AADvance Comprehensive Training Manual (Rev 1.7 Oct 2012)

System Training Manual
Operation,
System Build,
Configuration,
Programming,
Troubleshooting,
& Maintenance
For the AADvance

Programmable Controller
Revision 1.7
October 2012
Copyright Notice and Disclaimers

Notice
In no event will Rockwell Automation be responsible or liable for indirect or consequential
damages resulting from the use or application of this equipment. The examples given in
this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation does not
assume responsibility or reliability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, with respect to use of information,
circuits, equipment, or software described in this manual.
Reproduction of this manual in whole or in part, without written permission of Rockwell
Automation is prohibited.
All trademarks are acknowledged.
Disclaimer
It is not intended that the information in this publication covers every possible detail about
the construction, operation, or maintenance of a control system installation. You should
refer to your own (or supplied) system safety manual, installation instructions and
operator/maintenance manuals.
Revision and Updating Policy

This document is based on information available at the time of its publication; however, the
document contents are subject to change from time to time. You should contact Rockwell
Automation Technical Support by e-mail icstsupport@ra.rockwell.com to check if you
have the latest version of this publication.
Copyright Notice, Rockwell Automation 2012
This document contains proprietary information that is protected by copyright. All rights
are reserved.
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AADvance System Training Manual, version 1.7
Warning
Radio Frequency Interference
Most electronic equipment is influenced by radio frequency interference (RFI). Caution
should be exercised with regard to the use of portable communications equipment around
such equipment. Signs should be posted in the vicinity of the equipment cautioning against
the use of portable communications equipment.
Maintenance
Maintenance must be performed only by qualified personnel. Otherwise personal injury or
death, or damage to the system may result.
Company Background
ICS Triplex has been manufacturing and supplying safety critical shutdown and control
systems since 1969.
The Regent Triple Modular Redundant (TMR) system was introduced in 1986. It
incorporated Hardware-Implemented Fault Tolerance (HIFT). The Regent system has been
field-proven in hundreds of installation world-wide.
The Regent + Plus product family was introduced in 1995 and provided additional features
and lower cost to the marketplace.
The Trusted TMR system was introduced in 1997. The Trusted system is compatible with
legacy Regent and Regent + Plus systems allowing a direct migration path for existing
systems.
AADvance was released in 2008. AADvance is a flexible and scalable system designed to
enhance Trusted, not replace it. AADvance components can be configured as simplex, dual
or triplicated. Systems may be small and standalone, or large and distributed.
Applicability
This Training Manual applies to release 1.3.
Table of Contents
Issue Record
Issue
Date
Comments
1.6
June 2011
Updated for Release 1.2
1.7
July 2012
Integrated with user manuals and updated for release 1.3
Table of Contents
Chapter 1: Introduction
Course Goals .................................................................................................................... 1-1
Who This Course is Intended For .................................................................................... 1-2
Recommended Prerequisites ............................................................................................ 1-2
Course Length .................................................................................................................. 1-2
Chapter 2: System Overview

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

Purpose ............................................................................................................................. 3-1
Objectives......................................................................................................................... 3-1
System Components ......................................................................................................... 3-2
Hardware ........................................................................................................................ 3-2
Software .......................................................................................................................... 3-3
Processor Module ............................................................................................................. 3-4
Processor Base Unit ......................................................................................................... 3-8
Digital Input Modules .................................................................................................... 3-10
Analog Input Modules ................................................................................................... 3-12
Digital Output Module ................................................................................................... 3-14
I/O Module Base Unit .................................................................................................... 3-16
Field I/O Termination Assemblies ................................................................................. 3-18
Digital Input Termination Assemblies ......................................................................... 3-18
Analog Input Termination Assemblies ......................................................................... 3-22
Digital Output Termination Assemblies ....................................................................... 3-26
Table of Contents
Chapter 4: System Build

Purpose ............................................................................................................................. 4-1
Objectives......................................................................................................................... 4-1
System Build .................................................................................................................... 4-2
Environmental Limits ...................................................................................................... 4-3
Component Sizes and Weights ........................................................................................ 4-4
Free Space ........................................................................................................................ 4-6
Mount a Processor Base Unit ........................................................................................... 4-7
Mount the I/O Base Units ................................................................................................ 4-8
Mount Termination Assemblies ..................................................................................... 4-10
Mount I/O Expansion Cables ......................................................................................... 4-12
Module Power ................................................................................................................ 4-14
Module Power Supply Requirements.......................................................................... 4-15
Module Power Connections ........................................................................................ 4-16
Grounding ...................................................................................................................... 4-18
Security Dongle.............................................................................................................. 4-19
Processor Fault Alarm Contacts ..................................................................................... 4-20
Serial Connections ......................................................................................................... 4-22
Field Power .................................................................................................................... 4-23
Wire the Field Connections............................................................................................ 4-24
Digital Inputs............................................................................................................... 4-25
Analog Inputs .............................................................................................................. 4-27
Digital Outputs ............................................................................................................ 4-30
Cable Management ........................................................................................................ 4-32
Module Polarization ....................................................................................................... 4-34
Installing Modules and Blanks ....................................................................................... 4-36
Heat Dissipation ............................................................................................................. 4-38
Parts List ........................................................................................................................ 4-40
Chapter 5: Workbench Overview and Programming

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

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

Purpose ............................................................................................................................. 7-1
Objectives......................................................................................................................... 7-1
Loading a Resource in a Controller ................................................................................. 7-2
Monitoring Programs ....................................................................................................... 7-6
Locking / Forcing ............................................................................................................. 7-9
Difference Between Locking Inputs and Outputs ........................................................ 7-11
Unlocking All Variables ............................................................................................... 7-13
Viewing Live Data in the Equipment View ................................................................... 7-14
Spying Variables ............................................................................................................ 7-15
Show Variable Comments ............................................................................................. 7-16
Going Offline ................................................................................................................. 7-17
Chapter 8: Creating and Using Functions and Function Blocks

Purpose ............................................................................................................................. 8-1
Objectives......................................................................................................................... 8-1
Functions/Function Blocks .............................................................................................. 8-2
Creating a Structured Text Function ................................................................................ 8-3
Define Your Variables in the Dictionary ...................................................................... 8-4
Using the Function ........................................................................................................ 8-6
Creating a Function Block Diagram Function ................................................................. 8-8
Using the Function ...................................................................................................... 8-10
Chapter 9: Online Changes

Purpose ............................................................................................................................. 9-1
Objectives......................................................................................................................... 9-1
Modifying a Resource ...................................................................................................... 9-2
Checking Version Resource Numbers .......................................................................... 9-2
Online Changes ................................................................................................................ 9-3
Test Your Knowledge ...................................................................................................... 9-5
Table of Contents
Chapter 10: Bindings Between Resources

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

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

Purpose ........................................................................................................................... 13-1
Objectives....................................................................................................................... 13-1
OPC Server .................................................................................................................... 13-2
Data Access vs. Alarm & Event ................................................................................... 13-3
Configuring the OPC Server .......................................................................................... 13-4
Configuring OPC Clients ............................................................................................... 13-7
Chapter 14: Troubleshooting

Purpose ........................................................................................................................... 14-1
Objectives....................................................................................................................... 14-1
Self Test Cycle Times .................................................................................................... 14-2
Latching and Unlatching Faults ..................................................................................... 14-3
Fault Types ..................................................................................................................... 14-4
Viewing Variables Live ................................................................................................ 14-6
I/O State and LED Indications...................................................................................... 14-7
Processor Event Log ...................................................................................................... 14-9
Chapter 15: Replacing Modules

Purpose ........................................................................................................................... 15-1
Objectives....................................................................................................................... 15-1
Removing Modules ........................................................................................................ 15-2
Installing Modules.......................................................................................................... 15-3
Appendix 1: AADvance Discover Utility

Purpose .......................................................................................................................... A1-1
Objectives...................................................................................................................... A1-1
Processor Base Unit Configuration ............................................................................... A1-2
Appendix 2: Glossary
Purpose .......................................................................................................................... A2-1
Objectives...................................................................................................................... A2-1
Glossary ........................................................................................................................ A2-2
Table of Contents
Appendix 3: Puzzles and Exercise

Purpose .......................................................................................................................... A3-1
Objectives...................................................................................................................... A3-1
Hardware Puzzle ........................................................................................................... A3-2
Software Puzzle............................................................................................................. A3-3
Programming Exercise .................................................................................................. A3-4
Appendix 4: Safety Manual Considerations

Purpose .......................................................................................................................... A4-1
Objectives...................................................................................................................... A4-1
Please Read the Safety Manual!.................................................................................... A4-2
Rules vs. Recommendations ...................................................................................... A4-2
High Demand, SIL 3 and Energize to Action Applications ....................................... A4-3
Utilizing I/O Module Diagnostics .............................................................................. A4-3
Degraded Run Time Restrictions ............................................................................... A4-7
I/O Forcing ................................................................................................................. A4-8
Safety Manual Checklists......................................................................................... A4-10
10
Chapter 1
Introduction
Course Goals
To teach users of the AADvance system:
Introduction
How the AADvance system operates as a non-redundant

and fault tolerant programmable logic controller.
What modules and components are used in the

AADvance system.
How to put an AADvance system together.
How to use the workbench to create, modify, test,

download and update projects and programs to the
system.
How to create user defined functions and function

blocks.
How to pass safety critical data between controllers.
How to communicate with the system using OPC.
How to utilize the version control features.
How to troubleshoot a system and replace modules.

1-1
Who This Course Is Intended For
Personnel responsible for designing, configuring and

programming an AADvance system.
Personnel responsible for installation, troubleshooting

and maintenance of an AADvance system.
Personnel designing a control system that needs to

communicate with an AADvance system.
Recommended Prerequisites
A general knowledge of programmable logic controllers

(PLCs).
A background in industrial electronic control principles

and practices.
A level of competence using Microsoft Windows

operating systems and programs.
Course Length
4 days
The majority of the course is hands-on. Students implement
working solutions using actual hardware and software.
1-2
Chapter 2
System Overview
Purpose
To provide an overview of the AADvance system and its
components.
Objectives
System Overview
To understand the different system components and

configurations.
To understand what module configurations meet what

Safety Integrity Levels (SIL).
To understand the types and names of modules used in

the AADvance system.
To understand the configuration limits of the system.

2-1
AADvance System Overview

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

Emergency shutdown
Fire and gas detection/protection
Rotating machinery control
Burner management
Boiler and furnace control
Distributed monitoring and control
The system is designed for both high and low demand

applications.
Features
The main features of AADvance are:
2-2
Flexible modular construction using individual modules

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

The AADvance system consists of:
A processor base unit (that can hold up to three
processor modules)
I/O base units (that can hold up to three I/O modules)
I/O termination assemblies (that are inserted into the I/O
base units)
Processor and I/O modules (that are inserted into the
base units)
Figure 2-1: System Components
System Overview
2-3
48 simplex
modules, 24 dual,
or 16 triplicated.
There can be a mix
within a system.
A processor base unit can support up to 8 I/O base units (up to

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

not plug directly
into the left
connector of the
processor base unit.
Use an extension
cable.
Figure 2-2: Example System Layout
2-4
Internal Bus Structure

Internal communications between the processor and I/O
modules are supported by command and response buses that are
routed through the processor and I/O base units.
The processor modules send commands to the I/O modules and
process their returned responses. Each I/O module has a
dedicated response line back to the processors. An interprocessor link (IPL) provides the communication links between
dual or triple processor modules.
Figure 2-3: Internal Bus Structure
System Overview
2-5
Flexible Configurations
The AADvance system is flexible and scalable. Configurations
range from non-redundant fail safe to triplicated fault tolerant.
Individual modules are designed as fail safe. Redundant
modules are implemented for fault tolerance.
Processor Modules
A single processor module meets SIL 2 requirements.
Redundant processor modules (two or more) meet SIL 3
requirements. High demand applications also require the use of
redundant processor modules.
Input Modules
Individual input modules meet SIL 3 requirements. Redundant
modules are implemented for fault tolerance.
Output Modules
Individual output modules meet SIL 2 requirements in a
normally de-energized application and SIL 3 requirements in a
normally energized application. Redundant (dual) modules meet
SIL 3 requirements in a normally de-energized application and
provide fault tolerance in a normally energized application.
Triplicated output
modules are not
necessary and are
not supported.
Output modules incorporate dual redundant circuitry internally.

A dual module configuration provides a quad redundant output
circuit arrangement.
Typical system configurations are covered in the following
pages.
2-6
Non-Redundant, Fail Safe Architecture

Non-redundant modules will fail safe on the first detected fault
and the process under control will shut down.
This configuration meets SIL2 requirements (due to the single
processor) and is suitable for low demand mode applications
with either de-energise or energise to trip outputs.
This configuration is also known as 1oo1D.
Figure 2-4: 1oo1D Configuration
System Overview
2-7
Dual Processors, Non-Redundant I/O

Non-redundant I/O modules will fail safe on the first detected
fault and the process under control will shut down.
The processor modules will degrade to 1oo1D on the first fault
and must be replaced within the MTTR (Mean Time To Repair)
assumed in the PFD (Probability of Failure on Demand)
calculations in order to maintain the SIL 3 rating.
This configuration is suitable for high as well as low demand
mode applications and meets SIL3 requirements (SIL 2 for
energize to trip outputs).
Figure 2-5: 1oo2D Processors, 1oo1D I/O Configuration
2-8
Dual Architecture
Redundant I/O modules provide fault tolerance. Duplicated
output modules also meet SIL3 requirements for energise to trip
outputs.
Input modules will degrade to 1oo1D (fail safe configuration)
on the first detected fail danger fault with no time limit to
repair.
Processor modules will degrade to 1oo1D on a module fault and
must be replaced within the MTTR (Mean Time To Repair)
assumed in the PFD (Probability of Failure on Demand)
calculations in order to maintain the SIL 3 rating.
A failed output module used for a SIL3 energise to trip must be
replaced within the MTTR assumed in the PFD calculations.
There is no time limit in normally energized applications.
This configuration is also known as 1oo2D.
Termination
assemblies can
span across I/O
base units.
Figure 2-6: Dual Configuration
System Overview
2-9
TMR Input and Processor, Fault Tolerant

Output
Redundant I/O modules provide fault tolerance. Duplicated
output modules also meet SIL3 requirements for energise to trip
outputs.
Input modules will degrade to 1oo2D on a first fault. They will
degrade to 1oo1D on a second fault with no time limit to repair.
Processor modules will degrade to 1oo2D on a first fault. They
will degrade to 1oo1D on second module fault and a processor
must be replaced within the (Mean Time To Repair) assumed in
the PFD (Probability of Failure on Demand) calculations in
order to maintain the SIL 3 rating.
Output modules will degrade to 1oo1D on the first fault and
must be replaced within the MTTR assumed in the PFD
calculations (only for energize to trip outputs). There is no time
limit for normally energized applications.
Figure 2-7: TMR (2oo3D) Inputs & Processors, Fault Tolerant

Output Configuration
2-10
Mixed Architecture
There can be a mixture of architectures and SILs within one
system. Figure 2-7 shows non-redundant and dual I/O
configurations with dual processors. Triplicated inputs and/or
processors may also be included.
Figure 2-8: Mixed Architecture
System Overview
2-11
Distributed Architecture
It is possible to locate I/O modules in separate systems and link
the data using a network connection certified for safety
applications. The systems share variables using bindings, as
covered in Chapter 10.
Figure 2-9: Distributed Architecture
2-12
Test Your Knowledge

1. How many of each I/O module are required to meet SIL
3 in a normally energized application?
2. How many processor modules are required to meet SIL
3?
3. What is the minimum number of modules required for
fault tolerance?
4. What is the total number of I/O modules that a processor
can support?
5. Are triplicated output modules supported?
6. How many response buses does a processor have?
System Overview
2-13
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Chapter 3
System Components
Purpose
To provide an overview of the AADvance system and its
components.
Objectives
System Components
To understand the types and names of modules and

components used in the AAdvance system.
To understand module and component features.
3-1
System Components
Hardware
The current release of AADvance consists of a 9110 processor
module, 9401 & 9402 24V isolated digital input modules (8 &
16 channel), 9431 & 9432 4 20mA isolated analog input
modules (8 & 16 channel), 9451 24V digital output module and
9481 & 9482 isolated analog output modules (3 & 8 channel).
Other components required to complete the systems are a 9100
processor base unit, 9300 I/O base units for connecting the I/O
modules to the processor, 9310 bus extension cable and
termination assemblies for connecting the I/O modules to field
devices.
The hardware is modular. A processor base unit supports up to
three processor modules. I/O base units support up to three I/O
modules. I/O base units mate directly with the processor base
unit and other I/O base units. I/O base units provide the intermodule communications buses and route power from the
processor base unit to the I/O modules. The system becomes
one interconnected mechanical and electrical assembly once
assembled.
Figure 3-1: AADvance System

3-2
Item
Description
9110 Processor Module
Diagnostic Cable Connection
9401 Isolated 24Vdc Digital Input Modules
9451 24V Digital Output Modules
9852 Digital Output 24Vdc Dual 8 Ch. Termination Assembly
9802 Isolated Digital Input Dual 16 Ch. Termination

Assembly
9100 Processor Base unit
Ethernet Connection
Power Supply Unit
Table 3-1: AADvance Components
Hardware may be mounted on a DIN rail or flat panel. The

system does not require forced air cooling fans.
Software
AADvance can be a distributed system where each node
(referred to as a configuration) has at least a single processor
module and its associated I/O. Each node is a stand alone
system configured using IEC 61131-3 languages. Data may
easily be transferred between nodes using bindings. Programs
may be simulated offline for testing. AADvance runs a certified
for safety operating system.
System Components
3-3
Processor Module
The 9110 processor module communicates with the network,
handles I/O scanning and solves application logic. It
incorporates the following features:
Rated for applications up to SIL
2 (non-redundant) and SIL 3
(dual & triple)
IEC 61508 certified
Handles full range of IEC
61131-3 languages
Application processor,
communications co-processor
and math co-processor
Two Ethernet and two serial
ports (RS485) per processor
MODBUS, CIP and AADvance
safety network protocols
Built in diagnostic testing and
independent watchdog
Removal and replacement
without system interruption in
dual or triple configurations
System self-discovery at startup
Figure 3-2: AADvance

