations, you can remove a module and install a new
one without interrupting the system operation. In simplex configurations
removing a module will interrupt the system operation. However, certain
restrictions apply on module replacement timing for Safety Related systems
(see the AADvance Safety Manual - ICSTT-RM446 for guidance).
Field connection wiring is attached at the connectors on the termination
assemblies. Ethernet and Serial data connections are made at the T9100
Processor Base Unit. There are no physical links needed to be set up on any
modules or base units. Standard modules are used for all the different
configurations.
IMPORTANTProcessor modules must be replaced with a module containing
the same firmware revision, you cannot use processor modules
with different firmware revisions on the same controller.
Processor Back-up Battery
The 9110 processor module has a back-up battery that powers its internal Real
Time Clock (RTC) and a part of the volatile memory (RAM). The battery
only supplies power when the processor module is no longer powered from the
system power supplies. The specific functions that the battery maintains on
complete loss of power are:
• Real Time Clock - The battery supplies power to the RTC chip itself.
• Retained Variables - Data for retained variables is stored at the end of
each application scan in a portion of RAM, backed up by the battery. On
restoration of power' the retained data is loaded back into the variables
assigned as retained variables for use by the application.
• Diagnostic logs - The processor diagnostic logs are stored in the portion
of RAM backed by the battery.
The battery has a design life of 10 years when the processor module is
continually powered; for processor modules that are un-powered, the design
life is up to 6 months. Battery design life is based on operating at a constant
25°C and low humidity. High humidity, temperature and frequent power
cycles will shorten the operational life of the battery.
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Low Battery Alarm
A variable is available in the Workbench that can be set up and report the
battery status. It will give an alarm and set a warning light on the processor
front panel when the battery voltage is low.
Disabling the Low Battery Alarm
For applications that do not require Real Time Clock functionality, or there
are specific constraints, for example, the controller is in an inaccessible
location, that make it necessary to remove the battery when the system is
installed and set up, the battery failure alarm can be disabled at the Workbench.
Battery Location
The battery is supplied separately and inserted into a slot behind a removable
cover on the front panel of the processor module. The battery position is
shown in the illustration:
CAUTION: The battery may explode if mistreated. Do not recharge,
disassemble or dispose of in a fire.
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Battery Specification
A Polycarbon monofluoride Lithium Coin Battery with a nominal voltage of
3V; Nominal capacity (mAh) 190; Continuous standard load (mA) 0.03;
Operating temperature range -30ºC to +80ºC, manufactured by Panasonic.
Expansion Cable
This is used to add extra rows of I/O base units and modules.
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Technical Features
TUV Approved Operating System
The AADvance system runs an IEC 61508 approved operating system and the
overall system is certified to IEC 61508, Part 1-7: 1998 - 2000 SIL 3.
Internal Diagnostics and Fault Reset
The AADvance controller contains comprehensive internal diagnostic systems
to identify faults that occur during operation and trigger warnings and status
indications. The diagnostic systems run automatically and test the system for
faults related to the controller, and field faults related to field I/O circuits.
Serious problems are reported immediately, but faults that are not on noncritical items are filtered to help prevent spurious alarms. The diagnostic
systems monitor such items at regular times, and need a number of occurrences
of a possible fault before reporting it as a problem.
The diagnostic systems use simple LED status indications to report a problem.
The LED indications identify the module and can also identify the channel
where the fault has occurred. There is also a summary system healthy
indication for all of the controller. The application software uses its variable
structures to report a fault problem; these variables give status reports and are
configured using the AADvance Workbench.
Faults in the processor modules are none latching. The controller will recover
automatically and the fault indication will clear once the fault condition has
been removed. Faults in the I/O modules are latched. To clear them a fault
reset signal is sent from the processor module by pressing the Fault Reset
button on the processor module front panel. Field faults are not latched and
will clear as soon as the field fault is repaired.
When the Fault Reset button on each processor module is pressed it attempts
to clear a fault indication immediately, however, the diagnostic systems will
report a serious problem again so quickly there will be no visible change in the
fault status indications.
Remote Fault Reset
Using the Workbench software you can set up a fault reset variable to mimic
pressing the Fault Reset button on the front panel. This feature is provided for
systems located in inaccessible locations. Refer to the AADvance
Configuration Guide Doc No: ICSTT-RM458 for Workbench 2.x; regarding
instructions on how to set up the variable.
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Controller Internal Bus Structure
Internal communication between the processor modules and I/O modules is
supported by command and response busses that are routed across the
processor and I/O base units.
The processor modules acts like a communications master, sending commands
to its I/O modules and processing their returned responses. The two command
busses I/O Bus 1 and I/O Bus 2 take the commands from the processor to the
I/O modules on a multi-drop basis. An inter-processor link (IPL) supplies the
communication links between dual or triple processor modules.
Each I/O module has a dedicated response line which returns to the processor.
The unique response line for each I/O module supplies an unambiguous
identification of the source of the I/O data and assists with fault containment.
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On-line updates I/O Configuration Changes
The AADvance controller modular design makes it easy to create and change
the I/O configuration. The on-line update facility enables you to make changes
to the I/O configuration after the system is commissioned.
An on-line update can be used for the following changes.
• Expand a system and add new I/O modules, base units and termination
assemblies.
• Change the module type in a simplex or group arrangement.
• Expand a simplex or group arrangement.
• Downgrade a group arrangement.
• Move a module to a different slot.
• Change an application variable.
You only have to plug an additional I/O base unit into the side socket on an
installed I/O base unit. The command busses on the I/O base units do not
need different terminations on the open ends of transmission lines, and the
data response busses and power sources are supplied across all I/O base units.
Termination assemblies are pushed into the I/O base unit for the additional I/
O modules. To put the new modules on-line and make the changes to the
system fully operational, the hardware configuration in the AADvance
Workbench software must be updated by an on-line update.
IMPORTANTFor Release 1.3 you can change the I/O module configuration with an on-line
update. However, if you are using an earlier product release the I/O
configuration cannot be changed with an on-line update.
IMPORTANTAn on-line update could affect the operation of the controller such that the
application is stopped or the I/O data flow is interrupted. The AADvance
Safety Manual outlines the precautions you need to follow when doing online updates on a Safety System.
When there is not sufficient space for extra I/O base units on a row you can use
the Expansion Cable to connect a new row of I/O base units and modules to
further expand the I/O system.
Hot Swap I/O for Business Critical Channels
You can add a "hot swap" capability for business critical data channels. By
installing a single I/O module into a dual TA. When a dual TA is configured
you are leaving an empty spare slot for a replacement I/O module when a fault
occurs. You can insert a new I/O module into the spare slot and restore a failed
channel without interrupting the operation of the other channels.
TIPConfigure this "hot swap" arrangement when you configure your system at
installation and set up time.
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Processor Firmware Upgrades
You can check the firmware revision of you processor modules without
removing them to read the label and you can upgrade the firmware revision of
the processor modules. Upgrading the firmware in the 9110 processor module
is done in the Recovery Mode and is a two-stage process:
• Stage 1: Run the latest version of 350720_xxx_ControlFLASH.msi
program to install the ControlFLASH™ firmware upgrade kit for the
Recovery Mode on your PC. Then run the ControlFLASH utility to
upgrade your processor module and install the Recovery Mode. If your
module is delivered with the Recovery Mode installed then this stage is
not necessary.
Stage 1 must be performed individually on each processor; it does not
matter if you download the Recovery Mode one at a time in a specific
slot or in their own slots.
• Stage 2: Reboot the processor and press and hold the Fault Reset button
to enter the Recovery Mode. Then run the latest version of
354400_xxxx_ControlFLASH.msi program to install the
ControlFLASH to upgrade your processor's OS, FPGA, LSP and
BUSP.
When stage 1 is completed ControlFLASH can be used to upgrade
three processor modules in the same processor base unit all at the same
time.
NOTEDetailed information and procedures on firmware revision are given in the
AADvance Configuration Guide Doc No: ICSTT-RM405 and AADvance
Configuration Guide Doc No: ICSTT-RM458 for Workbench 2.0.
Tools and Resources
You will need the ControlFLASH firmware upgrade kit.
• Quick Start and RSLinx Classic Lite software or better.
• ControlFLASH programming tool, along with its required support
drivers and on line HELP.