Processor Module
3-4
Battery
A replaceable battery is used to retain
the following during a power loss:
Figure 3-3:
Processor Battery
1)
system diagnostic logs
2)
keep the real time clock running
3)
variables flagged as retained
Resources and programs are stored in

flash memory that does not need a
battery.
The battery is a coin type BR2032 and is secured in a holder

under the front cover of the module. The holder is provided
with a ribbon to facilitate removal of the battery, as shown in
Figure 3-3.
The battery will last

for approximately
ten years under
normal conditions
(powered) and six
months unpowered.
You gain access to the battery by unscrewing the protective

cover on the lower portion of the front panel.
Fault Reset Button

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

reset button does
not impact scan
time or the
handling of I/O.
Module Locking Mechanism

Modules will only
run when the screw
is in the locked
position.
System Components
Each module (processor and I/O) has a locking mechanism that

secures the module onto its base unit. The locking mechanism is
a screw visible on the front panel of the module. It is engaged
by a clockwise quarter turn of a flat blade screwdriver. The
module incorporates an interlock which detects when a module
is locked or unlocked.
3-5
LEDs
There are 10 LEDs on the front of the module. The meaning of
each LED is described in Table 3-2.
Indicator
Healthy
Ready
Run
System
Healthy
Force
AUX
3-6
Status
Description
Provides an indication of the modules fault and power status
Off
No power
Green
Module online with no fault
Red
Power up / reset in progress; module fault or unlocked; module
offline
Provides an indication of the modules education and synchronization status
Off
No power
Flashing Green
Education and/or synchronization in progress
Green
Processor educated and synchronized with partner(s)
Amber
Module is in the Recovery Mode
Red
Processor not educated or synchronized with partner(s)
Provides an indication of the modules resource status. Should be the same for all
educated and synchronized processors.
Off
No power
Green
Resource present and running
Amber
Resource present but not running, or module is in the Recovery
Mode
Red
Resource not present; module not educated or synchronized
Provides an indication of the global health of the system. Will be the same for all
educated and synchronized processors.
Off
No power
Green
No system or module fault(s) reported
Red
A system or module has a fault(s)
Provides an indication whether any variables are being locked/forced in the system.
Should be the same for all educated and synchronized processors.
Off
No power
Green
No variables locked/forced
Amber
At least one variable locked/forced, or or module is in the Recovery
Mode
Any
Under user control
Amber
Under user control or module is in the Recovery Mode
Serial 1 & 2
Ethernet 1 & 2
Provides an indication of serial port activity

Off
No port activity
Green
Receive
Red
Transmit
Amber
Receive and transmit activity in close proximity
Provides an indication of Ethernet port activity
Off
No port activity
Green
Link (connection) present
Amber
Receive or transmit activity
Table 3-2: Processor LED Status
System Components
3-7
Processor Base Unit
Figure 3-4: AADvance Processor Base Unit
The 9100 processor base unit accepts up to three processor

modules and incorporates the following features:
3-8
Module power is
connected to the
processor base unit
and connects
through the I/O
base units to power
all I/O modules.
Provides redundant connections for the system power
Provides the connection for ground
Provides the connections for the external redundant control

network via two Ethernet connectors per processor
Provides the connections for two serial ports per processor
Provides the connection for a security dongle
Figure 3-5: AADvance Processor Base Unit Detail
Lettering
Description
E1-1, E1-2
Ethernet Port 1 and 2 for Processor A
E2-1, E2-2
Ethernet Port 1 and 2 for Processor B
E3-1,E3-3
Ethernet Port 1 and 2 for Processor C
S1-1, S1-2
Serial Port 1 and 2 for Processor A
S2-1, S2-2
Serial Port 1 and 2 for Processor B
S3-1, S3-2
Serial Port 1 and 2 for Processor C
PWR -1, PWR-2
+24V dc System Supply & 0V connectors 1 and 2
FLT
Alarm Connector (no longer used)
KEY
Security Dongle connector
Earth Symbol
Ground Connection
Table 3-3: Processor Base Unit Connection Information
System Components
3-9
Digital Input Modules

The 9401 (8 channel) and 9402 (16 channel) are 24Vdc digital
input modules. They accept galvanically isolated inputs and
perform signal conditioning and conversion.
The modules incorporate extensive
diagnostics. Individual modules are
non-redundant, fail-safe, and
certified for use in SIL 3
applications.
Redundancy and fault tolerance is
achieved by grouping two or three
modules together with common
field connections.
Modules can be removed and
replaced online without system
interruption when used in
redundant (dual or triple)
configurations.
Sequence of events (SOE)
resolution is 10 msec.
The modules measure analog
voltage in order to perform line
monitoring and field fault detection
(e.g., open / short circuits).
Switching levels for each input
channel are configurable in the
workbench. The default parameters
are:
Off: 0 to 5V dc
On: 15 to 30V dc
Digital Input Module
3-10
There are 11 LEDs on the front of

the module. The meaning of each
LED is described in Table 3-4.
Indicator
Healthy
Ready
Run
Channel
Status
Description
Provides an indication of the modules general status
Off
No power
Green
Red
Module online with fault(s)
Provides an indication of the modules ability to report values to a running resource
Off
No power or unlocked
Green
Module locked and ready to report channel values
Red
Module locked but not ready to report channel values
Provides an indication that the module is reporting channel values to a running resource
Off
Green
Module reporting channel values
Red
Module not reporting channel values
Amber
Manual intervention (i.e., pressing the processor reset button) is
required before values can be reported
Provides the status of each input channel
Off
Channel is off (switch open)/de-energized or when RUN is not GREEN
Green
Channel is on (switch closed)
Amber
Field fault (open circuit or short circuit)
Red
Channel fault
Table 3-4: Digital Input Module LED Status Indications
System Components
3-11
Analog Input Modules

The 9431 (8 channel) and 9432 (16 channel) are 24Vdc analog
input modules. They accept galvanically isolated 4 20mA
inputs and perform signal conditioning and conversion.
The modules incorporate extensive
diagnostics. Individual modules are
non-redundant, fail-safe, and
certified for use in SIL 3
applications.
achieved by grouping two or three
field connections.
redundant (dual or triple)
configurations.
Monitoring levels for each analog
channel are configurable in the
workbench. The default parameters
are:
Fault:
0 to 3.8mA
Normal: 3.8 to 22.0mA

Fault:
>22.0mA
The modules support HART

(Highway Addressable Remote
Transducer) communications.

Analog Input Module
3-12
There are 11 LEDs on the front of

the module. The meaning of each
LED is described in Table 3-5.
Indicator
Healthy
Ready
Run
Channel
Status
Description
Off
No power
Green
Red
Off
Green
Module locked and ready to report channel values
Red
Module locked and not ready to report channel values
Off
Green
Module reporting channel values
Red
Module not reporting channel values
Amber
required before values can be reported
Provides the status of each input channel
Off
RUN is not Green
Green
Channel input is within normal range
Amber
Field fault (transmitter fault, open circuit, short circuit)
Red
Channel fault
Table 3-5: Analog Input Module LED Status Indications
System Components
3-13
Digital Output Module

The 9451 isolated digital output module connects to eight
isolated circuits and incorporates the following features:
Dual series output switches
per channel (1oo2)
Built in overload protection
per channel
1A continuous rating for each
circuit
Voltage and current
monitoring (feedback) per
channel
Short circuit and open circuit
line fault detection for on and
off channels
Dual redundant field power
without the need for external
diodes
Output channel reverse
current protection
The modules incorporate
extensive diagnostics. Individual
modules are fail-safe and certified
for use in SIL 2 normally deenergized and SIL 3 normally
energized applications.
Triplicated output
modules are not
necessary and are
not supported.

Digital Output Module

achieved by grouping two
field connections. Two modules
provide a quad output circuit
arrangement and full fault
tolerance.
redundant (dual) configurations.
3-14
There are 11 LEDs on the front of the module. The meaning of

each LED is described in Table 3-6.
Indicator
Healthy
Ready
Run
Channel
Status
Description
Off
No power
Green
Red
Off
Green
Module locked and ready to report values
Red
Module locked but not ready to report values
Off
Green
Module is being driven and reporting channel values
Red
Module is not being driven and not reporting channel values
Amber
required before the module can be driven and report channel values
Provides the status of each output channel
Off
Channel is off/de-energized or when RUN is not GREEN
Green
Channel is on/energized
Amber
Field fault
Red
Channel fault
Table 3-6: Digital Output Module LED Status Indications
System Components
3-15
I/O Module Base Unit
Figure 3-9: AADvance I/O Module Base Unit
The 9300 I/O module base unit connects the processor to I/O
modules. You can install up to three modules on a base unit.
Termination
assemblies can
span across base
units.
3-16
The base unit will also allow you to fit the same number of
termination assemblies in different combinations. For, example,
you can fit three simplex termination assemblies; or one dual
and one simplex together, or one triple termination assembly.
The combination will depend entirely on your required
configuration.
The I/O base unit incorporates the following features:
System Components
Provides connection for one, two or three input/output

modules depending on the redundancy requirements
Provides connections with termination assemblies that

connect to the field input/outputs
Routes power to the I/O modules from the processor base

unit
Routes common processor commands to the I/O modules
Routes responses between the I/O modules and processors
3-17
Field I/O Termination Assemblies

Field wiring is connected to termination assemblies (TAs).
Digital Input Termination Assemblies

A 9801 digital input termination assembly is a non-redundnat
unit that provides connections for 16 non-isolated digital input
channels and mates with a single 9401 or 9402 24Vdc digital
input module.
Figure 3-10: AADvance DI Non-Redundant Termination Assembly
3-18
Figure 3-11 & 12: AADvance DI Non-Redundant

Termination Assembly and Fuses
Fuse (shown in the figures above) will blow when an extreme

over voltage is applied. Fuses can be replaced without removing
a module using needle-nose pliers.
The assembly incorporates the following features:
System Components
16 input channels for a simplex configuration
Industry standard field device connections at the terminal

blocks
Fail safe design with individually fused channels and over

voltage protection
3-19
The 9802 termination assembly is the dual version and mates

with two 9401 or 9402 modules, as shown in Figure 3-13.
Figure 3-13: AADvance DI Dual Termination Assembly
3-20
The 9803 termination assembly is the triplicated version and

mates with three 9401 or 9402 modules, as shown in
Figure 3-14.
Figure 3-14: AADvance DI Triplicated Termination Assembly
System Components
3-21
Analog Input Termination Assemblies

A 9831 termination assembly is a non-redundant assembly that
provides connections for 16 non-isolated analog input channels
and mates with a single 9431 or 9432 analog input module.
Figure 3-15: AADvance AI Non-Redundant Termination Assembly
Each channel has a 50mA fuse to prevent component damage in

over-current situations. Fuses can be replaced without removing
a module using needle-nose pliers
3-22
Figure 3-16: AADvance AI Simplex Termination Assembly
The assembly incorporates the following features:
System Components
16 input channels for a simplex configuration
Industry standard field device connections at the terminal

blocks
Fail safe design with individually fused channels
3-23
The 9832 termination assembly is the dual version and mates

with two 9431 or 9432 modules.
Figure 3-17: AADvance AI Dual Termination Assembly
3-24
The 9833 termination assembly is the triplicated version and

mates with three 9431 or 9432 modules.
Figure 3-18: AADvance AI Triplicated Termination Assembly
System Components
3-25
Digital Output Termination Assemblies
Figure 3-19: AADvance DO Non-Redundant Termination Assembly

provides termination for 8 digital outputs and mates with a
single 9451 24Vdc digital output module.
The termination assembly routes the module output channels
via the mating connector to the field connection terminal
blocks.
The 24Vdc field voltages VFIELD 1 and VFIELD 2, used by
the output module for the output field voltages, are connected at
the terminal blocks and routed via two replaceable 10A fuses F1
and F2. These fuses, shown in Figures 3-19 through 21, give
protection for the output module against field faults.
3-26
Figure 3-20 & 21: AADvance DO Termination Assembly

and Field Power Fuses
System Components
3-27
Figure 3-22: AADvance DO Dual Termination Assembly
A 9852 termination assembly is a dual assembly that provides

termination for 8 digital outputs and mates with two 9451
24Vdc digital output modules.
3-28
Analog Output Termination Assemblies
Figure 3-19: AADvance AO Non-Redundant Termination Assembly

provides termination for 8 analog outputs and mates with a
single 9481 or 9482 analog output module.
The termination assembly routes the module output channels
via the mating connector to the field connection terminal
blocks.
Although it has a fuse cover, there are no fuses. The visible
components are capacitors for EMC suppression.
System Components
3-29
Figure 3-22: AADvance DO Dual Termination Assembly
A 9882 termination assembly is a dual assembly that provides

termination for 8 analog outputs and mates with two 9481 or
9482 analog output modules.
3-30
Test Your Knowledge

1. A processor base unit can hold how many processor
modules?
2. An I/O base unit can hold how many I/O modules?
3. How many Ethernet and serial connections are
supported by a single processor module?
4. What does the battery retain during a power loss?
5. What does the battery not need to retain during a power
loss, and why?
6. What two functions does the reset pushbutton have?
7. How is a field fault shown on the LEDs?
8. Can termination assemblies span across I/O base units?
System Components
3-31
Chapter 4
System Build
Purpose
To summarize how to assemble an AADvance system.
Objectives
System Build
To understand the environmental limits of the system.
To understand module power requirements, heat

dissipation and weight.
To be able to install base plates, termination assemblies,

cables and modules.
To be able to wire field devices to the system.
4-1
System Build
Note: This chapter is a condensed version of the AADvance
System Build Manual, which system integrators are
highly encouraged to read.
AADvance is a modular system. Base units snap together using
mating connectors and retaining clips.
The base units provide the interconnections for module power,
processor and I/O data. Once connected, the base units form a
single mechanical assembly.
The insertion and removal of modules will not disturb the
electrical connections with field devices.
AADvance modules are suitable for wall mounting or for
installation within an enclosure. The system is designed to meet
its electromagnetic compatibility criteria without further
protection from an enclosure.
AADvance can be panel or DIN rail mounted (using TS35
35mm x 7.5mm standard symmetric rails).
Use the following steps to assemble a system.
1) Mount a processor base unit
2) Mount the I/O base units
3) Mount termination assemblies
4) Mount I/O expansion cables (optional)
5) Wire the field connections
6) Connect power and ground
7) Mount the processor and I/O modules
8) Ensure adequate power and heat dissipation
4-2
Environmental Limits
The design of each installation must ensure that the operating
environment is within the tolerances of the equipment.
Consideration must be given to proper control of:
Temperature
Humidity
Vibration and shock
EMI / RFI
Temperature
Operating temperature: -20 to 70C (-4 to 158F)
Note: Processors limited to 60C (140F)
Storage & transport temperature: -40 to 70C (-40 to 158F)
Humidity
The system is designed to operate in the range of 10 to 95%
relative humidity, non-condensing. It is important to avoid
changes of humidity and temperature that could produce
condensation. Condensation on any type of electrical equipment
can result in equipment failures or improper operation.
Vibration and shock
The modules are designed to withstand a 15g peak shock and
vibration to 0.5g sinusoidal sweep between 10Hz to 150Hz.
Care must be taken to isolate the system from any sources of
extreme mechanical shock or vibration.
EMI / RFI
The modules have been designed to meet the requirements of
EN500081/82 and EN55011/55022.
System Build
4-3
Component Size and Weights

Item
Base unit
Module
Dimensions (H x W x D)
233 x 126 x 18 mm
(9- x 5 x in)
166 x 42 x 118 mm
(6- x 1- x 4- in)
Table 4-1: AADvance Component Sizes
The total depth of a base unit and module is 136 mm (5-in).
Figure 4-1: Component Dimensions (in mm)
4-4
Ensure that the mounting assembly can support the weight of

the AADvance components using the Table 4-2.
Component
Processor base unit
I/O base unit
Processor module
Digital input module (8 channel)
Analog input module (8 channel)
Digital output module
Analog output module (8 channel)
Simplex termination assembly
Dual termination assembly
Triplicated termination assembly
Processor blank cover
I/O module blank cover
Expansion cable (2 meters)
Power supply
Weight g (oz)
460 (16)
133 (5)
430 (15)
280 (10)
340 (12)
280 (10)
340 (12)
340 (12)
290 (10.5)
133 (5)
260 (10)
360 (13)
40 (1)
50 (2)
670 (24)
Varies
Table 4-2: AADvance Component Weights
System Build
4-5
Free Space
The system requires a free space at least 140mm deep (from
front to back) between the rear panel of an enclosure and the
inside of an enclosure door.
Allow sufficient free space around the base units. Every
application needs space on at least three sides, as follows:
Space above, to manipulate and install field wiring
Space below, to enable modules to fit and to be able to

grasp a module during removal
Space to the right, to maneuver an I/O base unit during

assembly or in the event of installing a new base unit.
If an expansion cable is to connect to the left-most base unit, the

controller also needs space to the left, to fit the expansion cable
adaptor.
Figure 4-2 shows the minimum recommended clearances for
DIN rail mounting.
Figure 4-2: Required Free Space (in mm)
4-6
Mount a Processor Base Unit

A processor base unit will support up to three processor
modules.
Figure 4-3: Installing a Processor Base Unit
1) Place the processor base unit onto the DIN rail.