• Firmware for the processor modules being upgraded.
Ethernet Communication Protocols
AADvance Ethernet ports are used to support several transport layer services;
these services are listed in the following table:
ProtocolPort NumberPurpose
TCP502MODBUS Slave
TCP1132ISaGRAF, application downloads, debug, SoE
TCP10001-10006Transparent Communication Interface (Serial Tunnelling)
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ProtocolPort NumberPurpose
TCP4818CIP™ Produce & Consume
TCPN/ATelnet (diagnostic Interface)
UDP1123,1124IXL Bindings
UDP2010Discovery and configuration Protocol
UDP2222CIP Produce & Consume I/O
UDP5000Trusted® peer-to-peer
UDP44818CIP Produce & Consume
The AADvance Workbench
and Software Development
Environment
The AADvance software lets you design one complete control strategy, and
then target parts of the strategy to individual controllers. Interaction between
the resources is automatic, significantly reducing the complexity of
configuration in a multi-resource system. Programs can be simulated and tested
on the workstation computer before downloading to the controller.
The workstation software is compliant with the IEC-61131 industrial
standard and has several powerful features:
• the regulation of the flow of control decisions for an interacting
distributed control system
• providing for the consistency of data
• providing a means for synchronous operation between devices
• mitigating the need to have separate synchronous schemes
• easing the development and maintenance of robust systems
The Workbench is a software development environment for a controller. It lets
you create local and distributed control applications using the five languages of
IEC 61131-3. (Instruction List (IL) and Sequential Function Chart (SFC)
languages are not supported by AADvance Workbench 2.0). Engineers can use
one language or a combination that best suits their knowledge and
programming style and the type of application.
The Workbench is a secure development environment. There is also a Program
Enable key that must be plugged into the processor base unit to allow the user
to modify and download the application resource or access the AADvance
Discover tool to set or change the controller IP address. The Program Enable
Key when it is removed protects the application from unauthorized access.
The development environment includes:
• tools for program development
•program documentation
•function block library management
• application archiving
• database configuration
• import/export utilities
• on-line monitoring
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• off-line simulation and controlled on-line changes
• Programs can be simulated and tested on the computer before
downloading to the controller hardware. Also supplied are a set of
configuration tools that enables you to define the hardware architecture
in the software; set up the processor functionality; and connect
application variables to the Workbench application resource program
that will monitor processor and I/O module status information and
report I/O channel data values to the Workbench. Resource Control
applications can be distributed across several hardware platforms,
communicating with each other through secure networks.
Operating Systems (32 or 64 bit)
The minimum workstation requirements for the application development
software are as follows:
• Microsoft® Windows XP Service Pack 3
CAUTION: Do not use XP Professional x64 Edition.
•Windows Vista
•Windows 7
• Microsoft Windows Server 2003
• Microsoft Windows Server 2008
IMPORTANTFor Workbench 1.3 Network Licensing - Windows 64-bit version will only
work with the USB license key and will not recognize a Workbench software
license key.
Hardware :
•1.6 GHz CPU
• 1 GB RAM (32-bit) or 2 GB RAM (64-bit) (add 512 MB if running in
a virtual machine)
• DirectX 9 capable video card running at 1024 x 768 resolution display
• 5,400 RPM hard disk
• 3 GB available hard disk space
• DVD drive or network connection, to read software distribution files
NOTEIf the application is Workbench 1.3 and adopts the USB dongle licensing
option the workstation PC will require one free USB port.
• Network port (10/100 Base T Ethernet), for communications with the
controller
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It is recommended that the PC has a 2.2 GHz or higher CPU; 1,024 MB or
more RAM, a 1,280 x 1,024 display and a 7,200 RPM or higher hard disk.
It is also recommended that the hard disk has at least 10 GB free space. This
provides sufficient space to hold the distribution zip file, the unzipped source
files and the installed program files, and also enough space for Windows to
operate reasonably quickly. You can get back a lot of this space by deleting the
source files after finishing the installation.
Importing and Exporting Data
The AADvance Workbench can import and export existing data in standard
file formats such as Microsoft Excel.
AADvance Workbench Licensing
The AADvance Workbench is licensed software. There are three types of
license: full, single controller and demo.
• The single controller license is applicable for applications which use only
one controller. The software features which add a second or subsequent
controller to the project are disabled, and you cannot open an existing
project which uses more than one controller.
• The full license supplies all of the features of the AADvance
Workbench. It is applicable for applications with one or more
controllers.
• The demo license is a like a full license, but with a time limit. You can use
all of the features of the AADvance Workbench for up to 30 days after
first running the AADvance Workbench is first run.
A demo license is supplied free of charge for a first installation on a computer.
You change the demo license to a single controller license or a full license by
purchasing an unlock code from Rockwell Automation, and entering the code
into the software. When you use the demo license, the AADvance Workbench
displays a Demo License window each time you try to open a project. The
window includes the contact details at Rockwell Automation required for
purchasing a license.
If you try to use the demo license for more than 30 days, the license expires. You
cannot open a project or create a new one until you purchase a license.
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Chapter 3
Controller Functionality
This chapter describes the controller functions that give you the flexibility to
create a system to meet your specific business needs.
Field Data Handling
Process Safety Time
The AADvance controller is a logic solver and I/O processing device. The field
data and field element control commands are routed across the field wiring to
the termination assemblies which are uniquely matched to their respective I/O
modules. An internal bus structure and a secure communication protocol
transport the data and command signals to and from the processing software.
The processor has a SIL 3 rated operating system and runs user developed
applications to analyze and respond to the field data and produce the necessary
field commands and user information. These application programs, developed
by the user to meet their safety and business requirements are downloaded
from a Workstation that has the AADvance Workbench application
development software installed. A security device on the processor backplane
helps prevent unauthorized access to the application software.
The Process Safety Time (PST) setting defines the maximum time that the
processor will let the outputs stay in the ON state if certain internal diagnostic
faults or systematic application faults occur. If the process safety time expires
the controller will go to its "safe state". The PST must be specified for the whole
controller, this is a top level setting that you make once for the whole controller
and is set at the processor module. I/O modules can be set at a lower PST but
must not go over this overall setting.
An AADvance controller adopts a default value for the PST = 2500 ms which
can be adjusted to meet your system requirements by using the following
simple equation:
where PSTeuc is the process safety time for the equipment under control.
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SNTP
CIP and its Producer and
Consumer Variables
The AADvance controller supports the 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.
SNTP clients 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.
An AADvance controller can also fulfill the role of one or more SNTP servers
(one for each processor) to supply a network time signal throughout the
network. To enable server time on an interface it is necessary to give the direct
broadcast address for that interface. This works for broadcast or unicast modes.
This way of configuring is derived from the NTP configuration command
language.
You can configure CIP produce and consume variables for an AADvance
controller.
One or more controller Ethernet ports may be used for CIP communications
so long as they are on separate subnets.
Consideration must be given to the number and mix of produce/consume
variables being used.
Each CIP consumer variable identifies the ControlLogix® controller and the
tag produced by that controller, which provides a value to be consumed.
The AADvance controller sets its consumer variables to the most recent
received value at the start of its application scan, before executing the logic.
The controller updates its producer variables at the end of its application scan,
after executing the logic. The AADvance controller uses the most recent value
of a producer variable when sending a packet.
You cannot define a default value for a consumer variable. If the connection
fails (typically because the communications link fails), the most recently
received value of the consumer variable is retained. The maximum size of a CIP
variable is 500 bytes.
If the variable is a structure having a mixture of element types, then each
element starts on a new byte or word depending on its size. For example, a
DINT following a single bit BOOL will start on a new 4 byte boundary.
Also:
•A LINT Must ALWAYS
• Any UDT that contains a LINT must ALWAYS
divisible by 8 bytes
align on a 64 bit (8byte) boundary.
be of a size that is
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.
IMPORTANTOnly use CIP produce/consume between AADvance and ControlLogix
Controllers. For data being exchanged between AADvance Controllers use
bindings and SNCP network.
For produce/consume with status the producing/consuming UDTs must be
identical. This means that not only must elements of the UDT be of the same
type but the UDT name itself must be identical in both controllers.
HART
HART variables can be configured on each analogue input and output channel
to monitor the HART field device.