2) Secure the base unit by pushing the bottom retaining
lever as far to the left as it will go until it latches in the
locked position.
Note: Base plates may also be mounted flush on a panel wall
using screws without a DIN rail.
System Build
4-7
Mount the I/O Module Base Units

You can install up to three I/O modules on an I/O base unit.
Figure 4-4: Installing an I/O Base Unit
1) Mount a 9300 I/O base unit onto the DIN rail and slide it
towards the 9100 processor base unit.
2) Ensure the joining connectors are fully mated.
3) Secure the base unit by pushing the bottom retaining
lever as far to the left as it will go until it latches in the
locked position.
4) Insert the plastic retaining clips into the top and the
bottom slots.
Note: Base plates mounted flush on a panel wall will need to
be connected before mounting.
4-8
This page is intentionally blank.
System Build
4-9
Mount Termination Assemblies

Termination assemblies connect to I/O base units. You can fit
three simplex assemblies, or one dual and one simplex, or a
single triplicated termination assembly. The combination used
will depend on your systems specific configuration
requirements.
Termination
assemblies can
span across base
units.
1) Insert the termination assembly (TA) retaining clip (at

the rear of the TA) into the slot on the plastic base unit,
as shown in Figure 4-5. Press down and slide the
assembly upwards as far as it will go.
2) Ensure the retaining tab clips over the circuit board to
secure the TA in position, as shown in Figure 4-6.
Figure 4-5: Installing a Termination Assembly
4-10
Figure 4-6: Installing a Termination Assembly
System Build
4-11
Mount I/O Expansion Cables

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

another I/O base unit or to the processor base unit. The
assembly consists of a cable, terminated by multi-way plugs,
and a pair of adaptors.
The adaptors, shown in Figure 4-8, are 'handed' left and right.
One adaptor connects to the right-hand bus connector of an I/O
base unit or to bus 2 (the left hand connector) of a processor
base unit. The other adapter connects to the left-hand bus
connector of an I/O base unit.
4-12
Figure 4-8: I/O Expansion Cable Adapters
Terminators are not

required at the end
of the bus (last base
unit).
System Build
Standard expansion cable assemblies are two meters long.

(Custom lengths can be supplied.) The maximum possible
length of an entire bus (the combination of I/O base units and
expansion cables) is 8 meters.
4-13
Module Power
Power supplies should be installed in a position where the 24V
dc supply wiring can be kept reasonably short. Figure 4-9
shows an arrangement with one power supply unit for a nonredundant, fail safe controller.
Figure 4-9: Power Supply Mounting
It is recommended that the negative side of the field supply be

grounded. This will avoid possible fail danger conditions that
can be caused by some earth fault monitors used with floating
power supplies.
The power supply protection of the system is within the
modules, not the base units. To protect the base units, the power
distribution arrangement must provide a circuit breaker on the
input side of each power source. The system can withstand a
reverse polarity connection without permanent damage.
4-14
Module Power Supply Requirements
Field devices
require an
additional source of
power.
High Availability
I/O (1715) use the
same hardware but
ratings are different
these are
calculated as worst
case using different
methods.
AADvance requires 24Vdc power with a tolerance between

18Vdc and 32Vdc. The system has been designed to operate
with most commercially available industrial uninterruptable
power supplies (UPS). To select a suitable power supply,
calculate the overall system load that must be powered (using
Table 4-3), include any additional devices and add a
contingency allowance between 25% and 50%.
Component
9110 Processor module
9401 Digital input module
9431 Analog input module
9451 Digital output module
Power supply
Power Requirement
8W
3.3 W
4.0 W
3.3 W
4.0 W
3.0 W
3.6 W
Varies
Table 4-3: AADvance Module Power Requirements
System Build
4-15
Module Power Connections
Power is distributed
to the I/O modules
through the base
units.
AADvance modules are designed to operate from two

independent 24Vdc sources with a common return. Power is
connected to the two plugs PWR-1 and PWR-2 on the processor
base plate, as shown in Figures 4-10 and 4-11. The center
terminals are normally left unconnected.
Figure 4-10: Processor Base Unit Power Connection
The terminal blocks

can be removed for
easy access.
Figure 4-11: Module Power Connection
4-16
The processor base unit links the +24V dc connections to the

center terminal of each connector, as shown in Figure 4-12.
This link may be used to connect the +24V dc supply to other
processor base units.
Figure 4-12: Processor Base Unit Power Connection Detail
Wiring Attribute
Conductor cross section,
stranded maximum
solid maximum
Stripping length
Size
2.5 mm (12 AWG)
2
2.5 mm2 (12 AWG)

7 mm (9/32 inch)
Table 4-4: Module Power Wiring Sizes
System Build
4-17
Grounding
AADvance systems may have up to three separate ground
systems:
An AC safety ground (sometimes called the dirty

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

ground or 0 Vdc ground) to provide a good stable 0V
reference for the system. Every signal return should be
referenced to the instrument ground, which will be
isolated from the AC safety ground.
Some field wiring will need shielded (screened) cable.

There may be a shield ground in addition to the AC
safety and instrument grounds to provide a common
point to terminate cable shields.
Figure 4-13: AADvance Processor Base Unit Safety

Ground Connection Detail
Systems may also be supplied with an IS (intrinsic safety)

ground as required.
Copper bus bars are normally used for grounding.
4-18
Security Dongle
The system uses a dongle to control security. The dongle must
be connected in order to download programs, make online
changes, or perform locking (forcing). The dongle is supplied
with the processor base unit.
Figure 4-14: Security Dongle
Processor Fault Alarm Contacts

The terminal block marked 'FLT' is no longer used and does not
work from release 1.1.
System Build
4-19
Serial Connections
Each processor has two serial RS485 connections. The system
supports both 2 wire (half duplex) and 4 wire (full duplex)
configurations, with multi-drop supported in both
configurations.
The terminal blocks
can be removed for
easy access.
The pin-outs for the six serial connections on the processor base
unit are shown in Figure 4-17 and Table 4-6.
Figure 4-17: Serial Connections
'Receive' and
'transmit') are with
respect to the
processor base unit.
Terminal
Function (4 wire)
TRX A
Receive data A
(inverting)
TRX B
Receive data B
(non-inverting)
0V
Instrument ground
TX A
Transmit data B
(non-inverting)
TX B
Transmit data A
(inverting)
Function (2 wire)
Transmit/receive data A
(inverting)
Transmit/receive data B
(non-inverting)
Instrument ground
Not used
Not used
Table 4-6: Serial Connections
4-20
Field Power
Field devices require an external source of power. This may be
the power source used for the controller or a separate power
source, depending on the application.
Each input circuit should be fused. Each output module group
(e.g., a module pair) should also have the field power fused. For
a typical system, it is recommended that you provide a single
breaker on the output of the field power source, followed by one
or more fused terminals.
System Build
4-21
Wire the Field Connections

Field wiring is connected direct to the terminal blocks of a
termination assembly (TA).
Wiring Attribute
stranded maximum
solid maximum
Stripping length
Size
1.5 mm (16 AWG)
2
1.5 mm2 (16 AWG)

6 mm ( inch)
Table 4-7: Field Connection Wiring Sizes
Non-redundant termination assemblies have commoned power.
4-22
Digital Inputs
Figure 4-18: Simplex Digital Input Field Connections
Figure 4-19: Dual and Triplicated Digital Input Field Connections
System Build
4-23
Figure 4-20: Standard Digital Input Field Loop Circuit
Figure 4-21: Line Monitored Digital Input Field Loop Circuit
Note: Please refer to the System Build manual for more details
on normally de-energized inputs, recommended resistor
values and input voltage threshold settings, etc.
4-24
Analog Inputs
Figure 4-22: Simplex Analog Input Field Connections
Figure 4-23: Dual and Triplicated Analog Input Field Connections
System Build
4-25
Figure 4-24: Two Wire Analog Input Field Loop Circuit
Figure 4-25: Three Wire Analog Input Loop Circuit
4-26
Figure 4-26: Four Wire Analog Input Loop Circuit
System Build
4-27
Digital Outputs
Figure 4-27: Simplex & Dual Digital Output Field

Terminations
4-28
Figure 4-28: Digital Output Field Loop Circuit
For inductive loads, connect a diode at the actuator to protect

the controller against back EMF.
System Build
4-29
Cable Management
The field, power and other system wiring will be connected to
terminals along the top of the base units. It is recommended a
length of trunking be located above each set of base units for
cable management.
Figure 4-29: Cable Management
4-30
System Build
4-31
Module Polarization
Module polarization prevents the wrong module from being
inserted into the wrong base unit. Modules are supplied with
plugs already fitted, as shown in Figure 4-30.
Figure 4-30: Module

Polarization
Termination
assemblies are
supplied with the
pins already
inserted.
Figure 4-31: Module

Polarizing Pin Base
Unit Positions
The legend for the polarization pins is shown in the lower left of
the processor base unit and on each I/O termination assembly,
as shown in Figure 4-31. The positions are numbered 1 through
6. The three pins are lettered A, B and C with A being on the
top. Each pin, shown in Figure 4-32, is fitted in the base unit so
that the index recess is next to the relevant numbered position
shown in Table 4-8, as shown in Figures 4-32 and 33.
Module
9110 Processor module
9431 Analog Input module
9432 Analog Input module
Pin A
1
2
2
2
2
3
3
3
Pin B
1
1
1
1
1
1
1
1
Pin C
1
1
1
3
3
1
2
2
Table 4-8: Module Polarizing Pin Allocation

4-32
Figure 4-32: Polarizing Pin
Figure 4-33 shows the pins inserted for a 9401 digital input
module and TAs.
T9801/2/3 TA
T9401
TA
Figure 4-33: Inserted Polarizing Pins
System Build
4-33
Installing Modules and Blanks

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

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

Blank plates should be installed over unused slot locations, as
shown in Figure 4-35. Long blank plates are designed for I/O
slot positions with no termination assembly.
Figure 4-35: Processor Blank Plate
System Build
4-35
Heat Dissipation
AADvance is designed to operate without forced air cooling.
Ensure that adequate ventilation is provided. Ambient
temperature within an enclosure should not exceed 60C
(140F), unless the enclosure does not contain the processors, in
which case the limit is 70C (158F).
Base plates and
modules must be
mounted vertically
to allow proper air
circulation through
the modules.
The system dissipates all the power it uses as heat. Module

power is connected to the processor base plate. Field power is
connected to I/O termination assemblies and some of that power
will also be dissipated as heat. Use Table 4-9 to estimate the
maximum heat generated by the modules.
Component
Processor module
Digital input channel
Analog input channel (25mA)
Digital output module
Digital output channel (1A)
Analog output module (8 channel)
Power supply
Heat Generated
8W
3.3 W
4.0 W
0.11 W
3.3 W
4.0 W
0.06 W
3.0 W
0.5 W
3.6 W
Varies
Table 4-9: AADvance Module Heat Dissipation
4-36
System Build
4-37
Parts List
Note: Parts may be added to this list in future releases. Please
consult Rockwell Automation for an updated list of available
parts.
Software Development Environment
9082
9083
9084
9085
9030
IEC61131 Workbench suite with single user, single

controller license
IEC61131 Workbench suite with single user,
unlimited controller license
IEC61131 Workbench suite with five user, unlimited
controller license
Five additional user license (for use with item 9084)
OPC portal server
Processor Equipment
9100
9110
9193
Processor base unit

Processor module
Blanking cover (short), for unused position on
processor base unit
Expansion Cable Assemblies
Expansion cable assembly, comprising expansion cable and two

adaptors (handed):
9310-02 2 meter expansion cable (approximately 6 feet)
9310-xx Custom length expansion cable
I/O Equipment
9300
9401
9402
9431
9432
9451
9481
9482
9191
I/O base unit

Digital input module, 24V dc, 8 channel
Digital input module, 24V dc, 16 channel
Analog input module, 8 channel
Analog input module, 16 channel
Digital output module, 24V dc, 8 channel
Analog output module, 3 channel
Analog output module, 8 channel
Blanking cover (tall), for unused position on I/O base
unit
The 9193 blanking cover may be used for positions on an I/O
base unit with a termination assembly fitted.
4-38
Termination Assemblies
9801
9802
9803
9831
9832
9833
9851
9852
9881
9882
Digital input TA, 16 channel, simplex, non-isolated

Digital input TA, 16 channel, dual
Digital input TA, 16 channel, TMR
Analog input TA, 16 channel, simplex, non-isolated
Analog input TA, 16 channel, dual
Analog input TA, 16 channel, TMR
Digital output TA, 24V dc, 8 channel, simplex, nonisolated
Digital output TA, 24V dc, 8 channel, dual, nonisolated
Analog output TA, 8 channel, simplex
Analog output TA, 8 channel, dual
Consumable Spares
9901
9902
9903
9904
9905
9906
System Build
Input fuse, 50mA (pack of 20)

Output fuse, 10A (pack of 20)
Coding peg / Polarizing Pins (pack of 20)
Backplane clip (pack of 20)
Battery, lithium, 3V 255mAh, coin pattern BR2032 or
equivalent, for 9110 processor module (pack of 10)
Replacement security dongle
4-39
Test Your Knowledge

1. What temperature range are the processors designed to
operate within?
2. What are the two ways to mount base plates?
3. Where is I/O module field power connected?
4. How much power would a system with the following
modules require? Assume all input modules are 16
channel.
dual processors
two sets of triplicated analog input modules
five simplex analog input modules
four simplex digital input modules
two sets of dual digital output modules
three simplex digital output modules
5. How much would the system described in question 4

weigh?
6. How many I/O module base units would be required for
the system described in question 4?
4-40
Chapter 5
Workbench Overview and

Programming
Purpose
To review the steps required to develop programs.
Objectives
To be able to create projects.
To be able to add variable names to the dictionary.
To be able to build an I/O configuration and assign

variable names.
To be able to configure the hardware: serial port

settings, input module thresholds, watchdog timers, etc.
To be able to create, edit and compile programs.
Workbench Overview and Programming
5-1
Workbench
The AADvance workbench is used to build control and safety
programs. These programs can be distributed across several
hardware platforms referred to as configurations.
Configurations communicate with each other through
networks. Configurations run resources which are groups of
programs (up to 250) that are compiled and downloaded.
This manual
describes software
functionality
included in release
1.31 (Build
1.20.508).
The workbench is IEC 61131-3 compliant, offering all five

languages (ladder, function block, structured text, instruction
list and sequential function chart). Programs can be simulated
and tested on the PC before downloading to actual hardware.
Starting the Workbench

Please refer to the
Configuration
Guide for more
information on the
licensing options
and the operation
of the License
Manager.
5-2
Start the workbench: Start All Programs AADvance

AADvance Workbench. The workbench will run in demo mode
for 30 days without a license. Full functionality requires a
license (e.g., USB dongle).
Start a New Project

To start a new project, select File | New Project/Library, or use
the New button. The following dialog box will appear.
Figure 5-1: New Project Dialog Box
The name is used as the project folder name. Project file names
are always PRJLIBRARY.MDB.
The topics of the

repository, version
control and checkin/out are covered
in Chapter 11.
The Workbench allows multiple people to work on a project at

the same time. This requires locating certain files in a location
that others can access (if you wish to utilize this capability). The
Destination Folder is the location on your PC where various
local files are stored. The Repository Path is the location folder
where other centralized version information is stored. The
default location for both folders is on the C drive of the PC that
has the software loaded, but the Repository folder can be
located on a central server.
5-3
Workbench Overview
The link architecture view graphically displays the resources of
a project and any links between them. This is the default view
of the workbench providing a main entry point to all editors.
If you do not see the

Project Tree on the
left, click Window |
Show Project Tree.
Figure 5-2: Link Architecture View
A configuration represents a hardware target (controller).

AADvance configurations run a single resource. A resource
consists of the dictionary of tag names, I/O configuration and
POUs (Program Organization Units).
5-4
Some of the more common buttons in the workbench are

summarized in Figure 5-3.
Figure 5-3: Common Workbench Buttons
5-5
Dictionary
The typical first step is to define variable (tag) names in the
dictionary. These names can then be connected to processor
variables, I/O modules, I/O channels and then used in programs.
However, it is not mandatory to define variables first. You can
create programs first and enter variable names in the program
editor. When doing so, the workbench will request basic
information on the variable (i.e., type, scope, direction,
attribute). While variables created this way will later appear in
the dictionary, you may need to define them in more detail in
the dictionary before compiling and running your program(s)
(e.g., MODBUS address, SOE, initial value, retain, etc).
Open the dictionary using the Project | Variables menu selection
or the dictionary button. Expand the tree on the left to see the
window displayed in Figure 5-4.
Figure 5-4: Workbench Dictionary View
5-6
The various components are sorted in a tree-like hierarchy. The

tree name is displayed on the window title bar. The four
dictionary tree views, as shown in Figure 5-5, are: variables,
parameters, types and defined words.
Figure 5-5: Dictionary Views
In the All Variables workspace on the right, you can toggle

between Grid Mode and Row Mode by right clicking in the
workspace and making the appropriate selection in the pop-up
menu, as shown in Figure 5-6.
Figure 5-6: Switching Between Grid and Row Mode
5-7
Data Types
Variables are unique identifiers of data which can be used in the
programs of a project. There are many different variables types,
such as:
5-8
BOOL: Boolean (true / false)
SINT: Signed short integer (8 bit) from -128 to +127.
USINT: Unsigned short integer (8 bit) from 0 to 255.
BYTE: Byte (8 bit) from 0 to 255.
INT: Signed single integer (16 bit) from -32,768 to

32,767.
UINT: Unsigned single integer (16 bit) from 0 to

65,535.
WORD: Word (16 bit) from 0 to 65,535.
DINT: Signed double integer (32 bit) from

-2,147,483,648 to +2,147,483,647.
UDINT: Unsigned double integer (32 bit) from 0 to

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

4,294,967,295.
LINT: Signed long integer (64 bit) from

-9,223,372,036,854,775,808 to
9,223,372,036,854,775,807.
ULINT: Unsigned Long Integer (64 bit) from 0 to

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

18,446,744,073,709,551,615.
REAL: Real (floating, single precision) (32 bit), 1 sign

bit + 23 mantissa bits + 8 exponent bits. The exponent
value cannot be less than -37 or greater than +37. A real
variable has six significant digits.
LREAL: Long Real (floating, double precision) (64 bit)

1 sign bit + 52 mantissa bits + 11 exponent bits. The
value cannot be less than 1.7E -308 or greater than 1.7E
+308. A long real variable has 15 significant digits.
TIME: Timer (32 bit) cannot be negative or exceed

1193h2m47s294ms.
DATE: Date (32 bit) from 1970-01-01 to 2038-01-18.
STRING: Character string with a defined size, up to