Make sure that your HART field devices support HART command 0 ('read
unique ID') and HART command 3 ('read current and four dynamic
variables'). The AADvance controller uses these commands to communicate
with the HART devices.
The AADvance analogue input and output modules use HART command
#03 to collect data from the field device as specified by Revision 5 of the
HART specification. The extra data available from HART-enabled field
devices is reported to the application in custom data structures:
T9K_AI_HART and T9K_AI_HART_FULL.
The structures supply the following data:
• Loop current in milliamps
• Process measurement in engineering units
• Errors on HART communication seen by the field device
• Status of the field device
• Time since the most recent update, in milliseconds
You can use the loop current variable for diagnostic checks in the application,
to compare the value of the variable with the value on the 4 to 20 mA loop and
react if there is a discrepancy. You can also monitor the status of the field device
and use this to report diagnostic errors and manual configuration changes.
Bindings and the SNCP
Network
IMPORTANTThe update rate for HART data from field devices is slower than the update
rate for the 4 to 20 mA analogue signal itself. HART data can take a
maximum of 4 seconds to update, depending on the device type and
configuration.
Bindings are based on a producer/consumer model. The controller consuming
the data establishes a binding link with the controller producing the data and
manages all of the sending and receiving of data. It schedules the sending and
receiving of data, sending the diagnostic data, managing the safety response if
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faults occur and managing the communications redundancy. An SNCP
network is illustrated in the diagram.
First there must be a physical connection between the two controllers. The
design of the Ethernet network and the equipment used does not impact the
SIL rating of the communications interface, but the design of the network does
change the reliability of the network and does impact the spurious trip rate.
SNCP Network data can be combined on a common network resulting in
safety and non-safety data sharing a common physical network. This does not
compromise the SIL rating of the network but again does introduce failure
modes and possibly security risks which can increase the spurious trip rate.
Therefore, careful consideration must be given to the network topology during
the applications specification and design phase.
SNCP Networks can be configured as Simplex (Fail Safe) or Redundant (Fault
tolerant). The network configuration is dependent on the applications safety
and availability requirements. The giving and receiving of data occurs
independently from the physical network configuration as the connection
between the controllers is treated as a logical network
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Serial Communication
Interface
Time Synchronization SNTP
Two serial ports on each processor module support the following signal modes
depending on their use:
• RS485fd: A four-wire full duplex connection that features different
busses for transmit and receive. This selection must also be used when
the controller is acting as a MODBUS Master using the optional fourwire definition specified in Section 3.3.3 of the MODBUS-over-serial
standard.
• RS485fdmux: A four-wire full-duplex connection with tri-state outputs
on the transmit connections. This must be used when the controller is
acting as a MODBUS Slave on a four-wire bus.
• RS485hdmux: A two-wire half duplex connection applicable for or
master slave or slave use. This is shown in the MODBUS-over-serial
standard.
The AADvance controller can be configured to operate as an SNTP client or
server or both.
• The SNTP client settings inform the controller of the following
information: the IP address of the SNTP 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 processor module can be configured as a unicast or broadcast
client.
• The AADvance controller can also fulfill the role of an SNTP server. To
enable serving of time on an interface, you need to enable the interface
and then you need to specify the direct broadcast address for that
interface. This works for broadcast or unicast modes. When the
controller is configured as a broadcast server, the controller can still
respond to unicast requests from clients.
• Configure the controller as both a client and a server if using an external
time server and you want to use the controller to supply the time data to
other controllers and devices.
MODBUS Master
IMPORTANTChanges to the SNTP settings are not active until after the power is cycled.
The AADvance controller can be used as a MODBUS Master to one or more
MODBUS Slave devices. Slave devices can include programmable logic
controllers, remote devices (typically with little or no processing ability) and,
more rarely, other functional safety controllers (Trusted or AADvance).
The controller supports the MODBUS RTU and MODBUS TCP protocols,
as well as a subset of MODBUS commands. You can use MODBUS RTU with
point-to-point and multi-drop serial links, and MODBUS TCP with
Ethernet.
NOTEThe AADvance controller does not support the MODBUS ASCII protocol.
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You can set up a list of messages (commands) for each slave device. MODBUS
read commands cause data to read from the slave device to the MODBUS
Master, while MODBUS write commands cause data to be copied from the
MODBUS Master to the slave device. You can also define a sequence of
broadcast write commands, which a MODBUS Master can send to multiple
MODBUS RTU slaves without requiring an acknowledgment. The
AADvance controller can control and monitor each of the MODBUS Master
objects and their slave links.
WARNING: The MODBUS Master functionality has a safety integrity level of
zero (SIL 0) and must only be used for non-safety applications.
MODBUS Master Hardware and Physical Connections
The MODBUS Master functionality is built into the 9110 Processor Module.
The physical communication ports are located on the 9100 Processor Base
Unit. You do not need to add any other hardware to the AADvance controller
apart from other components to make the physical connections to the
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processor base unit. The following illustration shows some possible
arrangements for MODBUS Master connections.
Controller IP Address
The MODBUS RTU slave devices are connected to one or more of the serial
ports on the controller; a usual arrangement uses a multi-drop (RS-485)
arrangement. The engineering workstation and the MODBUS TCP devices
are shown connected to the Ethernet ports on different networks.
Alternatively, these devices can be combined onto one network. Refer to the
AADvance System Build Manual for more details about physical connections
The AADvance controller stores its IP address data in non-volatile memory in
the 9100 processor base unit. The data is independent of the 9110 processor
modules in the controller, and so the controller keeps the address information
when you remove a processor module.
You must set up the IP address data when you create a new system, or if you fit
a new processor base unit.
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After having set up the IP address data in the controller, you can configure the
AADvance Workbench to find the controller on the network.
Recovery Mode
Differential Services
(DiffServ)
Recovery Mode is a shutdown mode and uses a base level firmware. It is
entered automatically when a critical firmware failure occurs or it can be
entered manually by pressing the processor Fault Reset button immediately
after the module has booted up. The Recovery Mode is also used when you
want to download a new firmware upgrade.
As an alternative firmware version it allows the following maintenance
activities:
• Update the firmware using the ControlFLASH utility
• Program the processor IP Address with the AADvance Discover utility
• Extract diagnostic information
In Recovery Mode the Ready, Run, Force and Aux LEDs go Amber and the
Healthy and System Healthy LEDs stay Green. The System Healthy and
Healthy LEDs could go Red if a fault is detected while in the Recovery Mode.
NOTEWhen in Recovery Mode the I/O communications are disabled and the
Application code is not running.
Differentiated services (DiffServ) gives a simple and coarse method to classify
the services of different applications, and thus specify the priority of IP traffic.
DiffServ is useful to make sure that high priority services are not delayed (or
less delayed) during periods of network congestion. When applied, the service
uses bit patterns in the "DS-byte" of IP, which for IPv4 is Type-of-Service
(ToS) octet.
When you configure DiffServ you apply a priority value to a service and thus
identify it as different to less important services. You do this by arranging
routers or switches that can examine IP headers and prioritize them by the ToS
header octet. The network devices will then apply their rules to prioritize IP
traffic. The AADvance controller maintains the priority when it responds to
incoming messages, and sets a priority according to the configuration for the
messages it sends out.
If you use DiffServ, the controller scan rate can be up to 5 ms larger or smaller
than the scan rate when DiffServ feature is disabled.
The TCP/IP stack can apply the user-specified ToS data in its datagrams
during the TCP negotiation (this is the 3-way handshake, RFC 793). You can
specify this behavior when you set up DiffServ.
IMPORTANTThe DiffServ feature is only available with release 1.3 onwards of the
AADvance Workbench and controller.
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Controller Functi onalityChapter 3
Serial Tunneling
Ethernet Forwarding
Not available for Workbench 2.0.
The Ethernet forwarding property lets an AADvance controller forward
Ethernet packets intended for a third party device, as shown in the illustration,
together with all broadcast and multicast messages.
When Ethernet forwarding is enabled, each 9110 processor module in the
controller forwards unicast messages intended for other devices, and all
broadcast and multicast messages, between its two Ethernet ports. A device
connected through the processor module can get its IP configuration through
BOOTP or DHCP, or statically.