255 characters.
You can define arrays (a set of elements of the same type) and
structures (a collection of elements of different types) using the
above data types. AADvance I/O are available as pre-defined
structures.
To enter a variable, double-click the ellipsis () line in the
right workspace area (shown in Figure 5-4). The dialog box
shown in Figure 5-7 will then be displayed (when in Row
Mode).
Figure 5-7: Dictionary Entry Dialog Box
5-9
Variable Data
The variable data to be defined are shown in Table 5-1.
Name
Alias
Variable name
A name, used in LD editor, limited to 16 characters
Group
Group name or "None"
Type
Data type (listed above)
()
If Type is STRING this represents the string length

(max. 255 characters)
Dimension
The size (number of elements) of an array. For

example: [1..3,1..10] - represents a two-dimensional
array containing a total of 30 elements.
Attribute
Read-only, write-only, or free (read/write)
Scope
Global or local to a program or function
Direction
of I/O Wiring; Input, Output or Internal
Init. Value
Initial value when the resource is executed. Numeric or

textual.
Wiring
Read-only cell, generated by the I/O wiring tool. Uses

syntax of directly represented variable.
Comment
User comments, free format
Retain
Whether the value is retained if the resource stops and

restarts. Yes or No
Address
Not applicable with AADvance
Table 5-1: Variable Data
Variable names:
May be up to 128 characters
Must begin with a letter
The following characters can be letters, digits or the

underscore character
Variables can have one of the following attributes:
5-10
Free: Variable which can be used for reading or writing
Read: Read-only variable
Write: Write-only variable
Variables have a direction:
Internal: Internal variable updated by the program(s)
Input: Variable connected to an input device (refreshed

by the system)
Output: Variable connected to an output device
I/O variables can be selected as structures. Make the selections

shown in Figure 5-8 for a digital input.
Figure 5-8: Dictionary Entry Dialog Box
The full structure for a digital input is shown in Figure 5-9. You
only need to assign one name for the structure (e.g., DI_1 in this
example); the system automatically assigns full names and data
types to all the variables within the structure.
Figure 5-9: Dictionary Showing Structures
5-11
True and False Labels

True/False names
are not used when
monitoring a
running program.
You can add optional names in the TRUE and FALSE message
fields of Boolean variables, as shown in Figure 5-10. These
names / messages will be used for Sequence of Events / OPC.
Figure 5-10: Boolean True & False Messages
5-12
Tagging Items for SOE

Boolean variables can be tagged for SOE (sequence of events)
recording, as shown in Figure 5-11.
Figure 5-11: Enabling SOE
All the SOE data is

passed as Alarm
and Events
information via
OPC (i.e., there is
no stand-alone SOE
collector).
The following items may be set on the SOE tab:
Falling-edge: indication of the variable changing from

TRUE to FALSE.
Rising-edge: indication of the variable changing from

FALSE to TRUE.
Severity level: the level of importance of the rising-edge

and falling-edge. Possible values range from 0 to 65535;
the default value is 0.
Filter Time: the minimum time lapse between two

events for a variable, in milliseconds. Possible values
range from 0 to 65535.
Reference variable: on an event, the value of this
variable is also sent with the event.
5-13
Modbus Addressing
Variables can be assigned Modbus addresses using the Modbus
tab, as shown in Figure 5-12.
Figure 5-12: Modbus Addressing
Refer to the
Configuration
Guide for more
details on Modbus.
Read only/Write protected: Defines the variable

direction and whether it can be written to. Available for
coils and holding registers.
Base Address: The Modbus base address of the

variable.
Each Modbus Type

has its own
separate map
Hint: enter the Base

Address first to
make the Modbus
Type field available
5-14
1 to 65,535 (one register wide) for BOOL, INT and

UINT variables (as shown in Figure 5-13)
1 to 65,534 (two-registers wide) for DINT, UNIT

and REAL variables (as shown in Figure 5-14)
1 to 65,532 (four-registers wide) for LINT, ULINT

and LREAL variables.
Modbus Type: The type of Modbus variables.
For Boolean variables, the available types are

discrete input or coil (as shown in Figure 5-13)
For INT, UINT, DINT, UDINT and REAL

variables, the available types are input registers and
holding registers (as shown in Figure 5-14)
Modbus Functions: The available Modbus functions

for use with the selected Modbus type.
Data Type: The variable data type.
Figure 5-13: Modbus Addressing for a Boolean Type
Figure 5-14: Modbus Addressing for a UINT Type
5-15
The Base Address is the actual address of the variable sent over
the protocol.
Original Modbus implementations allocated 10,000 addresses to
each Modbus type, e.g. Holding registers were 40,001-50,000.
However, the address field that was actually sent by the
protocol was based at zero, i.e. 1 to 10000.
Later implementations, including AADvance, opened up the full
16-bit range to 65,535. If AADvance is communicating to a
system using the original implementation, ensure that the
addresses are in the range 1 to 10, 000.
5-16
Common Industrial Protocol (CIP)
Produce/consume
variables are noninterfering. A
failure of the
Ethernet/IP stack
will not interfere
with the safe
operation of the
controller.
Common Industrial Protocol (CIP) over Ethernet/IP enables

AADvance controllers to exchange data with ControlLogix
controllers. The exchange of data uses the produce/consume
method similar to the bindings mechanism used by the
AADvance controller.
You configure the exchange of data by defining a production
variable (or structure) for one controller and a corresponding
consumption variable (or structure) for the other, as shown in
Figure 5-15.
Figure 5-15: CIP Configuration
At runtime, the
controller with the
consumption
variable pulls data
from the controller
with the production
variable.
Refer to the
Configuration
Guide and the
RSLogix online
Help system for
further information
on CIP.
A production or consumption variable can contain up to 500

bytes (400 before release 1.31).
You will need to create a CIP network in the Hardware
Architecture view of the workbench.
Notes: You can only use the CIP network to exchange data
using producers and consumers.
The CIP network cannot be used for downloading to or
monitoring a target.
Do not use the CIP network to exchange data between
AADvance controllers; use bindings over an SNCP
network instead.
5-17
Complete the Dictionary

Use the copy and paste features to create additional digital
inputs. Change their name and comment fields.
Make similar selections for analog inputs
(type: T9K_AI_FULL, attribute: read, direction: input).
Make similar selections for digital outputs
(type: T9K_DO_FULL, attribute: free, direction: output).
Add any other variable names you wish to use in your project
(e.g., processor variables, such as the number of locked inputs
or outputs, system health, battery health, etc.; I/O module
variables such as a TA group status structure, etc).
Save and close the dictionary.
5-18
5-19
Import / Export Variables

You can import or export variable data using either a commaseparated (CSV) file in a text editor or a Microsoft Excel
spreadsheet (if Excel 2007 or later is installed on your PC).
Exporting a Variable File
Export the current dictionary in order to see the file format and
what can be exported. The export variables selection is found in
the File menu, as shown in Figure 5-16.
Figure 5-16: Exporting Variables
This will open the Export dialog box, as shown in Figure 5-17.
5-20
Figure 5-17: Export Dialog Boxes
From this dialog box, you may select the file location and name
(using the Browse button), file type and what fields should be
included. Click the Export button to create the actual file.
An example of an exported variables file opened in Excel is
shown in Figure 5-18.
Figure 5-18: Exported Variable File
5-21
Creating and Importing a Variable File

When using a spreadsheet to enter information, enter each piece
of information in a separate cell. Leave cells empty if an item is
to be omitted.
Refer to the
programs help
system for a
complete listing of
the variable fields,
default values,
examples, etc.
Enter your data. Save the file in a CSV or XLS format.

The import selection is found in the File menu, as shown in
Figure 5-19.
Figure 5-19: Importing a Variable List
Select Variables, as shown in Figure 5-19. This will open the

import dialog box shown in Figure 5-20. From here you can
browse to open the particular file of interest.
Figure 5-20: Importing Variables
5-22
Equipment Editor
I/O wiring enables you to define links between the variables
defined in the dictionary and the I/O channels of your system(s).
If the project tree view is not shown on the left of your screen
(as in Figure 5-2) select Window | Show Project Tree View.
Then select either the Equipment tab on the bottom of the
project tree view, the I/O wiring button, or the Window | (your
project name) Config1 view, to display the equipment view, as
shown in the Figure 5-21.
Figure 5-21: Equipment Editor View
I/O Bus 1 extends to the right of the processor. Bus 2 extends to

the left.
Refer to the
Configuration
Guide for more
details on the
various processor
settings.
The different tabbed sheets in the right workspace area (shown

in Figure 5-21) are used to set the processor watchdog timer,
serial ports, SNTP (Simple Network Time Protocol) clients and
servers and more, as covered briefly in the following sections.
5-23
9110 Tab
Figure 5-22: 9110 Tab
The following settings can be made in the 9110 tab:
5-24
Process Safety Time: The maximum time that the

processor will allow the outputs to remain active in the
event of serious internal faults. The system will go to its
safe state if the process safety time is exceeded.
Battery Alarm: This setting is normally enabled. It is

provided as an option for systems which have no
batteries, e.g. sub-sea modules.
Serial Ports Tab
Figure 5-23: Serial Ports Tab
The AADvance controller provides up to six serial

communication ports, two for each 9110 processor module
present. Each pair of serial ports is identified as SX-1 and SX-2
where 'X' is the processor module. The serial port settings
define the protocol ('type') and the data characteristics of each
of the serial ports.
5-25
SNTP Clients and Servers Tabs
Figure 5-24: SNTP Clients Tab
The AADvance controller supports a fault tolerant Simple

Network Time Protocol (SNTP) service that can circulate an
accurate time around the network. As an SNTP client the
controller will accept the current time from external Network
Time Protocol (NTP) and SNTP network time servers. The
SNTP 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.
The AADvance controller can fulfill the role of one or more
SNTP servers (one for each processor) to provide a network
time signal throughout the network. Use the SNTP Servers tab
to enter the necessary information.
5-26
Modbus Slaves Tab
Figure 5-25: Modbus Slaves Tab
Ethernet slaves can

serve up to ten
masters each.
AADvance can operate as a Modbus slave and support up to ten

Modbus slaves per processor module. This gives a capacity of
thirty Modbus slaves for a controller with three processor
modules.
As a Modbus slave, the controller supports Modbus RTU using
a serial or Ethernet connection, and Modbus TCP using an
Ethernet connection. You can configure a combination of
connections for the Modbus slaves, subject to a limitation of no
more than two Modbus RTU slaves using serial
communications for each processor.
5-27
TCI Tab
Figure 5-26: TCI Tab
TCI stands for Transparent Communications Interface. This

facility bridges communications between Ethernet and the serial
ports. It only works when the application is stopped. An
Ethernet connection to one of the six ports in the TCP column
will open communications to that serial port. It is used in subsea
modules as a serial gateway but is not available for live
systems.
5-28
DiffServ
Figure 5-27: DiffServ Tab
DiffServ provides Ethernet protocol prioritization, again mainly

for subsea systems. It allows individual ports and remote
addresses to be given different terms of service or priority, so
that safety related communications can have precedence.
5-29
Variables Tab
Figure 5-28: Variables Tab
Status variables
retrieve status
information;
control variables
set status
information.
5-30
There are many internal status and control variables available

for use in your applications.
There are seven variable types:
Status Integers and Status Booleans provide information

about the controller
Control Integers and Control Booleans enable the

application to send specific information to the controller
RTC Status variables provide information about the

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

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

real-time clock
Inserting an I/O Module

Enter an I/O module by right clicking on an Empty tag in the
tree view. Select the module type and configuration, as shown
in Figure 5-29.
Figure 5-29: Inserting and I/O Module
Figure 5-30 shows a dual digital input module arrangement.
Figure 5-30: Equipment View for a Digital Input Module

5-31
Connect an I/O Tag

You can connect a variable to the diagnostic data to access all
the point in one go. The variable must be of type
T9K_TA_GROUP_STATUS.
Click the ellipsis () button to the right of Variable in the
right pane to open a dialog box in order to select a dictionary
variable name for that point.
At the bottom of the right pane are connections for the channels.
These can each be wired in three different ways:
1. Single element, e.g. a Bool for a digital input
2. Compact structure including Line Fault and Discrepancy
3. Full structure including all diagnostic points.
Select a channel and click the ellipsis () button beside the
table. Choose the type of variable. A full structure has been
chosen in the example in Figure 5-31. Select the variable to
connect to the channel.
Figure 5-31: Selecting a Dictionary Variable Name
5-32
Digital Input Voltage Thresholds

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

decreasing values to prevent chatter. For example, using the
values shown in Figure 5-31, the voltage must increase above
5.509 volts to enter state 3, and must decrease below 4.990 to
enter state 2.
5-33
Analog Input Current Thresholds

Figure 5-33 shows a similar window for analog input current
thresholds.
Figure 5-33: Analog Input Current Thresholds
5-34
HART Inputs
Figure 5-34 shows how HART structure variable names may be
assigned to analog inputs. This information can be utilized in
your application programs and passed to other systems via
OPC.
HART pass-through is available in release 1.31. This allows a
HART Asset Manager to access and maintain the field devices
through AADvance.
Figure 5-34: HART Inputs
5-35
Scaling of Analog Inputs

As shown in Figure 5-35, analog inputs are available as both
integers (tagname.CNT) and reals (tagname.PV). Integers return
values of 0 to 5120 for 0-20mA (1024 to 5120 for 4-20mA).
Reals default as 0 to 100.00 for 4-20mA.
Figure 5-35: Analog Inputs
If you wish to change the scaling for a channel, go to the

equipment view, expand the analog input module and select the
channel you wish to modify. You can configure any linear
conversion of either integer or real units by simply changing the
numbers in the low and high text boxes (as shown in Figure 535). Non-linear conversion of the tagtname.cnt or tagname.pv
variables can be accomplished using a user defined function or
function block.
Repeat the steps above to insert all the modules in your system
and connect the variable names to each I/O channel. Save the
hardware configuration.
5-36
Creating Programs
Go to the link architecture view using the link architecture
button, as shown Figure 5-36.
Figure 5-36: Link Architecture View
5-37
1) Select a Program Language

Enter a new program by right clicking on Programs in the
resource window in the right pane. Select Add Program and
select a language in this case FBD (Function Block Diagram)
as shown in Figure 5-37.
Figure 5-37: Selecting a Program Language Type
Both function block diagrams and ladder diagrams can be

created using either the workbench ladder diagram (LD) or
function block diagram (FBD) editors. The function block
editor is more commonly used as it provides more drawing
control and functionality.
IEC61499 event driven function blocks are not available at the
current releases.
One language is chosen when creating a program. Languages
cannot be changed or converted later.
The available programming languages are described in Table 53.
5-38
Programming
Language
Summary
Safety Issues
Ladder Diagram
(LD)
High level graphical

language
For Boolean
operations
Easy rules
Commonly used
for safety
applications
Function Block
Diagram (FDB)
High level graphical

language
For mixed type of
operations
Large library of
blocks
Commonly used
for safety
applications
Structured Text
(ST)
High level text based

language
Can be used for
functions or function
blocks
Used for safety

applications with
restrictions*
Sequential
Function Charts
(SFC)
For sequential
operations
Can handle parallel
processes
Can be used for

safety
applications
Instruction List
(IL)
Low level text based

language
Can be (but rarely

is) used for safety
applications, with
restrictions*
Table 5-3: Programming Languages

* From Safety Manual: Ensure logic has no infinite loops or logic which
never executes. Test all branches of code and possible conditions.
5-39
2) Enter a Program Name

Enter a name for the new program, as shown in Figure 5-38.
Figure 5-38: Naming a POU
A POU (Program Organization Unit) is a set of instructions

written in one of the IEC 61131-3 languages. A POU can be a
program, a function or function block.
5-40
3) Edit Your Program

Double-click the new program name to open the editor window,
Figure 5-39: Program Window
Enter a variable on the page by first clicking on the variable

button and then clicking within the window.
5-41
Assign Variable Names

When a variable is placed on the page, a dialog box will open
allowing you to select a variable name, in this case a Boolean
input variable (the input element/variable within the structure,
not the structure itself) as shown in Figure 5-40.
Figure 5-40: Select Variable Dialog Box
Note: If you enter a variable name that does not exist in the
dictionary, another dialog box will appear prompting
you for the necessary information. That variable will
then be added to the dictionary.
Enter another variable to the right of the first and select an
output element/variable within one of your available output
structures.
5-42
Connect Variables
Connect the two variables using the connection button (F4).
Mouse drag from one element to the other to connect them, as
Figure 5-41: Simple Logic
5-43
Create the rest of your sample program. A simple example is

Figure 5-42: Sample Program
5-44
Add Comments
Comment fields can be entered using the Comment button.
Comments make a program much easier to understand for
others who may have to modify it in the future.
Variable comments (from the dictionary) can be displayed using
the Options | Show I/O Variable Comments menu selection, as
Figure 5-43: Rung and Variable Comments
Save your program. Close the program window.
5-45
4) Build Your Program

Build (compile) the program using the build button in the main
workbench window, or the Project | Build Project menu
selection. You can build individual programs, resources or
entire projects using the different build buttons.
Compiler messages will be shown in the output window toward
the bottom of the workbench, as shown in Figure 5-44.
Figure 5-44: Compiler Output Messages
Once a project has been built, subsequent builds only recompile

the parts of the project needing recompilation. You can choose
to rebuild a project using the rebuild button or the Project |
Rebuild Project menu selection. This recompiles the whole
project and ensures that the complete compiled version is up-todate with the current workbench project.
Notice the CVT Analysis at the end of the report. This is the
Compiler Verification Tool, and it checks that the compiled
code matches the logic that you built. Any problems are
reported as mismatches, which must be investigated for safety
system projects.
5-46
Saving a Project
The project name is used to create a unique directory structure.
Saving the project saves it in the MS-Access database of the
project root directory. Other files related to the project are also
updated in this directory structure.
To save a project
From the File menu, choose Save Project, or use the save
button.
5-47
Test Your Knowledge

1. How many resources can an AADvance controller run?
2. Inputs are defined in the dictionary with which choices
of attribute (read, write, free)?
3. Outputs are defined in the dictionary with which choices
of attribute (read, write, free)?
4. Which field in the dictionary is used to assign
MODBUS addresses?
5. Which compiles everything Build Project or Rebuild
Project?
6. What formats can the Dictionary be exported to?
7. How many programming languages are available?
5-48
Chapter 6
Simulating and Testing

Programs
Purpose
To review the steps required to simulate and test programs.
Objectives
To be able to simulate resources on your PC.
To be able to change variables and test your programs.
Simulating and Testing Programs
6-1
Simulation
You can simulate (test) programs using the Debug | Simulation
menu choice, or the simulate button. (Your project must be
compiled before it can be simulated.)
When simulating, the button bars will change slightly and the
resource title bar will indicate that it is running code, as shown
in Figure 6-1.
Figure 6-1: Debug/Simulate Window
6-2
Changing Input Variables in a Program

You can change variables directly in a program. Double-click
on a variable to bring up the write variable dialog box, as shown
in Figure 6-2.
Figure 6-2: Write Variable Dialog Box in Program Window
Input variables in the simulator do not need to be locked

(forced) in order to change their value. Booleans inputs can be
toggled on and off using the TRUE and FALSE buttons. Analog
input values can be changed by entering a value in the text field
and clicking the Write button, as shown in Figure 6-3.
Figure 6-3: Entering an Analog Value
Verify that your program works as intended.

6-3
Changing Input Variables in the Equipment

View
You can also change input variables in the Equipment view
(without having to lock them), as shown in Figure 6-4.
Figure 6-4: Write Variable Dialog Box in Equipment View
After changing the state of an input, check that the

corresponding output responds appropriately.
6-4
Changing Variables in the Dictionary

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

Trying to change the value of an output in the same manner will
have no effect as the program is controlling the outputs.
However, outputs may be locked and then their value may be
changed (by opening the dialog box a second time), as shown in
Figure 6-6.
Figure 6-4: Locking an Output Variable in the Dictionary
This is essentially the same way outputs are locked and

controlled in a real system. The Locked column shows that the
variable is locked. For an output, the variable is disconnected
from the physical output, and the physical output is locked, not
the variable. This has no use in the simulator because there is no
physical output.
6-6
Stopping Simulation
Stop the simulation using the Debug | Stop Simulation menu
selection or using the stop debug button.
6-7
Test Your Knowledge

1. What is the point of simulating programs?
2. Must input variables be locked (forced) in order to
change their value when simulating?
3. Must output variables be locked (forced) in order to
change their value when simulating?
4. Does changing the value of a locked output change its
logical value, or its physical value?
6-8
Chapter 7
Downloading and
Monitoring Programs
Purpose
To review the steps required to connect, download and control
resources in the AADvance controller.
Objectives
To be able to connect to AADvance.
To be able to download to AADvance.
To be able to monitor a program online.
To be able to lock / force variables.
To be able to disconnect from AADvance.
Downloading and Monitoring Programs
7-1
Loading a Resource in a Controller

All programs in a project are compiled, downloaded and
controlled (i.e., started and stopped) together. The compiled file
is referred to as a resource.
Step 1: Set the IP Address of the Controller

IP addresses and resource numbers in AADvance are read and
set/programmed into chips in the processor base unit using the
AADvance Discover utility. Refer to Appendix 1 for this
procedure. You must then assign these addresses in the
workbench.
The IP addresses are set in the hardware architecture view,
which is accessed using the button shown on the left, or using
the Window | (Your Project Name) Hardware Architecture view
menu choice.
Select (left click) the vertical connecting link between the
SNCP network line and the configuration, as shown in Figure 71. Right click and select Properties. Alternatively, you may also
double-click the vertical connection.
Figure 7-1: Select and Right Click (or Double-Click) the

Vertical Connector
7-2
Enter the IP address of the port(s) that have been configured for
the system, as shown in Figure 7-2.
Figure 7-2: Setting the IP Address
Notes: 1) The IP addresses of the two ports of a processor need

to be on different subnets.
2) If you change an IP address, you will need to
recompile your project.
3) If you do not change an IP address, yet select the OK
button, you will still need to recompile your project.
Therefore, if you do not change an address, select the
cancel button instead.
4) Your computer IP address will need to be on the same
network in order to communicate with the system.
7-3
Step 2: Download to the Controller

Download your resource to the controller using the Debug |
Download menu choice, or the Download button. You will be
presented with the dialog box shown in Figure 7-3.
Figure 7-3: Download Dialog Box
Select the configuration and resource of interest and click the

Download button. The project will be checked into the
repository automatically. A progress bar will display the
download status. The Output window will also display a
message upon completion of the download.
7-4
If a Resource is Already Running

AADvance controllers can only run a single resource. If a
resource is already running in the controller, you will be
presented with the dialog box shown in Figure 7-4.
Figure 7-4: Resource Running Dialog Box
If you wish to download your resource, click the stop and

download button.
Warning! Downloads stop the I/O modules. Do not perform a
download on a system running an actual process or
you will shut down your plant!
If you simply wish to update or make changes to your running
resource, perform an on-line change instead of a download.
On-line changes are covered in Chapter 9.
Note:
You can successfully download to a controller that

does not have any I/O modules. The system will
simulate modules that are not connected. You can
install the I/O modules later without having to reload
the resource.
7-5
Monitoring Programs
Step 1: Connect Using Debug
After downloading a resource, you may then go online with the
controller using the Debug | Debug Target menu selection or the
Debug Target button. The toolbar will change slightly for the
debug mode and the resource status will be shown (e.g., RUN),
Figure 7-5: Debug Window, Hardware Architecture View
7-6
Step 2: Gain Write Access

From release 1.2, you cannot change or lock variables without
gaining access. Click on the resource window for the system
you want to work with, as shown in Figure 7-6.
Figure 7-7: Debug Window, Link Architecture View
Click on the yellow flash icon

window or on the icon bar.
, either on the resource
Figure 7-8: Restricted Access Control
Click Request to get access, and check the Status is Active.

Click OK. The yellow flash icon on the Resource window is
now a padlock icon.
7-7
Step 2: Open Your Program

Go to the Link Architecture view (using the second button in
the button bar) to see your program(s), as shown in Figure 7-9.
Figure 7-9: Debug Window, Link Architecture View
7-8
Double click on a program name to open and monitor it, as

Figure 7-10: Monitoring a Program
7-9
Locking (Forcing)
You can lock (force) I/O variables. Double click a variable to
open the locking dialog box, as shown in Figure 7-11. If
variables are being controlled (e.g., input sensors or a program
writing to outputs) you must lock a variable before you can
change its value.
Figure 7-11: Locking / Forcing
When you click the Lock button, the dialog box will
automatically close. The variable will be locked in its last value.
You will need to open the dialog box again to change the
variables value.
The Force LED on
the processor(s)
will turn amber
when any variables
are locked.
A locked variable will be shown with a * to the left of its

variable name, as shown in Figure 7-12.
Figure 7-12: A Locked Variable
Notes: 1) Internal variables cannot be locked.

2) The asterisk is not shown when running in demo
mode.
7-10
Viewing and locking a variable in a program window only

shows its logic value. It does not show the variables physical
(field) value.
Variable can also be locked in the dictionary. This allows you to
see both the logic and physical value, as shown in Figure 7-13.
Figure 7-13: Locking in the Dictionary
Viewing both the physical as well as logic values can be very

helpful for troubleshooting, as covered in the following pages.
7-11
Differences Between Locking Inputs and

Outputs
There are subtle differences between the locking of inputs and
outputs.
Tip! Inputs are locked in logic, not at the input module.
Outputs are locked at the output module, not in logic.
Figure 7-14 shows an example of a locked input. Imagine a
technician is going to test an input by de-energizing the switch.
The input is locked as shown by the * in the tag name and the
Locked | Yes value in the dictionary. The field (physical) value
of the input as shown in the dictionary is FALSE, while the
logic value is TRUE. If the lock were turned off, the logic value
would become FALSE and the corresponding output would trip.
Figure 7-14: A Locked Input
7-12
Figure 7-15 shows an example of a locked output. The output is

locked as shown by the * in the tag name and the Locked | Yes
value in the dictionary. The field (physical) value of the output
as shown in the dictionary is FALSE, while the logic value is
TRUE. If the lock were turned off, the physical value would
become TRUE.
Figure 7-15: A Locked Output
Locking is normally
only used for
maintenance
purposes.
Locking inputs allows you to test field devices (sensors)

without shutting the plant down.
Locking outputs allows you to test logic without shutting the
plant down.
Do not use locking to exclude a faulty field device long-term.
Use a maintenance override.
7-13
Unlocking All Variables

You can also view all locked variables and unlock them one at a
time or all of them at once. Select the Debug | Diagnosis menu,
Figure 7-16: Locked Variables
This will pull up the resource diagnostics dialog box, as shown

in Figure 7-17. From here, you can unlock one variable at a
time, or all of them at once.
Figure 7-17: Locked Variables
Note: Locks are not retained during a power loss.

7-14
Viewing Live Data in the Equipment

View
Live data can be viewed in the equipment view, as shown in
Figure 7-18.
Figure 7-18: Viewing Live Data in the Equipment View
Variables can also be locked in this view (by double clicking

the variable name and following the same steps described
above). The Value field shown above is the logical value.
7-15
Spying Variables
You can also view and lock variables using a spy window. This
can be very useful when viewing variables that may not appear
together in the dictionary, equipment view, or a program
window. Highlight a variable and use the Debug | Spy menu
selection, or the Spy button, to view the information shown in
Figure 7-19.
Figure 7-19: Spy List
The locked column

is not shown in a
spy list, but
variables may still
be locked in the spy
window.
Additional variables can be entered by double-clicking the

ellipsis line at the bottom of the window.
Note: Direct addresses can also be entered and viewed in a spy
list even if you did not assign variable names to certain
internal tags (e.g., module temperature, battery status,
etc). This can be very useful for diagnostic purposes.
Spy lists can be saved by right clicking in the spy window.
7-16
Show Variable Comments

You can view all variable comments (from the dictionary) using
the Options | Show Variable Comments menu selection, as
Figure 7-20: Displaying Variable Comments
7-17
Going Offline
Go offline by using the Debug | Stop Debug Target menu
selection, or the Stop Debug Target button.
Warning! Do not stop the resource running in the controller
that is controlling a process (i.e., do not use the
Stop Resource button or command)! Stopping the
resource will stop the running program(s) and shut
down your plant! There is no confirmation prompt
for the stop resource command on earlier
workbenches.
7-18
Test Your Knowledge

1. Can a controller run more than one resource?
2. What is the command to monitor a system online?
3. What visual indication does the controller hardware
provide that a variable is locked?
4. How can you tell looking at a variable whether it is
locked or not?
5. Can internal variables be locked?
6. Can you view both the physical and logical values while
looking at a variable in a program window only?
7. Where can you view both the physical and logic values
of a variable?
8. Are locks retained during a power loss?
9. What command do you use to go offline while leaving
the programs running in the controller?
7-19
Chapter 8
Creating and Using

Functions and Function
Blocks
Purpose
To describe how to create and use functions and function
blocks.
Objectives
To understand the difference between functions and

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

blocks.
Creating and Using Functions and Function Blocks
8-1
Functions and Function Blocks
Figure 8-1: Functions and Function Blocks
Functions and function blocks are reusable pieces of code.

Functions have only one output, may not contain internal
variables and are not retained in memory.
Function blocks can have more than one output, may contain
internal variables and are retained in memory.
In other words, if a function is used 200 times, it will only be
allocated space in memory once. If a function block is used 200
times, it will be allocated memory space 200 times, each one
storing the value(s) it solves.
There are many predefined functions and function blocks in the
workbench. However, you may wish to create your own userdefined functions and function blocks (e.g., a two-out-of-three
voter with discrepancy alarms and time delays).
Most functions and function blocks are created using the
function block, structured text or ladder diagram editors.
8-2
Creating a Structured Text Function

In the link architecture view, right click on Functions in the
resource box. Select a language type, as shown in Figure 8-2, in
this case structured text.
Figure 8-2: Creating a Function
Enter a name for your function (e.g., Vote_DI_2oo3).

Double-click on the function to open and edit it.
Figure 8-2 shows an example of a very simple 2oo3 voter block
without discrepancy alarms. Write the same code in your
function.
Note: The output variable name of a function is the same name
as the function itself.
Figure 8-3: Creating a Simple 2oo3 Boolean Vote Function
Save and close your function.
8-3
Define Your Variables in the Dictionary

The workbench must know what all the variable names are
(Boolean, integer, input, output, etc.) in order to compile your
program organization units properly. Variable names are
defined in the parameters tab sheet of the dictionary. Open the
dictionary and view the parameters tab (the 2nd tab), as shown in
Figure 8-4.
Figure 8-4: Parameters Tab in the Dictionary
Function and
Function Block
variables must be
defined in the
Parameters tab, not
the Variables tab!
Double-click on the variable name to edit it, as shown in Figure

8-5. Change the variable type of the output to Boolean (instead
of the default DINT). The short name is displayed within the
image of the function itself when it is used in other programs
(as the name may be too long to view within such a small area).
Figure 8-5: Defining Function Parameters
8-4
Add the remaining input variable names to your list. The

remaining names will default with a direction of input. Add a
short name and select the type as Boolean, as shown in Figure
8-6.
Figure 8-6: Defining Function Input Parameters
Figure 8-7 shows the four variables defined for this function.
Figure 8-7: Function Parameters
8-5
Using the Function

You may now reuse the function you created over and over in
any of your programs.
While in a program, open the function block list using the F3
key or the function block button in the editor window.
Functions that you create will be shown in the User Defined
area of the function block dialog box, as shown in Figure 8-8.
Figure 8-8: Using a Function in a Program
8-6
Figure 8-9 shows an example of using the 2oo3 vote function in

a program.
Figure 8-9: Using a Function in a Program
Save your changes, close the program window, and rebuild

(recompile) the project.
You can now simulate, download or update the resource in your
controller.
Simulation is covered in Chapter 6.
Downloading is covered in Chapter 7.
Updating is covered in Chapter 9.
8-7
Creating a Function Block Diagram

Function
Create another function, this time using the FBD (function
block diagram) language editor. Name the function AI_Mid.
Do not edit the
function yet!
What you will create will eventually look like the example
Figure 8-10: Mid Value Function
There are similar

conversion blocks
for converting any
variable type to
another.
8-8
The example above takes INT inputs, converts them to the type
DINT, uses pre-defined max and min blocks (that only work
with DINT variables) to select the middle of the three values,
converts the result back to a type INT, and writes to an INT
output.
Tip!
Create the parameter variables in the dictionary (in the

parameters tab) before editing your function. If you edit
your function first, the function block editor will ask you
for the variable information, but it will create and save
the variables in the variables tab sheet. You would then
need to delete them there and recreate them on the
correct tabbed sheet (i.e., parameters).
View the parameters tab (2nd tab) in the dictionary and add the
variables here (using the exact same names as you will use in
your function). Make sure they are type INT and add a short
name for each. Also, change the output to a type INT and add a
short name.
Figure 8-11 shows the four variables defined for this function.
Figure 8-11: Declaring Function Values
Note: The output variable name of a function must be the same

name as the function itself.
Open the function and edit it to be similar to the example shown
in Figure 8-10. Select the correct variable types from your
dictionary.
8-9
Using the Function

You can now use this function in any of your programs, as
Figure 8-12: Example Using the Mid Value Function
Save your changes, close the program window, and rebuild

(recompile) the project.
You can now simulate, download or update the resource in your
controller.
8-10
Simulation is covered in Chapter 6.
Downloading is covered in Chapter 7.
Updating is covered in Chapter 9.
Test Your Knowledge

1. A function can have how many outputs?
2. Which are retained in memory, functions or function
blocks?
3. Where are function variable names defined?
4. What must a function output variable name be the same
as?
5. What language cannot be used to create functions or
function blocks?
8-11
Chapter 9
Online Changes
Purpose
To review how to change and update resources online.
Objectives
Online Changes
To be able to modify resources and update them online.
9-1
Modifying a Resource
Open an existing resource and make changes to it (e.g., change
a program). Rebuild (recompile) the project.
Checking Resource Version Numbers

This procedure
assumes you
already have your
resource running in
the controller.
If you connect to the system using debug target without first

loading your revised resource, a dialog box similar to Figure 9-1
will be displayed.
Figure 9-1: Version Mismatch Dialog Box
If you select Yes, the workbench will retrieve and display the
earlier source code version from your repository.
If you select No, the workbench will remain offline.
Note: 1) The version numbers shown in Figure 9-1 represent
the number of times the resource has been
built/compiled; they do not represent local or
repository version numbers (as covered in Chapter
11).
9-2
Online Changes
You can update the resource running in a controller online
without stopping the current resource or shutting your process
down. Use the Debug | On-line Change: Download, or the Online Change: Download button. The dialog box shown in Figure
9-2 will appear.
Figure 9-2: Online Change Dialog Box
Select the configuration to be updated, go with the default first

option (download, save on target and update) and click the
Download/Update button.
Online Changes
9-3
When you are online, you can see the differences between the
compiled resource versions in the workbench (your PC),
running (in RAM) and stored (in flash memory) using the
Debug | Diagnosis menu, Version Information tab, as shown in
Figure 9-3.
Version numbers
may differ if you
select something
other than the
default option in
Figure 9-2.
Figure 9-3: Viewing Version Information
Note: 1) The version numbers shown in Figure 9-3 represent

the number of times the resource has been
built/compiled; they do not represent local or
repository version numbers (as covered in Chapter
11).
9-4
Test Your Knowledge