The processor module in the first position (slot) in the 9100 processor base
unit forwards these messages from port E1-1 to E1-2, and in the opposite
direction from port E1-2 to E1-1. Similarly (if fitted), the processor module in
the second position in the 9100 processor base unit forwards traffic from port
E2-1 to E2-2, and from port E2-2 to E2-1. The third processor module (if
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fitted) forwards traffic from port E3-1 to E3-2, and from port E3-2 to E3-1. In
each case, the second of these ports represents an uplink to the remainder of
the network or (if applicable) to a different network. A device connected to
this port sees all the traffic which can be of use to it: broadcasts, multicasts, and
unicast traffic not destined for the 9110.
The processor module continues to consume the unicast messages intended for
itself, and all broadcast and multicast messages, as it does when Ethernet
Forwarding is disabled.
Ethernet forwarding is not designed to make links from one processor module
to a different processor module, for example from ports E1-2 to E2-1 and E2-2
to E3-1. Do not do this.
The controller keeps its Ethernet forwarding setting if you change one or more
of the 9110 processor modules. You do not have to change the setting during
corrective maintenance.
Compiler Verification Tool
The OPC Portal Server
The Compiler Verification Tool (CVT) is a software utility that validates the
output of the application compilation procedure. It is automatically enabled
for resources when a project is created and when you add a resource to an
existing project. This procedure in conjunction with the validated execution
code produced by the AADvance Workbench confirms that there are no errors
introduced by the Compiler during the development of the application.
To achieve this CVT decompiles the application project file and then
compares each individual application project (POU) source files with its
decomposed version. The CVT analysis is displayed in the Workbench
window.
The OPC Portal 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 process data. It conforms to version 1.10
of the Alarms and Events Standard published by the OPC Foundation.
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AADvance System Architectures
An AADvance controller can be configured to manage non-safety and up to
SIL 3 safety related system requirements for low demand or high demand fault
tolerant applications.
This chapter describes the different system architectures that can be configured
for SIL 2 and SIL 3 applications.
NOTEArchitectures are independent of I/O module capacity so 8 or 16 channel I/O
modules can be used.
SIL 2 Architectures
SIL 2 architectures are recommended for fail-safe low demand applications. All
SIL 2 architectures can be used for energize or de-energize to trip applications.
In any configuration when a faulty processor or input module is replaced then
the previous fault tolerance level is restored. For example in a fault tolerant
input arrangement and one module is faulty then the system will degrade to
1oo1 (1 out of 1 with diagnostics), by replacing the faulty module the
configuration is restored to 1oo2D (1 out of two with diagnostics).
In all SIL 2 architectures, when the processor modules have degraded to
1oo1D on the first detected fault, the system must be restored to 1oo2D by
replacing the faulty processor module within the MTTR assumed in the PFD
calculations; also, unless compensating measures are defined in the Safety
Requirements Specification (SRS) and documented in operating procedures,
the application program must be designed to shut down safety instrumented
functions if a module failure due to a dangerous fault has not been replaced
within the MTTR.
SIL 2 Fail-safe Architecture
The following is a simplex fail-safe SIL 2 architecture, where I/O modules
operate in 1oo1D under no fault conditions and will fail-safe on the first
detected fault. The processor will operate in 1oo2D under no fault conditions,
will degrade to 1oo1D on the first fault in either processor module and will
fail-safe when there are faults on both processor modules.
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NOTESimplex output modules used for energize to action applications can only be
used for low demand applications.
Table 5 - Modules for SIL 2 Fail-Safe Architecture
PositionModule Type
I/P AT9401/2 Digital Input Module, 24 Vdc, 8/16 Channel +
T9801 Digital Input TA, 16 Channel, Simplex. or
T9431/2 Analogue Input Module, 8/16 Channel +
T9831 Analogue Input TA, 16 Channel, Simplex
T9300 I/O Base Unit
CPU A 2 x T9110 Processor Module, T9100 Processor Base Unit
T9851 Digital Output TA, 24 Vdc 8 Channel, Simplex
1 x T9481/T9842 Analogue Output Module, 3/8 Ch, Isolated + T9881 Analogue Output TA, 8 Ch,
Simplex
SIL 2 Fault Tolerant Input Architectures
A SIL 2 fault tolerant input architecture can have dual or triple input modules
with a dual processor and single output modules. The illustration shows a dual
input arrangement where the dual input modules operate in 1oo2D under no
fault conditions, they degrade to 1oo1D on detection of the first fault in either
module of the redundant pair, and when a fault occurs on the second module
the controller fails-safe.
The processor operates in 1oo2D under no fault conditions, will degrade to
1oo1D on the first fault in either processor module and will fail-safe when
there are faults on both processor modules. The output module operates in
1oo1D under no fault conditions and fail-safe on the first detected fault.
When a triple input module arrangement is configured the group of input
modules operate in 2oo3D under no fault conditions, degrade to 1oo2D on
the detection of first fault in any module, then degrade to 1oo1D on the
detection of faults in any two modules and fail-safe when there are faults on all
three modules.
NOTESimplex output modules used for energize to action applications can only be
used for low demand applications.
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V = voting
Table 6 - Modules for SIL 2 Architecture
PositionModule Type
I/P A and B2 × T9401/2 Digital Input Module, 24 Vdc, 8/16 Channel +
T9802 Digital Input TA, 16 Channel, Dual or
2 × T9431/2 Analogue Input Module, 8/16 Channel, Isolated, + T9832 Analogue Input TA, 16
Channel, Dual
T9300 I/O Base Unit
CPU A2 x T9110 Processor Module, T9100 Base Unit
O/P AT9451 Digital Output Module, 24 Vdc, 8 Channel +
T9851 Digital Output TA, 24 Vdc, 8 Channel, Simplex; T9300 I/O Base Unit or
1 x T9481/T9842 Analogue Output Module, 3/8 Ch, Isolated + T9881 Analogue Output TA, 8 Ch,
Simplex
AADvance System ArchitecturesChapter 4
SIL 2 Fault Tolerant Output Architecture
A SIL 2 Fault Tolerant output architecture has a single output module with
dual processor and single or redundant input modules.
The illustration shows a SIL 2 single output arrangement where the output
module operates in 1oo1D under no fault conditions and fail-safe on the first
detected fault. The processor will operate in 1oo2D under no fault conditions,
will degrade to 1oo1D on the first fault in either processor module and will
fail-safe when there are faults on both processor modules.
Digital Output
For digital output modules the following applies:
• If the required safe state is ON, you must use dual digital output
modules for High Demand applications.
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Analogue Output
For Analogue Output the following applies:
• The fail-safe state current of the analogue output module is less than 2
mA.
•A safe state is an output configured to go to a specific value, or
configured to hold last state. If the required safe state is larger than 4
mA, you must use dual analogue output modules for High Demand
applications.
Table 7 - Modules for SIL 2 Fault Tolerant Output Architecture
Position Module Type
I/P A & BT9401/2 Digital Input Module, 24 Vdc, 8/16 Channel +
T9801 Digital Input TA, 16 Channel, Simplex or
T9431/2 Analogue Input Module, 8/16 Channel +
T9831 Analogue Input TA, 16 Channel, Simplex
T9300 Base Unit
CPU A2 x T9110 Processor Module, T9100 Processor Base Unit
O/P A T9451 Digital Output Module, 24 Vdc, 8 Channel + T9851 Digital Output TA, 24 Vdc, 8 Channel,
Dual and T9300 I/O Base Unit or
1 x T9481/T9842 Analogue Output Module, 3/8 Channel, Isolated +
T9881 Analogue Output TA, 8 Ch, Simplex
SIL 2 Fault Tolerant Input and SIL 2 High Demand Architecture
A SIL 2 fault tolerant "High Demand" architecture has dual input, dual
processor and dual output modules. In a dual arrangement the input modules
operate in 1oo2D under no fault conditions, degrade to 1oo1D on the
detection of the first fault in either module, and will fail-safe when there are
faults on both modules.
A triple input module arrangement can also be configured if it is required to
increase the fault tolerance of the input. When a triple input module
arrangement is configured the input modules operate in a 2oo3D under no
fault conditions, degrade to 1oo2D on detection of the first fault in any
module, then degrade to 1oo1D on the detection of faults in any two modules,
and will fail-safe when there are faults on all three modules.