1. Can a controller be updated online without shutting the
system or your process down?
2. What is such a change called?
3. Can the workbench recognize different compiled
resource versions between the workbench and the
controller?
4. Is it possible to view the compiled version numbers of
the workbench and online resources?
Online Changes
9-5
Chapter 10
Bindings Between
Resources
Purpose
To summarize how bindings are used to transfer variables
between resources.
Objectives
Bindings between Resources
To be able to link variables between resources.
10-1
Variable Bindings
Bindings are directional links between variables located in
different resources running in different configurations
(controllers). One variable is referred to as the producing
variable and the other as the consuming variable. The value
stored in the producing variable is transferred to the consuming
variable.
Bindings are shared over Ethernet using a proprietary protocol
certified for safety. A separate network is not necessary for
bindings, but is recommended (especially if there is high
network traffic). Redundant networks are also not necessary,
but are recommended, as shown in Figure 10-1.
Figure 10-1: Bindings Between Configurations
The workbench enables bindings between resources within the

same project (contained within different configurations). These
are referred to as internal bindings.
Note: You will need to be running a workbench license
capable of multiple configurations in order to add
additional configurations to your project. It is not
possible to add a second configuration when running in
demo mode.
10-2
Plan Your Project

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

could have an input Boolean variable (not a structure) in one
system write directly to an output Boolean variable (not a
structure) in the second system, passing the I/O Boolean
variables directly using bindings. This would not require the use
of internal variables or writing any application logic in either
system! However, defining the input and output as Booleans
(instead of structures) means that you lose potentially valuable
diagnostic information (e.g., voltage, state, line fault, etc.).
Note: Binding variable types must match.
10-3
Prepare Your Project

You must be
running a
workbench license
capable of multiple
configurations in
order to add
additional
configurations.
The following example is based on a single project with two

configurations (1 & 2), each with a single resource, with data
passing from Config1 to Config2 as shown in Figure 10-2. One
set of bindings will use internal variables, the other will pass an
I/O variable directly without using internal variables.
In the Hardware Architecture view, right click in the workspace
area on the right and select Insert Configuration, as shown in
Figure 10-3.
Figure 10-3: Inserting a Configuration
A Configuration Properties dialog box will open. Set the target

as a 9000 series controller, as shown in Figure 10-4.
Figure 10-4: Selecting the Target Hardware

10-4
Right click in the workspace area on the right and select Insert
Network. In the dialog box that appears, select an SNCP (Safety
Network Control Protocol) network, and give the network a
name, as shown in Figure 10-5.
Figure 10-5: Adding a Network for Bindings
Connect the configurations to the SNCP network by leftclicking and dragging from the network line up to the
configuration. Double-click the vertical line to open the
connection properties dialog box. Enter IP Addresses for each
configuration. Your project may now look similar to Figure 106.
10-5
Figure 10-6: Entering IP Addresses for Bindings
Complete the dictionary for each configuration. Refer to Figure

10-2 as an example. For example:
a) Change one digital input from a structure to a Boolean
in both the dictionary and the equipment view.
b) Add an internal Boolean variable that you will write to
from one of your existing digital input structures.
c) Add I/O modules to the second configuration and assign
appropriate variable names and types.
Write simple application logic in both resources that will utilize
information from the other (i.e., write the input variable
structure Boolean element to the internal Boolean in the first
resource, and write the internal Boolean to an output structure
Boolean element in the second resource). Again, refer to Figure
10-2 as an example.
10-6
Linking Resources
You need to first link resources before binding variables
belonging to them. Data links between resources are directional.
When in the Link Architecture view, use the Project | Internal
Binding List menu selection or the Internal Binding List button
to open the Binding List window shown in Figure 10-7.
Figure 10-7: Binding List Window
You create links between resources in the left side of the

Binding List window. The following example consists of two
variables produced in resource 1 and consumed in resource 2, as
Think of it as the
row number writing
to the column
number. The small
curved arrow is the
key.
Double-click in the upper right quadrant 1 2. An icon will

appear in that quadrant as shown in Figure 10-8.
Figure 10-8: Binding Selection
Double-click on the ellipsis () in the right pane to open the

dialog box shown in Figure 10-9.
10-7
Figure 10-9: Binding Details Dialog Box
Select the producing and consuming variables. You can only

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

variables.
Figure 10-10: Populated Binding List Window
Close the Binding List window.

The link architecture view will indicate bindings with a line (or
two lines for bi-directional bindings) shown between resources,
Figure 10-11: Project With Two Configurations And Bindings
Rebuild (recompile) the project.
10-9
Simulate and Test Your Bindings

Simulate the project and test the bindings. In this case, turning
on either input in config1 will turn on the corresponding output
in config2.
If your workbench is only physically connected to one resource
(not both), the workbench will produce communication error
messages in the output window, as shown in Figure 10-12.
Figure 10-12: Communication Error Messages
You can disable communications to a configuration using the

Debug | Manage Configurations to debug menu selection (when
offline). This will bring up the dialog box shown in Figure 1013, where you can de-select configurations to debug.
Figure 10-13: Managing Configurations to Debug
10-10
If you have two actual controllers, you will need to change the
resource number of the second controller using the AADvance
Discover utility (as configurations require unique resource
numbers). Use the utility to also set the IP addresses.
10-11
Test Your Knowledge

1. An AADvance controller (configuration) can run how
many resources?
2. What are the names of bindings used within the same
project?
3. Can bindings be defined between variables of different
types?
4. Must producing and consuming variable names match
(i.e., be the same)?
5. Is a separate network for bindings required?
10-12
Chapter 11
Version Source Control
Purpose
To review version control, the repository, check in and check
out of program organization units, and file comparison features.
Objectives
To be able to set the repository path where files are

stored.
To be able to check in and check out program

organization units.
To understand the different status of program units.
To be able to compare different version files.
To be able to open earlier version files.

11-1

Different versions of workbench elements including projects,
configurations, resources, and POUs (program organization
units) are managed by saving them to a version source control
repository. This enables you to retrieve older versions of the
elements at a later time.
Repository
Source files are stored in a repository. The repository path is set
when creating a project. The default location of the repository
will be on the C drive of the computer the workbench is
installed on, as shown in Figure 11-1.
The destination
folder is where your
local files are kept.
Figure 11-1: Repository Path
The full default destination path in Windows XP is:

C:\Document and Settings\All Users\
Application Data\AADvance\AADvance\Repos.
In Windows 7 it is:
C:\Users\Public\
Application Data\AADvance\AADvance\Repos.
11-2
Viewing the Repository Path of an Existing

Project
Once you are in a project, you can view the repository path
using the File | Project Properties menu selection, the Version
Control tab and its browse button, as shown in Figure 11-2.
Figure 11-2: Viewing the Repository Path of an Existing Project
11-3
Check In and Check Out

When creating a project, the workbench automatically checks
the project into the repository. The project remains checked out
after the check in.
All POUs are
automatically
checked in when
you perform a
download or an
online change.
Recursive means
that item and all of
its sub-elements.
Program Organization Units (POUs) that you create are not

automatically checked-in. They will be shown in the workbench
as new (as described on the following page). You decide
when you wish to check things into the repository and perform
this step manually.
When checking items in, you can choose to set a recursive
check in that includes all sub-elements. For example, when you
check in a configuration with the recursive option set, its
resource and all of its POUs are checked-in (i.e., everything in
the project tree view). Keeping the item checked out allows you
to continue editing it, as shown in Figure 11-3.
Figure 11-3: Checking In a Configuration
When you check out an item from the repository, that items
version number is incremented.
The output window
will generate
messages
reminding you of
this.
11-4
Note: Items must be checked in before they can be deleted.
Version Status Icons

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

11-5
Comparing Earlier Versions

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

or program organization unit, you can choose to compare a
previously checked in version of the element with the current
version (by selecting another version) or with another checkedin version (by selecting two versions while pressing the Ctrl
key). Click the Diff (Differences) button (in Figure 11-5) to
show the file differences window, as shown in Figure 11-6.
Figure 11-6: File Differences Window
11-6
Click the View Sources button to view the difference between

file versions, as shown in Figure 11-7.
Figure 11-7: Viewing Different Source Versions
The workbench will graphically show you what has been

removed, modified or inserted.
11-7
Retrieving Earlier Versions

Select the version you are interested in (in the history window
shown in Figure 11-5) and click the Get button. That version
will be retrieved from the repository.
The local version in your workbench will now have the same
version number as the item you just retrieved, although the tool
tip will still show the highest version number available for that
item in the repository.
Checking the item in will increment the version number.
11-8
Test Your Knowledge

1. Does the workbench save previous versions of
configurations, resources and programs?
2. Where are previous files stored?
3. Can items that are checked out be deleted?
4. Can the workbench graphically compare different file
versions?
11-9
Chapter 12
Miscellaneous Workbench
Features
Purpose
To review miscellaneous workbench features.
Objectives
To be able to use the cross reference browser.
To be able to print projects.
To be able to set up password protection schemes.
To be able to export and import workbench elements.
To be able to archive and restore projects.
Miscellaneous Workbench Features
12-1
Cross Reference Browser

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

project program organization units.
E The output window where messages and error messages
are displayed.
Figure 12-1: Cross Reference Browser
A broken link symbol indicates an object is not used in any

program organization units.
12-2
The information displayed in the browser can be a bit confusing

to understand initially, especially when structures are used. The
browser shows not only the variable name, but the direct
address of all of the elements in the structure using the
following designations:
I
Q
X
B
W
R
Input
Output
Boolean
8-bit unsigned short integer
16-bit integer (signed or unsigned)
32-bit real
The number associated with the I/O configuration address

indicates the processor bus number, module number and
channel number.
Viewing Dependencies
Right click on a variable in the cross reference browser (in area
A of Figure 12-1) and select View Dependencies. The example
shown in Figure 12-2 indicates the dependencies used in the
earlier binding exercise.
Figure 12-2: Variable Dependencies
12-3
Printing
You can print complete or partial documentation for your
project using the document generator. You can access the
document generator from the hardware architecture view, link
architecture view, dictionary view, or any of the language
editors using the File | Print menu selection or the print button.
The document generator window has three tabs, as shown in
Figure 12-3:
Table, showing a table (or tree) representing all items

that can be printed for the current project, shown in
Figure 12-3.
Options, showing a list of printing options, shown in

Figure 12-4.
Preview, displaying a preview of the project to print,

shown in Figure 12-5. This window is resizable.
Figure 12-3: Document Generator Window, Table View

12-4
Figure 12-4: Document Generator Window, Options View
12-5
Different fonts, sizes,

colors, etc. can be
selected using the
Options ->
Customize menu
choice in any editor
window.
Figure 12-5: Document Generator Window, Preview View
Clicking the Print button will bring up the standard Windows

print dialog box, as shown in Figure 12-6.
Figure 12-6: Print Dialog Box

12-6
Passwords
The password access control described in the following pages is
relevant for release 1.3. Access control is expected to change in
a future release.
12-7
POU Access Control

You can control access to user-defined POUs (program
organization units) using a password.
Right click the POU and select Properties to open the dialog
box shown in Figure 12-7. Select the Security tab.
Figure 12-7: POU Properties Dialog Box
Users that do not have the password may still be able to open
the POU in read only mode depending upon how the resource in
which it is contained has its access control configured.
The security state of a POU is indicated by its icon color in the
resource, as shown in Table 12-1.
Icon
Security State
Yellow. The POU has no access control. All users have read and
write access in the POU. In the dictionary view, local variables and
parameters are visible and editable.
Red. The POU is locked. Users not having the POU password
cannot access the POU; these users do not have read or write
capabilities. In the dictionary view, local variables and parameters
are visible but not editable.
Blue. The POU is in read-only mode. Users not having the
resource password can view the POU; these users do not have
write capabilities. The read-only mode for the POU is inherited from
the resource to which it belongs. In the dictionary view, local
variables and parameters are visible but not editable.
Green. The POU is unlocked. User can access the POU; this user
has read and write capabilities. In the dictionary view, local
variables and parameters are visible and editable.
Table 12-1: POU Icon and Security States
12-8
Resource Access Control

You can control access to resources using a password. You can
also choose to apply the read-only mode to a resource.
You set access control for a resource in its properties' security
tab. Right click on a resource window title bar and select
Properties to open the dialog box shown in Figure 12-8.
In read-only mode,
users not having the
password will have
read-only access.
Figure 12-8: Resource Properties Dialog Box
The security state of a resource is indicated by the color of the

lower triangle in the resource title bar icon, as shown in Table
12-2.
Icon
Security State
Gray. The resource has no access control. All users have read and
write access in the resource. POUs in the resource may have
individual access control.
Red. The resource is locked. Users not having the resource
password cannot access the resource or its POUs; these users do
not have read or write capabilities. These users can change
resource properties, wire and bind variables, modify the memory
for retain, and add devices to wired variables.
Cyan. The resource is in read-only mode. Users not having the
resource password can view the resource and its POUs; these
users only have read capabilities. These users can change
resource properties, wire and bind variables, modify the memory
for retain, and add devices to wired variables. POUs in the
resource may have individual access control.
Green. The resource is unlocked. User can access the resource
and its POUs; this user has read and write capabilities. However,
POUs in the resource may have individual access control.
Table 12-2: Resource Icon and Security States

12-9
Configuration (Controller) Access Control

You can control access to a configuration (controller) with a
password. The configuration access control prevents the
connection of all clients not having the target's password.
Note: The password is embedded on the target controller and
can only be set or changed while in debug mode (i.e.,
online).
While debugging a target, right click on the configurations title
bar in the hardware architecture view, select Properties and the
security tab, as shown in Figure 12-9.
Figure 12-9: Configuration Properties Dialog Box
Enter and confirm the password. Acknowledge the confirmation

prompt.
At run time, the security state of a configuration is indicated by
its title bar icon as shown in Table 12-3.
Icon
Security State
The configuration has no access control. All clients can access the
target.
The configuration is not accessible; the target does not recognize
the password. IXL clients not having the target password cannot
access the target.
The configuration is accessible; the target recognizes the
password. IXL clients having the target password can access the
target.
Table 12-3: Configuration Icon and Security States
12-10
Project Access Control

You can control access to the entire project using a password.
You have the option of applying read-only mode to the project.
In read-only mode, users not having the password will have
read-only access to the project. When opening a project in readonly mode, all resources and POUs making up the project are
set to read-only mode.
Resources and program organization units making up projects
can have their own access control. A resource having its own
password without the read-only option remains locked and
cannot be viewed without its password. While in read-only
mode, you cannot build (compile) a project.
You open the project security dialog box from the File | Project
Properties menu selection. The project properties dialog box
will be displayed, as shown in Figure 12-10.
Figure 12-10: Project Properties Dialog Box
12-11
Export / Import Workbench Elements

Export
You cannot export
entire projects; use
the archive feature
instead.
You can export and import workbench elements

(i.e., configurations, resources, program organization units,
variables (dictionary)) from one project to another.
Exporting saves files without their history (earlier file versions).
To export a workbench element, use the File | Export menu and
select the element type of interest. An Export dialog box will be
displayed, as shown in Figure 12-11.
Figure 12-11: Exporting a Configuration
You do not select a destination location for the exported files;

they are saved in their respective folders.
12-12
Import
Import files using the File | Import | Exchange file menu
selection to bring up the dialog box shown in Figure 12-12.
Figure 12-12: Importing a File, Step 1
Notes: Password definitions are retained when exporting and

importing elements having access control.
It is not possible to upload from the target.
Click the Next button to bring up the dialog box shown in
Figure 12-13.
12-13
Select the Browse button to bring up the dialog box shown in

Figure 12-14.
Select the file name of interest and click the Open button. You
can then select the items of interest to import, as shown in
Figure 12-15.
Click the Next button to be presented with the final dialog box,
as shown in Figure12-16.
12-14
Export/Import Types
Configuration:
The entire configuration, resource, programs etc.
Entire Resource:
Overwrites existing resource of same name with resource,
programs, variables etc.
Resource Properties:
Cycle time, retain settings, compiler options etc.
Resource I/O Device Instances:
Module definitions
Resource Wired Variables:
Variables wired to module definitions (you must import the
I/O Device Instances first so the right boards are there to
wire to)
Resource External Bindings:
CIP setup NOT bindings between resources within one
project
POU:
Program
Variables:
Excel (2007 or later) or .csv of variable parameters
12-15
Archive / Restore Projects

Archive
A project can be archived and restored complete with its history
(earlier file versions), although you can select latest version
only in the archive type drop down list.
Note: Your project must be checked-in in order to archive it.
Use the Tools | Check in | Project menu selection.
Use the File | Archive/Restore Project menu selection to display
and use the dialog box shown in Figure 12-17.
Figure 12-17: Archive / Restore Dialog Box
Select a destination archive file name and location using the

ellipsis button in the Destination section shown above, which
will open the dialog box shown in Figure 12-18.
12-16
Figure 12-18: Archive Save As Dialog Box
The Archive button will now be enabled in the archive dialog

box shown in Figure 12-17. Click the Archive button to create
the archive file. A dialog box will confirm the success of the
archive operation, as shown in Figure 12-19.
Figure 12-19: Archive Completed Successfully
You may then copy the .vsc file to another computer for
restoring.
12-17
Restore
Use the File | Archive/Restore Project menu selection to display
the dialog box shown in Figure 12-20.
Figure 12-20: Restoring a Project
Select the Restore option. Click the ellipsis button in the Source
Archive File section to use the open dialog box, as shown in
Figure 12-21.
12-18
Figure 12-21: Selecting an Archive File to Restore
Find and select the .vsc file name of interest. Click the Open
button. This will take you back to the dialog box shown in
Figure 12-20.
It is not necessary to make a selection in the Repository Projects
pull down menu (shown in Figure 12-20).
Click the Restore button (shown in Figure 12-20). A dialog box
will confirm the success of the restore operation.
12-19
Opening the Restored Project

Restoring a project does not open it. To open the project select
the File | Open menu selection or use the Open button. The
Open Dialog box will be displayed, as shown in Figure 12-14.
Figure 12-14: Open Dialog Box
The project file of interest will not be shown yet as you must
first open the project from the repository. Click the Open from
repository button, to display the dialog box shown in Figure 1215.
12-20
Select the desired project in the drop-down list, as shown in

Figure 12-15, and click the OK button.
Figure 12-15: Open from Repository Dialog Box
Note: As an alternative to archiving/restoring a project, you

can zip the entire project folder, but this will not include
repository information.
12-21
Test Your Knowledge

1. What is the purpose of the cross reference browser?
2. Is print preview available in the workbench?
3. How many passwords can be set at the resource level?
4. If a user does not have the resource level password, and
read-only access has not been enabled, are users able to
view the files in read-only mode?
5. How many passwords may be set in the controller?
6. What are some of differences between Archive and
Export?
12-22
Chapter 13
OPC
Purpose
To review the steps to implement OPC.
Objectives
OPC
To understand the fundamentals of OPC.
To be able to implement the AADvance OPC server.
To be able to configure sample OPC clients and collect

data from the OPC server.
13-1
OPC Server
The AADvance OPC Server is a Windows-based application
that allows OPC compatible clients, such as HMIs and SCADA
systems, to connect to one or more AADvance controllers to
access data, as shown in Figure 13-1.
Figure 13-1: Services Window
The AADvance OPC server runs as a Windows service. A

service is an application type that runs in the background.
Service applications typically provide features such as
client/server applications, web servers, database servers, and
other server-based applications, both locally and across a
network.
You can start, stop, pause, resume, or disable a service on
remote and local computers (with the appropriate permissions).
You can also set up recovery actions to take place if a service
fails (e.g., restarting the service automatically).
13-2
Data Access vs. Alarm & Event

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

historian or event log type applications. OPC alarm & event
clients query the OPC server by controller name. Instead of
being able to query by variable name, the alarm & event clients
receive all events originating from subscribed controllers.
Installation
The AADvance OPC server is installed from a separate CD.
OPC
13-3
Configuring the OPC Server

The following information describes:
The OPC server (build 153) supplied as version

1.20.508.
Using the server and clients on the same PC.
Note: More detailed information is available in the OPC Portal

Server Manual (e.g., how to configure DCOM when the
server and client are running on different PCs,
synchronizing clocks between the controller and PC,
etc.).
A wizard is used to create an XML file used by the OPC server.
When you build or rebuild a project, the workbench will open a
dialog box asking if you wish to create the XML file, as shown
in Figure 13-2.
Figure 13-2: Start ConfigGen Tool Dialog Box
Click Yes. The Wizard will open, as shown in Figure 13-3.
13-4
Figure 13-3: OPC Configuration Wizard
Select Next. Check or browse for the project folder and the
project database PrjLibrary.mdb, as shown in Figure 13-4. The
password is the Project password, if one is set (see chapter 12).
Figure 13-4: Project Path
Continue through the Wizard steps. You do not need to check

the requested options (although you may). Go with the default
file location shown in the final screen, as shown in Figure 13-5.
OPC
13-5
Figure 13-5: Default File Location
Click the Next> button. The Wizard will automatically create

the configuration file, as shown in Figure 13-6.
Figure 13-6: Wizard Configuration File
Click the Restart OPC Service Now button. This will restart the
service and direct it to the new XML file. Click the Finish
button once that process is completed.
13-6
Configuring OPC Clients

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

1. OPC | Connect menu selection.
2. Select the appropriate server (ICSTriplexOPCServer in this
case), as shown in Figure 13.7. Click the OK button.
Figure 13-7: Select OPC Server Dialog Box
OPC
13-7
3. OPC | Add item menu selection.

Expand the configuration and resource and select the tags
that you wish to view, as shown in Figure 13-8.
Data Access clients
constantly poll for
selected variables.
Figure 13-8: OPC Add Item Dialog Box
Figure 13-9 shows an example of a simple OPC Data

Access client running and monitoring digital and analog
values.
Figure 13-9: Sample OPC Data Access Client
13-8
Sample Alarm & Event Client

1. OPC | Connect menu selection.
2. Select the appropriate server (ICSTriplexOPCServer in this
case) as shown in Figure 13.10. Click the OK button.
Alarm & Events clients
receive information
pushed out by the
server. Specific
variables do not need
to be selected.
Figure 13-10: Select OPC Alarm Server Dialog Box
1,000 events are stored

in the controller SOE
buffer. The buffer is not
retained on a power
loss.
Figure 13-11 shows an example of a simple OPC Alarm &

Event client running and monitoring sequence of events
information.
Figure 13-11: Sample OPC Alarm & Event Client
OPC
13-9
Test Your Knowledge

1. Which OPC client type requests data?
2. Which OPC client type automatically receives data?
3. Is the OPC configuration file created by the workbench?
4. True or false: the OPC server will generate alarm and
events for all tags defined in the dictionary.
13-10
Chapter 14
Troubleshooting
Purpose
To review basic troubleshooting of the AADvance system.
Objectives
Troubleshooting
To be familiar with the fault detection capabilities of the

AADvance system.
To be able to analyze the LED fault indicators and

identify faulty modules.
To be able to view diagnostic information online.
To be able to upload the processor log.
14-1
Self Test Cycle Times

AADvance diagnostics occur at different intervals. Some faults
are reported on their first detection. Others can take hours
before being reported.
Most faults are filtered by requiring a number of successive
faults before being reported (i.e., turning on a red LED). As
shown in Figure 14-1, if an error is present, a fault counter
increments. If the error is not present during the next test
interval, the fault counter decrements (by a lower value). If the
counter exceeds a threshold, the fault is reported as permanent.
At that point, one or more LEDs will turn red, fault information
will be available in the system, and entries will be placed in the
processor log.
Figure 14-1: Fault Filtering
14-2
Latching and Unlatching Faults

Some system faults are latching. In order to clear them, you
must remedy the source of the fault (usually by replacing a
module) and then press the Fault Reset button on a processor
module.
Note: During the reset operation, the system continues to run
at its normal scan rate. There is no change in system
performance and no additional vulnerability to faults.
Some system faults are non-latching. The system will attempt to
recover automatically and the fault indication will clear once the
fault condition has been remedied.
Indications of field faults (e.g., open or short circuits, which are
indicated by amber channel status indicators) are non-latching.
You may therefore not see some short term problems. The fault
indication clears as soon you remedy the source of the problem.
Figure 14-2: Indication of a Latching Channel Fault
Troubleshooting
14-3
Fault Types
Note: Please refer to the Troubleshooting and Maintenance
Manual for more detailed troubleshooting information
and tips.
Faults are classified as follows:
System faults
Module faults
Channel faults
Field faults
System Faults
A system fault is indicated when a detected fault cannot be
isolated to a single module (e.g., a bus failure or backplane
fault) or the fault is not the result of a hardware failure that
needs a module replacement (e.g. a software fault, calibration
drift). When this type of fault occurs in the system, only the
System Healthy LED on the processor(s) will turn red.
Module Faults
A module fault is indicated when a fault is isolated to the
hardware of a specific module. The Healthy LED turns red on
the faulty module and the System Healthy LED on the
processor(s) also turns red.
Channel Faults
A channel fault is indicated when a faulty channel is isolated to
a specific channel of an I/O module. Channel faults are also
reported as module faults. The Channel LED will turn red, the
I/O module Healthy LED will turn red and the System Healthy
LED on the processor(s) will turn red.
14-4
Field Faults
A field fault is indicated when a fault condition is isolated to a
field condition or field device and not an I/O module itself (e.g.,
open or short circuit field connection, no field power, out-ofrange signal, etc). These faults are indicated by a Channel LED
turning amber and are not indicated as a channel, module or
system fault.
Figure 14-3: Module Fault Types
Troubleshooting
14-5
Viewing Variables Live

When online (debugging), live values of all variables can be
viewed in the dictionary, as shown in Figures 14-4 and 14-5.
Figure 14-4: Viewing Variables Online in the Dictionary
Figure 14-5: Viewing I/O Variables Online in the Dictionary
Variables can also be viewed in programs and spy lists.
14-6
I/O State and LED Indications
Current, voltage and

other information can
also be read live.
Viewing the state of an I/O variable structure (tagname.STA),

as shown in Figure 14-5, can be useful for troubleshooting. The
state variable reports a numeric value (from 1 to 7) which
reflects the current state of the channel. The following figures
indicate the state values and the corresponding I/O LED
indications for various I/O types.
Figure 14-6: Digital Input Conditions and Indications
Figure 14-7: Analog Input Conditions and Indications

Troubleshooting
14-7
Figure 14-8: Digital Output Conditions and Indications
Figure 14-9: Analog Output Conditions and Indications
14-8
Diagnostic Collection
The processor keeps a system event log of 500 entries in a
rotating buffer. This covers several weeks of history in a quiet
system but it can fill rapidly with a chronic issue. In a future
release, the events will be added to the OPC Alarm and Events
output, so that the events may be collected by a HMI.
It is not usually necessary to read the processors event log. The
most likely system faults are also provided on diagnostic
variables. A module that consistently shows a red Healthy LED
almost certainly needs repair or replacement. However, a
second opinion is sometimes desirable.
A diagnostic collection tool is available that will collect the
processors event log as well as all diagnostic system data. This
is available in the Rockwell Automation knowledgebase as
article 68174. Within Rockwell Automation, it is on the ICS
Triplex product support website techsupport.icstriplex.com,
linked from the RAIN page A-Z as SSB Technology Support.
Installation
Run the installation program. You can leave the options at their
defaults. The installer offers to run the collection tool.
Communications Setup
Figure 14-10: Communications Setup
You can connect to the system by serial cable or Ethernet.

For a serial connection, unscrew the cover on the front of a
processor. The cover hides a round serial port as well as the
battery. Use a TC-304-01 maintenance cable and connect the
processor to a computer serial port. If a computer has no serial
ports, the Rockwell Automation 9300-USBS adapter is
Troubleshooting
14-9
recommended. Choose the appropriate serial port from the dropdown list.
For an Ethernet connection, ensure the computer is on the same
subnet as the systems Ethernet port that you are connected to.
Type the systems IP address into the setup window. After
successfully connecting, that IP address will be available for
next time by clicking the drop-down arrow.
Click OK. The program will start collecting diagnostic data. As
it receives data on module serial numbers and versions, it
displays these in the window.
Figure 14-11: Data Collection
When the program has finished collecting, it asks for details of

the log.
Figure 14-12: File name details
These details will help identify the system the log only
contains the name of the application that is running, which may
not be enough information to identify the system.
Click OK. Two files are now saved. One file contains all the
diagnostic data and is encrypted, but it can be opened by
14-10
support personnel. The other is a comma separated variable

(.csv) file that can be opened in Excel. This provides all the
serial numbers and firmware versions of the modules in the
system.
The encrypted file contains the state of the system as it was
when the log was taken, with a certain amount of history in the
processor logs. It provides detailed diagnostics on many
different functions of the system. It does not include the
application logic, SOE events and variable states and cannot be
used to diagnose a problem with the application.
Troubleshooting
14-11
Test Your Knowledge

1. What LED color indicates an I/O channel fault?
2. What LED color indicates an I/O field fault (e.g., short
circuit)?
3. If an I/O channel is indicated as faulty, what other LEDs
will indicate a fault?
4. If a field fault disappears, will LEDs change state
(color)?
5. What does state 3 mean for a digital output and what is
the expected channel LED color?
14-12
Chapter 15
Replacing Modules
Purpose
To review the procedure for replacing modules in an AADvance
system.
Objectives
Replacing Modules
To be able to replace faulty modules.
15-1
Removing Modules
Modules can be removed on line without shutting anything
down or upsetting the process in redundant configurations only.
Pulling out a non-redundant module will most likely impact
your process.
Modules are removed by carefully pulling them out of the base
unit using the following procedure.
The module Run LED
will turn red when the
module is unlocked.

module turn counter clockwise. The screw slot will be
vertical when the module is unlocked.
2. Carefully remove the module from the base unit.
Contact Rockwell Automation in order to obtain a return
material authorization and return the module.
15-2
Installing Modules
Modules are installed by carefully pressing them onto the base
unit, as shown in Figure 15-1, using the following procedure.
1. Inspect the connectors on the back of the module for
bent or damaged pins.
2. Make sure the slot of the module locking screw is
vertical.
3. Place the new module on to the dowel pins on the base
unit.
4. Push the module until the connectors are fully mated.
module turn clockwise.
When replacing a
processor, press its
Fault Reset button
once its Run LED
turns amber.
6. Wait for the module Run LED to turn amber. Press the
Reset button on a processor to enable the module to run.
Figure 15-1: Inserting a Module
Replacing Modules
15-3
Inserting a New Processor Battery

When installing a new processor module, Insert its internal
back-up battery as follows:
1. Use a small Phillips screwdriver to release the battery
cover.
2. Remove the cover. Take care to retain the screw and
grommet.
3. Insert the battery (a BR2032 coin cell) into the slot with
the ribbon on its left and its + positive side to the
right. The front plastic has + marks to indicate the
positive side.
4. Refit the cover.
Figure 15-2: Removing the Processor Battery Cover
15-4
Test Your Knowledge

1. What tool is required to replace modules?
2. Can non-redundant modules be replaced online without
impacting the process?
3. Can redundant modules be replaced online without
impacting the process?
4. What must you do after replacing a module to enable it
to run?
5. What must you also do when installing a new processor
module besides just plugging it into the base unit?
Replacing Modules
15-5
Appendix 1
AADvance Discover Utility
Purpose
To review how to configure the IP addresses of the six Ethernet
ports and set the resource number of the processor base unit.
Objectives
To be able to configure the IP addresses of the six

Ethernet ports using the AADvance Discover utility
To be able to set the resource number of the processor

base unit using the AADvance Discover utility.
A1-1
Processor Base Unit Configuration

Before a group of programs making up a resource can be
downloaded to a system, the system must have a valid IP
address and resource number. The following material describes
how to view and configure IP addresses and resource numbers.
A resource number uniquely identifies the system
(configuration) when there are multiple systems
(configurations) in a distributed project. A configuration can
only run one resource.
The processor base unit has a unique MAC (Media Access
Control) address range configured at the factory. The
AADvance Discover utility will detect and report the MAC
addresses that are connected to a network and allow you to
configure a new - or modify an existing - IP address, as well as
read and set the resource number.
The processor base unit holds the two IP addresses of each
processor slot, six addresses in all.
Notes: 1) Each Ethernet port of the pair on a processor slot
must be configured on a different subnet.
2) IP Addresses cannot be changed on a running
system.
Having the IP addresses set in the base unit means that you can
remove a faulty processor module and install a new one without
needing to set or load anything in the module.
A processor module must be connected in order to configure the
chip in the base unit for that slot, as shown in Figure A1-1.
Setting the addresses for one slot does not change the settings
for the other two slots. However, when a second or third
processor is added to a running system, it will copy the settings
to its own base unit chip.
A1-2
Figure A1-1: Process Base Unit
A1-3
Configuring or Viewing the Resource Number and

IP Address of a Processor Base Unit
You need to configure the IP addresses for each processor slot
of a new processor base unit.
Make a note of the MAC address range for the base unit shown
on the label on the 9100 processor base unit.
Decide on an IP address for each Ethernet port. Each Ethernet
port of the pair for a processor slot must be configured on a
different subnet.
Configuring the IP Addresses and Resource Number:
1) Connect an Ethernet cable between your PC and a port
on the controller base unit connected to a processor.
2) Insert the Program Enable key into the KEY socket on
the processor base unit. The settings cannot be
changed if the key is not fitted.
3) Start the AADvance Discover utility (Start > All
Programs > AADvance > AADvance Discover).
4) Find the MAC Address listed on the screen, as shown
in Figure A1-2.
Figure A1-2: AADvance Discover Screen
A1-4
Note: The AADvance Discover utility will find any

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

Ethernet port E1-1/2 to E3-1/2. Click Apply. The
controller status will show In Progress and then
Configurable when the IP Addresses are updated.
8) Change the resource number if you will have multiple
resources (controllers) in a distributed system. Each
system must have a unique resource number.
9) Cycle power to the controller to complete a change to
the resource number.
10) Refresh the screen to confirm that the resource number
is correct.
A1-6
Appendix 2
Glossary
Purpose
To summarize common AADvance, workbench and industry
terms.
Objectives
Glossary
To be familiar with and understand common