The processor will operate in 1oo2D under no fault conditions, will degrade to
1oo1D on the first fault in either processor module and will fail-safe when
there are faults on both processor modules. For high demand applications the
processor must be repaired within the MTTR assumed in the PFD calculations
or the high demand safety instrumented functions must be shut down.
WARNING: For High Demand applications you must use a minimum of a
dual processor configuration. High demand energize to action applications
will require dual output modules. (Analogue Output Modules where the
normal output current is less than 4 mA are classed as energize to action
applications).
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WARNING: For Continuous Mode applications the measures specified in this
section for High Demand applications must be applied.
Table 8 - Modules for SIL 2 Fault Tolerant High demand Architecture
PositionModule Type
I/P A & B2 × T9401/2 Digital Input Module, 24 Vdc, 8/16 Channel +
CPU A & CPU B2 x T9110 Processor, T9100 Processor Base Unit
O/P A & B2 × T9451 Digital Output Module, 24 Vdc, 8 Channel + T9852 Digital Output TA, 24
T9802 Digital Input TA, 16 Channel, Dual or
2 × T9431/2 Analogue Input Module, 8/16 channel +
T9832 Analogue Input TA, 16 Channel, Dual
1 × T9300 I/O Base unit
Vdc, 8 channel, T9300 Base Unit or
2 x T9481/T9842 Analogue Output Module, 3/8 Ch, Isolated +
T9882 Analogue Output TA, 8 Ch, Dual and T9300 Base Unit
SIL 3 Architectures
SIL 3 architectures have at least two or three processor modules and are
applicable for use with:
• SIL 3 de-energize to trip applications.
• SIL 3 energize to action applications when fitted with dual digital
output modules.
• SIL 3 high demand applications where the required safe state is more
than 4 mA, when fitted with dual analogue output modules (A ‘safe
state’ is an output configured to go to a specific value, or configured to
hold last state).
Faulted input modules in a SIL 3 arrangement can be replaced without a time
limit; faulted output modules must be replaced within the MTTR assumed in
the PFD calculations.
In all SIL 3 architectures, when the processor modules have degraded to
1oo1D on the first detected fault, the system must be restored to at least
1oo2D by replacing the faulty processor module within the MTTR assumed in
the PFD calculations or all SIL 3 safety instrumented function and high
demand safety instrumented functions must be shut down.
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SIL 3 Fail-safe I/O, Fault Tolerant Processor
A SIL 3, fail-safe I/O with a fault tolerant processor architecture has a simplex
input and output arrangement with dual or triple processor modules. The dual
processor modules operate in 1oo2D under no fault conditions and degrade to
1oo1D on detection of the first fault in either module. When there are faults
on both modules the configuration fails-safe.
If required you can configure triple processor modules as a variation of this SIL
3 architecture. Using this arrangement the processor modules operate in
2oo3D under no fault conditions and 1oo2D on the detection of the first fault
in any module. They degrade to 1oo1D on the detection of faults in any two
modules and fail-safe when there are faults on all three modules.
Digital Output Modules
• For de-energize to action operation one 9451 output module is
sufficient for SIL 3 requirements. However, for energize to action
operation, dual digital output modules are required.
• A digital output module fault must be repaired within the MTTR
which was used in the PFD calculation. This rule applies to simplex
digital output modules in de-energize to trip applications and to dual
digital output modules in energize to action applications.
Analogue Output Modules
• The fail-safe state current of the analogue output module is less than 2
mA.
• If the required safe state is more than 4 mA, you must use dual analogue
output modules for high demand applications.
• An analogue output module fault must be repaired within the MTTR
which was used in the PFD calculation. This rule applies to simplex
analogue output modules where the safe state is less than or equal to 4
mA and to dual analogue output modules where the safe state is more
than 4 mA.
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Table 9 - Modules for SIL 3 Fail-safe I/O, Fault Tolerant Processor
PositionModule Type
I/P AT9401/2 Digital Input Module, 24 Vdc, 8/16 Channel +
CPU A & CPU B2 x T9110 Processor Module, T9100 Base Unit
O/P A1 x T9451 Digital Output Module, 24 Vdc, 8 Channel +
T9801 Digital Input TA, 16 Channel, Simplex or
T9431/2 Analogue Input Module, 8/16 channel +
T9831 Analogue Input TA, 16 Channel, Simplex
T9300 Base unit
T9851 Digital Output TA, 24 Vdc, 8 Channel, Simplex or
1 x T9481/T9842 Analogue Output Module, 3/8 Ch, Isolated +
T9881 Analogue Output TA, 8 Ch, Simplex
SIL 3 Fault Tolerant I/O Architectures
A SIL 3 fault tolerant I/O is achieved by dual input and output module
configurations with dual or triple processor modules. The processor modules
operate in 1oo2D under no fault conditions, degrade to 1oo1D on the
detection of the first fault in either module and fail-safe when there are faults
on both modules.
Input modules operate in 1oo2D under non faulted conditions and 1oo1D on
detection of the first fault in one module and fail-safe when there are faults on
both modules.
For high demand applications the processor must be repaired within the
MTTR assumed in the PFD calculations or SIL 3 safety instrumented
functions must be shut down.
WARNING: For SIL 3 applications you must use a minimum of a dual
processor configuration.
For de-energize to action operation one digital output module is sufficient for
SIL 3 requirements. However, for energize to action operation, dual digital
output modules are required.
The single output module operates in 1oo1D under no fault conditions and
fail-safe when there are is a fault on the module. For energize to action
operation, the output modules operate in 1oo2D under no fault conditions,
degrade to 1oo1D on the detection of the first fault in either module and failsafe when there are faults on both modules.
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Digital Output Modules
A digital output module fault must be repaired within the MTTR which was
used in the PFD calculation. This rule applies to simplex digital output
modules in de-energize to trip applications and to dual digital output modules
in energize to action applications.
Analogue Output Modules
An analogue output module fault must be repaired within the MTTR which
was used in the PFD calculation. This rule applies to simplex analogue output
modules where the safe state is less than or equal to 4 mA and to dual analogue
output modules where the safe state is more than 4 mA.
Table 10 - Modules for SIL 3 Fault Tolerant Architectures
PositionModule Type
I/P A
and
I/P B
CPU A & CPU B2 × T9110 Processor Module, 9100 Processor Base Unit
O/P A
and
O/P B
2 × T9401/2 Digital Input Module, 24 Vdc, 8/16 Channel +
T9802 Digital Input TA, 16 Channel, Dual or
1 x T9451 Digital Output Module, 24 Vdc, 8 Channel +
T9851 Single Digital Output TA, 24 Vdc, 8 Channel for de-energize to action
T9300 Base unit
2 x T9451 Digital Output Module, 24 Vdc, 8 Channel +
T9852 Dual Digital Output TA for energize to action
T9300 Base Unit
Or
2 x T9481/T9842 Analogue Output Module, 3/8 Ch, Isolated +
T9882 Analogue Output TA, 8 Ch, Dual
T9300 Base Unit
SIL 3 TMR Input and Processor, Fault Tolerant Output
A SIL 3 TMR architecture offers the highest level of fault tolerance for an
AADvance controller and consists of triple input modules, triple processors
and dual output modules.
• The input and processor modules operate in a 2oo3D under no fault
conditions, degrade to 1oo2D on detection of the first fault in any
module, and degrade to 1oo1 on the detection of faults in any two
modules and will fail-safe when there are faults on all three modules.
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AADvance System ArchitecturesChapter 4
In the event of a failure in any element of a channel, the channel processor will
still produce a valid output which could be voted on because of the coupling
between the channels. This is why the triple modular redundant
implementation supplies a configuration that is inherently better than a typical
2oo3 voting system.
Digital Output Modules
A digital output module fault must be repaired within the MTTR which was
used in the PFD calculation. This rule applies to simplex digital output
modules in de-energize to trip applications and to dual digital output modules
in energize to action applications.
Analogue Output Modules
An analogue output module fault must be repaired within the MTTR which
was used in the PFD calculation. This rule applies to simplex analogue output
modules where the safe state is less than or equal to 4 mA and to dual analogue
output modules where the safe state is more than 4 mA. (A ‘safe state’ is an
output configured to go to a specific value, or configured to hold last state).
Table 11 - Modules for TMR Input and Processor, Fault Tolerant Output
T9803 Digital Input TA, 16 Channel, TMR
or
3 × T9431/2 Analogue Input Module, 8/16 Channel +
T9833 Analogue Input TA, 16 Channel, TMR
2 × T9300 I/O Base Unit
9852 Digital Output TA, 24 Vdc 8 Channel, Dual; 1 x T9300 Base Unit
Or
2 x T9481/T9842 Analogue Output Module, 3/8 Ch, Isolated +
T9882 Analogue Output TA, 8 Ch, Dual; 1 x T9300 Base Unit
NOTEAll configurations that use dual or triplicate processor modules are
applicable for SIL 3 architectures with de-energize to trip outputs. Dual
outputs are always required for SIL 3 energize to action outputs.
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Certified Configurations
Revisions of modules are subject to change. A list of the released versions can
be obtained from Rockwell Automation.
Table 12 - Central Modules
ModulesCertified
Processor Module
T9110
Configuration
1oo2D, 2oo3DSafety-related and can be used for safety-critical
Table 13 - Input Modules
ModulesCertified ConfigurationConditions
Digital Inputs
T9401/2, 24 Vdc, 8/16 Channel,
isolated.
+
T9801/2/3 Digital Input TA, 16
channel, Simplex/Dual/TMR
Analogue Inputs
T9431/2, 8/16 Channel, isolated
+
T9831/2/3 Analogue Input TA, 16
Channel, Simplex/Dual/TMR
1oo1D, 1oo2D, 2oo3D De-energized to action (normally
1oo1D, 1oo2D, 2oo3DWithin the manufactures specified safety
Conditions
applications in SIL 2 with 2 modules fitted and SIL 3
applications with 2 or 3 modules fitted.
Note: For both Low and High Demand applications
you must use a minimum of two processors.
energized): SIL 3 with 1, 2 or 3 modules
fitted.
Energize to action (normally deenergized): with 1, 2 or 3 modules fitted
Note: When the integrity level is at 1oo1D
then the faulty module must be replaced
to restore the integrity level back to 1oo2D.
accuracy limits of 1 %. The safety st ate of
the analogue input has to be set to a safe
value which is a calculated value based on
a count value of 0 mA. (refer to the
AADvance Configuration Guide Doc Nos:
ICSTT-RM405 and ICSTT-RM458 for more
details)
SIL 3 with 1, 2 or 3 modules fitted.
Note: When the integrity level is at 1oo1D
then the faulty module must be replaced
within the MTTR assumed for the PFD
calculations to restore the integrity level
back to 1oo2D.
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1oo1, 1oo2 or 1oo2DDe -energize to action (normally
energized): SIL 3 with 1 or 2 modules
fitted. (1oo2D with dual output modules
fitted).
Energize to action (normally deenergized): SIL 2 with 1 module fitted and
SIL 3 with 2 modules fitted.
A faulty digital output module must be
repaired or replaced within the MTTR
which was used in the PFD calculation. This
rule applies to all simplex digital output
modules and to dual digital output
modules in energize to action applications.
1oo1, 1oo2 or 1oo2DSIL 3 with 1 or 2 modules fitted where the
safe state is less than or equal to 4 mA
SIL 3 with 2 modules fitted where the safe
state is more than 4 mA (1oo2D with dual
output modules fitted).
A faulty analogue output module must be
repaired or replaced within the MTTR
which was used in the PFD calculation. This
rule applies to all simplex analogue output
modules and to dual analog output
modules where the safe state is > 4 mA
Example Architectures with
Approved Modules
Table 15 - Auxiliary Modules
ModulesConditions
Processor Base
T9100
I/O Base
T9300 (3-way)
Safety-related and can be used for safety critical applications in SIL 2
applications with 2 modules fitted or SIL 3 applications with 2 or 3 modules
fitted
Safety-related and can be used for safety critical applications in SIL 3.
The controller supports a range of architectures as defined in the previous
chapter. This chapter describes how to assemble a range of architectures
configurations and includes selected examples that illustrate the alternative
options. The modular construction of the controller makes it easy to create
module arrangements and these can be tailored for a specific application.
Standard Architectures
The standard AADvance modules can be arranged to supply two fundamental
architectures based on dual and triple modular redundant processors modules.
To these can be added I/O modules for redundant and/or fault tolerant
configurations based on the following arrangements:
• Input modules in simplex, dual and triple modular redundant
formations
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Figure 10 - Example Simplex SIL 2 System
• Output modules in simplex and/or dual arrangements
Figure 11 - Example SIL 3 with Dual Input and Output Modules
An AADvance system can mix different I/O architectures within one
controller — for example simplex and dual input modules with dual processor
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AADvance System ArchitecturesChapter 4
modules. The modular construction of the controller enables you to create
numerous other arrangements that can be tailored for a particular application.
Once a system has been built and commissioned it can be expanded using
additional modules from the range to create many different architectures and
meet specific additional safety and fault tolerant business requirements.
Simplex I/O Architecture
A simplex configuration uses one input module for a field input, one output
module for a field output, and two processor modules. Each input and output
module will fail safe on the first detected fail danger fault and the process
under control will shut down. The processor operates in 1oo2D under no fault
conditions, will degrade to 1oo1D on the first fault in either processor module
and will fail-safe when there are faults on both processor modules.
Low Demand SIL 2 Architecture
This is an example of a SIL 2 controller which is suited to low demand mode
applications with de-energize and energize to action outputs. The T9801 and
T9851 illustrated are the related simplex termination assemblies that mate
with the T9401 and T9451 I/O modules. This arrangement is also applicable
for non-safety applications.
Figure 12 - Low Demand SIL 2 Architecture System
This example supports 8 field inputs and 8 outputs. There is space for one
more processor module and one more I/O module. To expand the I/O
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capacity you have to add I/O base units then the required number of I/O
modules and termination assemblies.
Data Input and Output
A controller can support up to 48 I/O modules in total (on 16 I/O base units);
as an example, here is a controller with four 8 channel T9401 digital input
modules and two 8 channel T9451 Digital Output Modules, giving 32 inputs
and 16 outputs.
Figure 13 - Data Input and Output System
Two or three processor modules in a redundant arrangement are rated SIL 3,
however, a minimum of two processor modules in a redundant arrangement
are still required for architectures designed to meet SIL 2.
The T9401/2 digital input module (the same as the module for the SIL 2
controller) is rated SIL 3 as it stands. The only constraint is that the simplex
output stage will not drive an energize to action output for SIL 3 - this requires
a dual arrangement of output modules. This output configuration is applicable
for a de-energize to action output at SIL 3.
The second processor module supplies the increased fault tolerance and gives
the configuration its SIL 3 rating. If either processor module fails, the module
must be replaced in the MTTR.
This controller suits many applications needing a mixture of SIL 3 de-energize
to action and SIL 2 outputs which do not need the additional fault tolerance
offered by dual and triple modular redundant configurations. The possibilities
for expansion are the same as those for the SIL 2 controller.
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Figure 14 - Dual Processor System
AADvance System ArchitecturesChapter 4
Dual Architecture for Fault Tolerant Applications
Fault Tolerant Input and SIL 3 Outputs
A dual architecture configuration shown uses two dual redundant modules for
each stage. The use of two processor modules supplies SIL 3 integrity for the
processor stage (as for the previous example) while the second input module
supplies fault tolerance for the inputs.
A SIL 3 fault tolerant processor and I/O is achieved by dual input and output
module configurations with dual or triple processor modules.
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Figure 15 - Dual Inputs, Processor and Output System
Increasing I/O Capacity
The capacity of this controller is increased by adding pairs of I/O modules and
related dual termination assemblies. The subsequent example shows how to
supply 16 inputs and 16 outputs (this could also be 32 inputs if 16 channel
input modules are used). The outputs shown are digital output modules.
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Figure 16 - Increased I/O System
AADvance System ArchitecturesChapter 4
The T9852 dual termination assembly can be used with both 8 channel and 16
channel input modules.
Triple Modular Redundant Architecture
A SIL 3 TMR architecture offers the highest level of fault tolerance for an
AADvance controller and consists of triple input modules, triple processors
and dual output modules.