AADvance, workbench and industry terms.
A2-1
Actuators - Devices which cause an action (electrical, mechanical, pneumatic, etc.) to

occur when required within a plant component. Examples would be valves and pumps.
AIChE - American Institute of Chemical Engineers
Analog - Type of variable. These are continuous integer or real variables.
ANSI - American National Standards Institute
API - Application Program Interface, and also American Petroleum Institute
Architecture - Organizational structure of a computing system which describes the
functional relationship between board level, device level and system level components.
ASCII - The American Standard Code for Information Interchange. Uses seven bits to
represent 128 characters. Both upper and lower case letters, numbers, special symbols and
a wide range of control codes are included.
Asynchronous - A data communications term describing the method by which signals
between computers are timed. Although the number of characters to be sent per second is
undefined, the rate at which a characters bits are sent is pre-determined. Each character is
preceded by a start bit and terminated by a stop bit.
Availability - The probability that a system will be able to perform its designated function
when required for use, normally expressed as a percentage.
Backplane - A printed circuit board which supports bussed functions to connectors
mounted on a printed circuit board. Plug-in components and modules are then able to
connect to the bus pins.
Boolean - Type of variable. Such variables can only take true or false values.
BPCS - Basic Process Control System
Buffer - A type of memory in which information is stored temporarily during transfer
from one device to another, or one process to another. Normally used to accommodate the
difference in the rate or time at which the devices can handle the data.
Bus - A group of conductors which carry related data. Micro-based systems have an
Address Bus, Data Bus and a Control Bus.
CCPS - Center for Chemical Process Safety
Coil - Graphic component of an LD program used to represent the assignment of an output
variable.
A2-2
Comment - Text included in a program that has no impact on the execution of that
program.
Configuration A software object made up of one or more resources.
Contact - Graphic component of an LD program. It represents the status of an input
variable.
COTS - Commercial Off The Shelf
Coverage - The percentage of faults that will be detected by automatic system diagnostics.
Cross References - Information calculated by the workbench relating to the dictionary of
variables, and where those variables are used in a project.
DCS - Distributed Control System
Diagnostics - Tests performed on equipment to detect faults.
Dictionary - Set of internal, input, output variables and defined words used in programs.
DIN - Deutsche Industrie-Norm (German Industrial Standard)
Discrepancy - A difference exists between one or more elements of a redundant system.
E/E/PES - Electrical (Relay) / Electronic (Solid State) / Programmable Electronic System
EMC - Electromagnetic Compatibility
EMI - Electromagnetic Interference
EPROM - Erasable Programmable Read Only Memory. A non-volatile storage medium
which is electronically programmed. The EPROM device may be erased by strong ultraviolet light.
EEPROM Electrically Erasable Programmable Read Only Memory.
ESD - Electrostatic Discharge, also Emergency Shutdown
EUC - Equipment Under Control
F&G - Fire and Gas
Glossary
A2-3
Fail Safe - The capability to go to a pre-determined safe state in the event of a specific
malfunction.
Fault Tolerance - Built-in capability of a system to provide continued correct execution of
its assigned function in the presence of a limited number of hardware and software faults.
FB - Function Block
FBD - Functional Block Diagram. One of the graphical IEC 61131-3 languages.
Field Devices - Equipment connected to the field side of the I/O terminals. Such
equipment includes field wiring, sensors, final control elements and those operator
interface devices hard-wired to I/O terminals.
Firmware - Special purpose memory units containing software embedded in protected
memory required for the operation of programmable electronics.
Function Block - Graphic component of the FBD language which represents a standard
elementary function from the IEC 61131 TOOLSET libraries.
Global - Range of variables or defined words. Such variables or words may be used in any
program of one project.
GUI - Graphical User Interface.
HMI - Human Machine Interface
Hot Replacement - The ability to remove and replace modules without removing power
or stopping system operation.
ICS - Industrial Control System, also Industrial Control Services (the original name of the
company).
IEC International Electrotechnical Commission
IEC 61131 - International standard defining programming languages, electrical parameters
and environmental conditions for programmable electrical systems.
IEC 61508 - An international standard that covers functional safety, encompassing
electrical, electronic and programmable electronic systems; hardware and software
aspects. This standard is focused for vendors.
IEC 61511 - An international standard that covers functional safety and Safety
Instrumented Systems for the process industry, encompassing electrical, electronic and
A2-4
programmable electronic systems, hardware and software aspects. This standard is

focused for users, contractors and system integrators.
IEEE - Institute of Electrical and Electronics Engineers
IL - Instruction List. A low level IEC 61131 language, similar to the simple textual PLCs
language.
Input - Attribute of a variable. Such variables are linked to an input device.
Input Module - Interface that converts input signals from external devices into signals that
the control system can utilize.
Integer - Class of analogue variables stored in a signed integer 32-bit format.
Internal - Attribute of a variable which is not linked to an input or output device.
I/O Input / Output.
I/O Channel - Single connection point of an I/O module. An I/O channel may receive an
I/O variable.
ISA International Society of Automation.
Ladder Diagram - Graphic language mixing contacts and coils for the design of Boolean
equations.
LED Light Emitting Diode
LD - Ladder Diagram An IEC 61131-3 language composed of contact symbols
representing logical equations and simple actions. The main function of the ladder
diagram is to control outputs based on input conditions.
Local - Range of variables or defined words. Such variables and words may be used in
only one program of one project.
Locked I/O - Input or output variable disconnected logically from the corresponding I/O
module by a Lock (force) command sent by the user from the workbench. Locking is
typically used during testing and maintenance of field devices.
MMI - Man Machine Interface. The operators window to monitoring and keys, knobs,
switches, Graphical User Interface of the Operator Workstation, etc. for making
adjustments in the process.
Glossary
A2-5
Modbus - An industry standard communications protocol developed by Modicon. Used to

communicate with external devices such as distributed control systems (DCSs) or operator
interfaces.
M-oo-N - m-out-of-n. See Voting System.
Module - An electronic (generally pluggable) sub-system.
MTBF - Mean Time Between Failure
MTTF - Mean Time To Failure
MTTR - Mean Time to Repair
Network Address - Optional address defined for each variable. This address is used by the
Modbus protocol when the target system is connected to other systems.
OPC - OLE (Object Linking and Embedding) for Process Control
OSHA - Occupational Safety and Health Administration
Output - Attribute of a variable. Such variables are linked to an output device of the target
system.
Output Module - Interface that converts output signals from the control system into
signals that can actuate external devices.
OWS - Operator Workstation see HMI and MMI.
PES - Programmable Electronic Systems
PFD - Probability of Failure on Demand
PHA - Process Hazards Analysis
PLC - Programmable Logic Controller
Power Rail - Main left and right vertical rails at the extremities of a ladder diagram.
POU Program Organization Unit. A POU can be a program, a function or function
block.
Program - Basic programming unit in a project. A program is described with one
language, and is placed in the hierarchy architecture of the project.
A2-6
Project - Programming area which groups all the information (configurations, resources,
programs, variables, target code etc.).
Protocol - A set of rules governing data flow in a communication system. The protocol
governs such matters as the way a messages are is addressed and routed, how often it is
sent, how to recover from transmission errors and how much information is to be sent.
PST - Process Safety Time
RAM - Random Access Memory. A volatile (unless battery backed) form of read/write
memory. The time to access different locations is the same. It may be static (SRAM - data
held in a flip- flop) or dynamic (DRAM data held as a capacitive charge).
Real - Class of analog variables stored in a floating IEEE single precision 32-bit format.
Redundancy - The employment of two or more devices, each performing the same
function, in order to improve reliability and/or availability.
Resource The POUs and definitions making up a virtual machine.
RFI - Radio Frequency Interference
RIM - Regent Interface Module. Development term for Trusted TMR Interface Module.
RISC - Reduced Instruction Set Computer.
RRF - Risk Reduction Factor. 1/PFD
RS-232C, RS-422, RS-485 - Standard interfaces introduced by the Energy Industries
Association covering the electrical connection between data communication equipment.
RS-232C is the most commonly used interface. RS-422 allows for high transmission rates
over longer distances.
RTU - Remote Telemetry Unit
SFC - Sequential Function Chart. A IEC 61131-3 language that divides the process cycle
into a number of well-defined steps separated by transitions.
SIF - Safety Instrumented Function
SIL - Safety Integrity Level. One of four possible discrete levels for specifying the safety
integrity requirements of the safety functions to be allocated to the safety-related systems.
SIL4 has the highest level of safety integrity; SIL1 has the lowest.
SIS - Safety Instrumented System
Glossary
A2-7
Slice: One portion of a redundant system.

SOE - Sequence of Events
Software (Application Software) - Software specific to the user application. Generally, it
contains logic sequences, permissives, limits, expressions, etc. that control the appropriate
input, output, calculations and decisions necessary to meet system safety functional
requirements.
ST - Structured Text. A high level IEC 61131-3 language with a syntax similar to Pascal.
Used mainly to implement complex procedures that cannot be expressed easily with
graphical languages.
Swingframe - An empty hinged metal surround, designed to contain 483mm (19 inch)
standard equipment.
Synchronous - A data-communication term describing the method by which signals
between computers are timed. In synchronous communications, a prearranged number of
bits is expected to be sent across a line per second. To synchronise the sending and
receiving machines, a clocking signal is sent on the same line by the transmitting
computer. There are no start or stop bits in synchronous communications.
Target The hardware platform on which virtual machines run resources of a project.
You download configurations onto a target.
TCP/IP - Transfer Control Protocol/Internet Protocol
TMR - Triple Modular Redundancy.
TV - Technischer berwachungs-Verein
TV Certification - Independent third party certification against a defined range of
International standards including DIN V VDE 0801, IEC 61508, IEC 801.
U - Units of electronic module size (1 inches).
UPS - Uninteruptible Power Supply
Virtual Machine (IsaVM.exe) The instantiation of a resource on a target.
Voting System - Redundant system, e.g. m out of n, 1-oo-2, 2-oo-3 etc. which requires at
least m of the n channels to be in agreement before the system can take action.
A2-8
Watchdog - Watchdog circuitry (timer) provides dynamic and/or static monitoring of

processor operation and is used to annunciate processor or processor related failures (such
as an endless loop).
WDT - Watch Dog Timer
Glossary
A2-9
Appendix 3
Puzzles and Exercise
Purpose
To review and reinforce the material.
Objectives
To remember the names of AADvance hardware and

software components.
To be able to build a project from scratch.
A3-1
Hardware Crossword Puzzle for AADvance

1
7
9
10
11
12
13
14
15
16
17
18
19
20
21
www.CrosswordWeaver.com
ACROSS
DOWN
1 Power is distributed to the I/O modules

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

_________.
3 A single processor module meets SIL
___ requirements.
4 The Processor Base Unit has a
connection for the security _____.
5 AADvance can be panel or ___ rail
mounted.
6 A _____ is used to help remove the
coin-type battery from the processor.
7 An internal circuit is used to detect
impending module ______.
10 Digital Output Modules have _____
current protection.
15 Analog Input Modules accept ____
signals.
17 Two Digital Output Modules provide a
____ circuit arrangement.
19 The maximum possible Expansion
Cable length is ____ meters.
A3-2
Software Crossword Puzzle for AADvance

1
10
11
12
13
14
15
16
17
18
19
20
21
22
www.CrosswordWeaver.com
ACROSS
DOWN
1 Programs may be ______ offline for testing.

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

variables of the _____ type.
2 The software components are sorted in a
____-like hierarchy.
4 Configurations communicate with each other
through ______.
5 The opposite of a producing variable is a
________ variable.
6 _____ are not retained during a power loss.
7 You can view both logic and field values in
the ________.
9 You can control access to resources using a
_______. There are _____ classifications of
faults.
11 The Project must be _____ out to make any
changes.
16 Each ___ is a stand alone system with at
least 1 processor & it's associated I/O.
17 Bindings are directional _____ between
variables in different resources.
21 There are _____ programming languages
available.
A3-3
AADvance Programming Training Exercise
PSV
1001
To Flare
HH
HH
PI
1001
LI
1001
ESS
ESS
SDC
1001
ESS
SDC
1003
ESS
SDV
1003
L
LL
SDC
1002
SDV
1001
ESS
SDV
1002
PS
1001A
PS
1001B
PS
1001C
Gas To Injection
Compression
LIT
1001
SDC
1004
ESS
SDV
1004
From
Manifold
V-1000
High Pressure Separator
Oil To LP
Separator
SDC
1005
ESS
SDV
1005
Separator Low Low Level
< 10%
Water valve
LI1001 LL
SDV1005
< 50%
Oil Valve
Separator Low Level
SDV1004
LI 1001 L
Gas valve
> 90%
SDV1003
Separator High Level
Inlet valve 2
LI1001 HH
SDV1002
Separator High Pressure (2oo3)
Inlet valve 1
PI1001 HH
A3-4
Setpoint
SDV1001
Description
Description
Tag
Tag
Water To
Hydrocyclone
s
X
X
X
X
Notes:
1. Use the tag names shown in the P&ID (balloons) for your actual I/O variable
names. If you do not understand the P&ID, please ask your instructor for
clarification.
2. Develop a function for two-out-of-three voting of the digital inputs.
3.
Use a 5 second time delay for all three level trips.
4. Test your project in the simulator before loading it into the controller.
5. If you have time, add a second configuration to your project with a digital input and
output module. Create bindings between the configurations so that when the
separator shuts down due to high pressure, an action takes place in the second
configuration. Test this modified project in the simulator (as we do not have a
second controller to use in class) and show it to your instructor.
A3-5
Appendix 4
Safety Manual
Considerations
Purpose
To summarize product specific safety issues related to system
implementation.
Objectives
To understand the product specific implementation

issues in order for the system to comply with
international functional safety standards.
Safety Manual Considerations
A4-1
Please Read the Safety Manual!

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

The safety manual contains rules and recommendations.
Rules are mandatory and must be followed if the
resulting system is to be SIL3 compliant. These are
identified by the term shall.
Recommendations are not mandatory, but if they are
not followed, extra safety precautions must be taken in

order for the system to be compliant. Recommendations
are identified by the term it is highly recommended.
A4-2
High Demand, SIL 3 and Energize to

Action Applications
For high demand applications, a minimum of dual processors
are required.
For SIL3 applications, a minimum of dual processors are
required.
For de-energize to action (normally energized) operation, one
digital output module is sufficient for SIL3 requirements.
However, for energize to action operation, dual digital output
modules are required.
Utilizing I/O Module Diagnostics

Input Modules
The analog .cnt

variable will be 0;
the .pv variable will
be calculated
(scaled) based on a
count of 0.
When an input channel is not capable of reporting a value

within specification of the full scale measurement (1% for
analog inputs, 4% for digital inputs) safe values are reported
by the variables (0 for analog, FALSE for digital).
Figure A4-1: I/O Structure Variables
A4-3
When the accuracy between channels in a redundant input

module configuration exceeds limits (2% for analog inputs, 8%
for digital inputs) then a discrepancy alarm (.dis variable) is set
for the input channel. The discrepancy alarms shall be
monitored for safety critical applications by an application
program and used to provide an alarm to the plant operations
personnel (so they may replace the module within the repair
time assumed in performance calculations).
All I/O modules include line-monitoring facilities. These
facilities shall be utilized for normally de-energized I/O. Refer
to the safety manual for recommended end of line resistor
values and digital input voltage threshold value settings.
Figure A4-2: Digital Input Voltage Thresholds
A4-4
Digital Output Modules

The shut down state for digital outputs can be configured for the
following settings:
Off, de-energize (fail-safe, the default)
Hold last state
Careful consideration should be given to the affect on the
process of using the hold last state setting.
Figure A4-3: Digital Output Shutdown States
A4-5
The digital output module incorporates line test functionality

that can report and indicate no load field faults. This
functionality can be enabled or disabled. The settings are:
Yes - disables reporting and indication of no load field
faults
No No load field faults are reported and indicated
Figure A4-4: Disabling Digital Output Testing
A4-6
Degraded Run Time Restrictions

The maximum duration for single-channel operation of modules
depends on the specific process and must be specified
individually for each application.
Input modules can operate in a simplex arrangement
without time limit for SIL3 and lower applications.
Output modules can operate in a simplex arrangement
without time limit for SIL3 de-energize to action
(normally energized) applications.
Output modules can operate in a simplex arrangement
without time limit for SIL2 energize to action
applications, or for up to the MTTR when used in SIL3
energize to action applications. An application program
must be designed to shut down energize to action SIL3
safety instrumented functions if a faulty output module
has not been replaced within the MTTR.
Processor modules can operate in a simplex arrangement
without time limit for SIL2 applications, or for up to the
MTTR when used in high demand mode applications, or
for up to the MTTR when used in SIL3 applications. An
application program must be designed to shut down the
system if a faulty processor module has not been
replaced within the MTTR.
A4-7
I/O Forcing
The AADvance Workbench supports forcing of individual
inputs and outputs. The Workbench uses the term locking to
describe forcing.
Forcing requires the program enable key to be fitted to the 9100
Processor Base Unit. Forcing is intended only for the purposes
of engineering, installation and commissioning activities. When
the system is in-service, maintenance overrides for safetyrelated inputs and outputs should be implemented using an
application program instead of forcing (e.g., external hard-wired
switches connected to conventional system inputs).
The Force LED on the front of the T9110 Processor Module
indicates when one or more I/O points are forced. The
application program can determine how many points are
currently forced. It is highly recommended that this information
be used to control an additional status display and/or for logging
purposes.
Figure A4-5: Processor Integer Status Variables
A4-8
If the forcing facility is used when the system is in-service, a

safety-related input connected to an operator accessible switch
shall be implemented to initiate the removal of the force
condition.
Figure A4-6: Processor Boolean Control Variables
In order to accommodate maintenance overrides safely, TV

has documented a set of principles that shall be followed. These
principles are published in the document "Maintenance
Override" by TV Sddeutschland / TV Product Service
GmbH and TV Rheinland.
A4-9
Safety Manual Checklists

Please refer to the Chapter 5 checklist section in the safety
manual for additional helpful information.
A4-10

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System Training Manual

For the AADvance

Copyright Notice and Disclaimers

Revision and Updating Policy

AADvance System Training Manual, version 1.7

Updated for Release 1.2

Integrated with user manuals and updated for release 1.3

AADvance System Training Manual, version 1.7

Chapter 2: System Overview

Chapter 3: System Components

Chapter 4: System Build

Chapter 5: Workbench Overview and Programming

AADvance System Training Manual, version 1.7

Chapter 6: Simulating and Testing Programs

Chapter 7: Downloading and Monitoring Programs

Chapter 8: Creating and Using Functions and Function Blocks

Chapter 9: Online Changes

Chapter 10: Bindings Between Resources

Chapter 12: Miscellaneous Workbench Features

AADvance System Training Manual, version 1.7

Chapter 13: OPC

Chapter 14: Troubleshooting

Chapter 15: Replacing Modules

Appendix 1: AADvance Discover Utility

Appendix 3: Puzzles and Exercise

Appendix 4: Safety Manual Considerations

AADvance System Training Manual, version 1.7

How the AADvance system operates as a non-redundant

What modules and components are used in the

How to put an AADvance system together.

How to use the workbench to create, modify, test,

How to create user defined functions and function

How to pass safety critical data between controllers.

How to communicate with the system using OPC.

How to utilize the version control features.

How to troubleshoot a system and replace modules.

Who This Course Is Intended For

Personnel responsible for designing, configuring and

Personnel responsible for installation, troubleshooting

Personnel designing a control system that needs to

A general knowledge of programmable logic controllers

A background in industrial electronic control principles

A level of competence using Microsoft Windows

AADvance System Training Manual, version 1.7

To understand the different system components and

To understand what module configurations meet what

To understand the types and names of modules used in

To understand the configuration limits of the system.

AADvance System Overview

Critical process control

The system is designed for both high and low demand

Flexible modular construction using individual modules

AADvance System Training Manual, version 1.7

General System Layout

Figure 2-1: System Components

A processor base unit can support up to 8 I/O base units (up to

I/O base units do

Figure 2-2: Example System Layout

AADvance System Training Manual, version 1.7

Internal Bus Structure

Figure 2-3: Internal Bus Structure

Output modules incorporate dual redundant circuitry internally.

AADvance System Training Manual, version 1.7

Non-Redundant, Fail Safe Architecture