If a failure occurs in an element of a channel, the channel processor will still
supply a satisfactory output which could be voted on because of the coupling
between the channels. This is why the triple modular redundant
implementation has a configuration that is inherently better than a typical
2oo3 voting system.
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Figure 17 - Triple Modular Redundant System
IMPORTANTAll configurations that use dual or triplicate processor modules are
applicable for SIL 3 architectures with de-energize to action outputs. Dual
output modules are required for SIL 3 energize to action outputs.
You can add more groups of three input modules and pairs of output modules
to increase I/O capacity. For example, a triple modular redundant controller
using 8-channel modules for 16 inputs and 16 outputs could be arranged like
this. For 16 channel TMR input you must use the T9402 16 channel digital
input modules in the same arrangement.
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Figure 18 - Increasing I/O capacity with an Expansion Cable
AADvance System ArchitecturesChapter 4
Mixed Architectures
Using an Expansion Cable
In the example a T9310 expansion cable assembly is used to connect the righthand I/O base unit to another I/O base unit and modules.
It is straightforward to make dual and triple I/O controller architectures. A
system can have a mixed level of redundancy, fault tolerance and safety
integrity levels to meet your business application needs without over-specifying
the I/O.
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Mixed I/O Architectures
An application could readily justify dual I/O for some field circuits, but not for
all. It is easy and economical to configure one controller to offer a solution to
cover both options. Consider a dual processor system that needs 16 inputs and
16 outputs, half of which must be duplicated and half of which can be simplex.
This can be fulfilled by controller architecture like this.
Figure 19 - Mixed I/O System Equation
Mixed Safety Integrity Levels
Such is the flexibility of AADvance that a single controller can support mixed
safety integrity levels, for example, if a system needs SIL 3 energize to trip
outputs alongside SIL 2 outputs.
The following example shows how a small a viable controller for mixed
integrity levels can be when built from AADvance modules. There are 16
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AADvance System ArchitecturesChapter 4
inputs (or 32), two duplicated 8 channel inputs (or duplicated 16 channel
versions), and two groups of 8 outputs (one dual, one simplex) for field devices.
Figure 20 - Mixed Safety System
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Distributed Architectures
AADvance is designed to support a distributed safety architecture. Using an
SNCP network a SIL 3 architecture can be maintained across multiple
controllers by sharing safety data over an Ethernet network shown in the
example below:
Figure 21 - Distributed Safety Architecture
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AADvance System ArchitecturesChapter 4
Example Distributed Controller Systems
The following example shows a process protected by one distributed
AADvance system. It uses an 8000 Series Trusted controller to handle bulk I/
O, and four AADvance controllers for other parts of the plant.
Controllers 1 and 2 show two similar controllers which are almost the same
applied to the same, duplicated areas of plant. The duplication of plant
(represented by the two compressors K1 and K2) in this system allows
controllers 1 and 2 to be fail safe designs.
The parts of the plant managed by Controllers 3 and 5 are assumed (for the
sake of this illustration) to need safety instrumented systems certified to a
mixture of SIL 2 and SIL 3. Controller 3 exploits the flexibility of the
AADvance system to supply mixed SILs in one controller.
Controller 4 manages the fire and gas system in the plant. The example uses an
8000 Series Trusted controller here in a role which uses a large quantity of field
devices. The 8000 Series Trusted controller is fully integrated into the system
and shares the applications with the AADvance controllers.
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Figure 22 - Distributed System
Typical Network Applications
A usual distributed AADvance system uses two networks:
• An information network, which supplies connectivity to the BPCS
(basic process control system) and to OPC devices
• A dedicated safety network, which handles data shared between the
AADvance controllers
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Figure 23 - Distributed Network System
AADvance System ArchitecturesChapter 4
The engineering workstation could connect to the safety network (as
illustrated), to the data network or to the two networks.
As drawn, the OPC portal server collects data from the controllers and displays
it on the HMIs and, conversely, delivers commands from the HMIs to the
controllers. The data network carries real time data (MODBUS TCP) from
the BPCS to the controllers.
Controller External Network Connectors
The controller features six auto-sensing 10/100BASE-TX Ethernet ports
which let it to connect to a local area network through standard RJ45 Ethernet
cable. There are two ports for each processor module.
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The controller Ethernet ports are found on the T9110 processor base unit and
identified like this:
Table 16 - Allocation of 10/100BASE-TX Ports to Processor Modules
10/100BASE-TX Ports T9110 Processor Module
E1–1, E1–2Processor A
E2–1, E2–2Processor B (if fitted)
E3–1, E3–2Processor C (if fitted)
Specifying a Safety Network
Once a system uses distributed controllers with shared data, the topology of
the safety network must be robust. To do this, make sure the network has no
single point of failure, refer to the AADvance Safety Manual (Document:
ICSTT-RM446) for further details about specifying a safety Network.
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Chapter 5
AADvance Scalability
The AADvance design concept gives an expandable solution for each
application through its current range of I/O modules and termination
assemblies. Increased I/O capacity is possible because it is easy to add new
modules and it gives you the flexibility to create different architectures by
changing the I/O capacity and arrangement.
I/O Channel Capacity
When creating a system, AADvance offers horizontal scalability. The
maximum I/O channel capacity of a single controller depends on if you
assemble I/O modules in simplex, dual or triple modular redundant
configurations.
You increase the I/O capacity of a controller by adding I/O base units,
termination assemblies and I/O modules. You can also use 16 channel
modules on a termination assembly and thus increase the I/O channel capacity
per module. An expansion cable allows you to use the controller second I/O
bus (I/O Bus 2) and add up to 24 I/O modules giving a total of 48 I/O
modules per controller.
An AADvance system also supports and integrates fully with existing
MODBUS subsystems and, through its own server, supplies interoperability
with HMIs and other OPC devices.
Simplex I/O Channel Capacity
When you need I/O modules arranged in simplex configurations you must use
the simplex termination assembly for each module type. You can use a physical
arrangement of 8-channel and 16-channel input modules with their simplex
termination assemblies, also any arrangement of output modules with simplex
termination assemblies. For example, you can put all digital inputs together in a
rack and all analogue inputs together, or mix them together.
The maximum number of simplex I/O channels is limited only by the selection
of modules. For example, 16 x 16 Channel input modules and 32 x 8 Channel
output modules, equals a maximum of 512 channels.
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Figure 24 - Simplex I/O Modules
Dual I/O Channel Capacity
When you need I/O modules arranged in dual redundant formations, each
pair of modules shares a dual termination assembly and occupies two-thirds of
an I/O base unit. The termination assemblies can bridge adjacent I/O base
units, so two base units will hold three pairs of dual redundant module
configurations, while three base units will hold four pairs. Arrange base units in
groups of two or four to optimize capacity for dual redundant modules.
If you assemble base units in groups of two or four, a single controller supports
24 pairs of I/O modules. The capacity using for example eight pairs of 16channel input modules and sixteen pairs of output modules is 256 I/O
channels (8 x 16 = 128, 16 x 8 = 128).
The capacity using 8-channel modules in dual configurations (24 pairs) is 24 ×
8 = 192 I/O channels. This can, for example, be 64 digital inputs, 64 analogue
inputs and 64 digital outputs, or any combination of these values with a
granularity of eight, the capacity of one I/O module.
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Figure 25 - Dual I/O Modules
Triple Modular Redundant Channel Capacity
AADvance ScalabilityChapter 5
Adding I/O Channel Capacity
When you need input modules arranged in triple modular redundant
formations, each group of three modules will share a single triple termination
assembly and occupies all of an I/O base unit. A single controller supports 16
groups of three modules, so a hypothetical controller using 16-channel input
modules and needing no output channels will have a capacity of 16 x 16 = 256
input channels.
A solution using 8-channel modules and needing dual output modules as well
as triplicated input modules will, with a ratio of 2:1 of inputs to outputs, supply
96 input channels and 48 output channels. These capacities are derived like
this:
Input Channels
• 12 groups of three 8-channel input modules have 12 base units and yield
12 x 8 = 96 input channels.
Output Channels
• 6 pairs of output modules have the remaining 4 base units and yield 6 x 8
= 48 output channels.
You can identify a new controller to have the correct quantity of I/O channels
that you need and also configure spare I/O channels that you anticipate you
could need in the future. Having done this, it is straightforward to add more
T9300 I/O base units and modules when you expand the controller.
However, if you haven't configured spare slots for new hardware you can still
expand your system. You can install the new hardware and change the
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controller hardware configuration in the AADvance Workbench and load the
changed application.
On-line updates I/O
Configuration Changes
The AADvance controller modular design makes it easy to create and change
the I/O configuration. The on-line update facility enables you to make changes
to the I/O configuration after the system is commissioned.
An on-line update can be used for the following changes.
• Expand a system and add new I/O modules, base units and termination
assemblies.
• Change the module type in a simplex or group arrangement.
• Expand a simplex or group arrangement.
• Downgrade a group arrangement.
• Move a module to a different slot.
• Change an application variable.
You only have to plug an additional I/O base unit into the side socket on an
installed I/O base unit. The command busses on the I/O base units do not
need different terminations on the open ends of transmission lines, and the
data response busses and power sources are supplied across all I/O base units.
Termination assemblies are pushed into the I/O base unit for the additional I/
O modules. To put the new modules on-line and make the changes to the
system fully operational, the hardware configuration in the AADvance
Workbench software must be updated by an on-line update.
Bus Connectors and
Expansion Cable
IMPORTANTFor Release 1.3 you can change the I/O module configuration with an on-line
update. However, if you are using an earlier product release the I/O
configuration cannot be changed with an on-line update.
IMPORTANTAn on-line update could affect the operation of the controller such that the
application is stopped or the I/O data flow is interrupted. The AADvance
Safety Manual outlines the precautions you need to follow when doing online updates on a Safety System.
When there is not sufficient space for extra I/O base units on a row you can use
the Expansion Cable to connect a new row of I/O base units and modules to
further expand the I/O system
The T9100 processor base unit command and response busses and system
power for I/O modules are output by the two connectors on each side of the
base unit:
• The right-hand connector (specified I/O bus 1 in the project tree
configuration) mates with a connector on the T9300 I/O base unit. I/O
bus 1 supports a maximum of eight I/O base units and 24 I/O modules.
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AADvance ScalabilityChapter 5
• The left-hand connector (specified I/O bus 2 in the project tree
configuration), mates with the T9310-02 Backplane Expansion Cable,
which will connect it to another T9300 I/O base unit. I/O Bus 2
supports a maximum of 8 I/O base units and has response lines for a
maximum of 24 I/O modules.
The expansion cable carries module power, command busses and individual
response busses for each I/O module.
Figure 26 - Expansion Cables for I/O Bus 1 & 2
Redundancy and Fault
Tolerance
An important advantage of the AADvance design is the option to add
redundant modules to increase fault tolerance as an when they are required.
Redundant configurations let you replace faulty modules without affecting the
system operation.
This flexibility and operational persistence is made possible by Termination
Assemblies that supply redundant I/O module capacity. By installing a triple
termination assembly you can configure the I/O and use it in a simplex, dual or
triple redundant arrangement.
The AADvance controller, therefore, gives an economical solution for
redundancy and fault tolerance expansion. You can install the termination
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Chapter 5AADvance Scalability
assemblies and base units for increased capacity in the future, then add the
extra I/O modules only when you actually need them.
Expansion using Distributed
Controllers
You can expand an AADvance system by adding more controllers to create a
distributed system. The AADvance Discover (Discovery and Configuration
utility) enables you to connect to external controllers.
IMPORTANTThe recommended maximum size of a typical distributed AADvance system
is 20 controllers.
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Chapter 6
Specifying a New Controller
This chapter goes through a list of key information needed to specify a new
AADvance controller. The flowcharts and tables that follow will guide you
through the process of defining a system for your business application and
system requirements.
Information to Specify a New
Controller
Define a New System
The following sets of information are needed to specify a new controller:
• The intended safety integrity level (SIL 2 or SIL 3) for your application
• The desirable degree of fault tolerance
• Whether any final elements are energize to action (affects output
module arrangements for SIL 3 requirements)
• The type and quantity of inputs and outputs
• The process safety time for each safety function
• Do you need a "hot swap" feature for any channels
All of these items must be assessed and known for the specified plant and the
intended application.
The charts use minimal designs to illustrate solutions.
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Specifying a New ControllerChapter 6
Specify I/O Base Units
Choosing Termination
Assemblies
The T9300 I/O base unit (3 way) is a single, standardised design which suits all
termination assemblies and I/O modules. The base unit can have one triple
modular redundant assembly, one dual assembly and one simplex assembly or
up to three to simplex assemblies. The dual and triple modular redundant
assemblies can bridge adjacent base units, so two base units can (for example)
hold three dual assemblies.
The use of termination assemblies gives the AADvance system flexibility for
creating different architectures and expanding the system. Each termination
assembly is a very simple circuit that is matched to a type of I/O module and to
a specified module configuration. This table shows a summary of the
termination assemblies which are available and the related I/O module
configurations.
Table 17 - Choosing a Termination Assembly
Simplex I/O Module
Configuration
Digital inputT9801, Digital Input TA, 16
channel, Simplex Commoned
(non-isolated)
Analogue input T9831, Analogue Input TA, 16
channel, Simplex, commoned
(non-isolated)
Digital outputT9851, Digital Output TA, 8
channel, Simplex, commoned
(non-isolated)
Analogue Output T9881, Analogue Output TA,
8 Channel, Simplex,
commoned
Dual I/O Module
Configuration
T9802, Digital Input TA, 16
channel, Dual
T9832, Analogue Input TA,
16 channel, Dual
T9852, Digital Output TA, 8
channel, Dual
(non-isolated)
T9882, Analogue Output TA,
8 channel, Dual
Trip le I/O Modul e
Configuratio n
T9803, Digital Input TA, 16
channel, Triple
T9833, Analogue Input TA,
16 channel, Triple
Not applicable
Not applicable
IMPORTANTThe termination assemblies for inputs have 8-channel I/O modules and 16-
channel I/O modules. A dual or triple arrangement can be made of 8- or 16channel modules, but not a mixture of the two.
You need one termination assembly for each group of related modules. For
example:
• Four T9401 digital input modules used in two, dual redundant
configurations need two T9802 termination assemblies — one for each
pair of modules
• Four T9401 digital input modules used for simplex inputs need four
T9801 termination assemblies — one for each module
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Chapter 6Specifying a New Controller
Estimate AADvance
Controller Weight
Use the following table to make an estimate of the weight of your controller.
Table 18 - AADvance Controller Module Weight
ItemNumber UsedWeight Allowance g (oz.)Subtotal
T9100 Processor Base Unit× 460 g (16 oz.)
T9110 Processor Module× 430 g (15 oz.)
T9401 Digital input module, 24 Vdc, 8 channel× 280 g (10 oz.)
T9402 Digital input module, 24 Vdc, 16 channel× 340 g (12 oz.)
T9431 Analogue input module, 8 channel× 280 g (10 oz.)
T9432 Analogue input module, 16 channel× 340 g (12 oz.)
T9451 Digital output module, 24 Vdc, 8 channel× 340 g (12 oz.)
T9482 Analogue output module, 8 channel× 290 g (10.5 oz.)
T9300 I/O base unit (3 way)× 133 g (5 oz.)
T98x1 Simplex Termination assembly× 133 g (5 oz.)
T98x2 Dual Termination Assembly × 260 g (10 oz.)
T98x3 Triple Termination Assembly× 360 g (13 oz.)
T9310 Expansion cable assembly and 2 m cable× 670 g (24 oz.)
T9841 Termination Assemblies (average weight)× 175 g (6 oz.)
System Installation
Environment
Tot al es tima ted cont rol ler w eig ht
The installation environment can be a source of common cause failure so it is
necessary that the installation assessment covers the environmental
specification for the AADvance system and includes the following:
• the prevailing climatic conditions
• type of area, e.g. is it a hazardous or non-hazardous area
•location of power sources
• earthing and EMC conditions
In some customer installations parts of the system can be installed in differing
locations; in these cases the assessment must include each location.
Power Sources and Heat Dissipation Calculations
It is highly recommended that module supply power and field loop power
consumption calculations are done to find out the heat dissipation before
designing a suitable enclosure and making a decision about the installation
environment (see topic "System Design for Heat Dissipation").
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