Page 1 ® ® Advant with Master software User’s Guide 3BSE 002 415R701 Rev A...
Page 2 In no event shall ABB Automation Products AB be liable for direct, indirect, special, incidental or consequential damages of any nature or kind arising from the use of this document, nor shall ABB Automation Products AB be liable for incidental or consequential damages arising from use of any software or hardware described in this document.
Page 3 ® Advant Controller 450 User’s Guide Table of Contents TABLE OF CONTENTS Chapter 1 - Introduction General Information....................1-1 Manual Organization ....................1-2 Conventions ......................1-5 Related Documentation.................... 1-5 Release History ......................1-9 Terminology......................1-12 Product Overview ....................1-16 1.7.1 Product Versions ...................
Page 4 ® Advant Controller 450 User’s Guide Table of Contents 1.7.10.1 Diagnostics ..............1-108 1.7.10.2 Redundancy ..............1-111 1.7.11 Mechanics ................... 1-116 1.7.11.1 Cabinets ................ 1-116 1.7.11.2 Subracks ............... 1-120 1.7.11.3 Submodule Carrier and Submodule ......1-123 User Interface ....................... 1-124 Chapter 2 - Installation Site Planning Environment ..................
Page 5 ® Advant Controller 450 User’s Guide Table of Contents 2.2.5.7 Grounding of Process Signals ........2-25 2.2.5.8 Grounding of Additional Equipment ......2-26 2.2.5.9 Spare Conductors ............2-26 2.2.6 Cable Routing in Cabinets ..............2-26 2.2.7 Power Supply Connection ..............2-28 2.2.7.1 General ................
Page 6 ® Advant Controller 450 User’s Guide Table of Contents 2.4.2.5 Configuration/Application Building....... 2-63 2.4.2.6 Dumping and Loading............ 2-63 2.4.2.7 Summary of the Controller Start-up and Verification of the Start ..............2-65 2.4.2.8 Installation of Battery for Backup of Memory ....2-66 2.4.3 Peripheral Equipment................
Page 7 ® Advant Controller 450 User’s Guide Table of Contents 3.1.2.4 Backup of Application Program ........3-4 3.1.3 Power Supply..................3-4 3.1.4 Process Interface ................... 3-10 3.1.4.1 S100 I/O System ............3-13 3.1.4.2 S400 I/O System ............3-19 3.1.4.3 S800 I/O System ............3-21 3.1.5 Communication..................
Page 8 ® Advant Controller 450 User’s Guide Table of Contents 3.2.4.2 Applied Communication ..........3-66 3.2.5 Process Control ..................3-67 3.2.5.1 Logging ................3-68 3.2.6 Operator’s Interface ................3-69 3.2.6.1 Local Operator Station ........... 3-69 3.2.6.2 Central Operator Station..........3-69 3.2.6.3 Printer ................
Page 9 ® Advant Controller 450 User’s Guide Table of Contents 4.1.9.3 PC Program ..............4-20 4.1.10 Execution ....................4-21 4.1.10.1 Interpreter............... 4-21 4.1.10.2 Execution Sequence within an Execution Unit....4-23 4.1.10.3 Sequence of Execution of Execution Units....4-23 4.1.10.4 Execution Sequence for an Individual PC Element ..4-24 4.1.10.5 Execution Sequence of PC Elements ......
Page 10 ® Advant Controller 450 User’s Guide Table of Contents Fault Finding and User Repair ................. 5-6 5.5.1 Introduction ..................... 5-6 5.5.2 Diagnostics and Fault Announcement ............ 5-7 5.5.2.1 System Status and Plain Language System Messages ..5-9 5.5.3 Fault Finding Principles ................ 5-34 5.5.4 Fault Classification and Scheme of Measures ........
Page 11 ® Advant Controller 450 User’s Guide Table of Contents 5.5.13 Adjustment of Isolation Amplifier............5-82 5.5.14 Adjustment of Reference Voltage............5-82 5.5.15 System Restart following Maintenance Activities........ 5-82 5.5.16 System Restart, INIT ................5-83 5.5.17 Loading of Application Program ............5-84 CPU Load Measurement..................
Page 12 Appendix J - Hexadecimal to Decimal Representation Conversion Guide..................... J-1 ILLUSTRATIONS Figure 1-1. Example of Advanced Control System with Advant Controller 450 ... 1-1 Figure 1-2. Basic Documentation Structure ..............1-2 Figure 1-3. Cabinet for Advant Controller 400 Series, RM500, in a Front View ..1-16 Figure 1-4.
Page 13 Figure 1-11. Location of Additional Program Cards ............1-26 Figure 1-12. Principle of Power Supply of an Advant Controller 450 (a.c. mains supply)..................1-38 Figure 1-13. Principle of Redundant Power Supply of an Advant Controller 450 (a.c. mains supply)..................1-39 Figure 1-14. Voltage Regulation in Controller Subrack..........1-42 Figure 1-15.
Page 14 Figure 1-50. Cabinet, type RM500................1-117 Figure 1-51. Typical Cabinet minimum Configuration, Redundant Power Supply ..1-119 Figure 1-52. Advant Controller 450, Controller Subrack 9S ........1-120 Figure 1-53. Front of I/O Subrack ................. 1-121 Figure 1-54. I/O Subrack Configuration................ 1-122 Figure 1-55.
Page 15 Examples of Distribution Board Fusing, d.c..........3-9 Figure 3-6. Reduction Factors for Cabinets Installed in Groups........3-33 Figure 3-7. Advant Controller 450 Priority System............3-40 Figure 3-8. CPU Load Calculation Methods..............3-42 Figure 3-9. Load from Cyclic Functions, Overview ............. 3-45 Figure 3-10.
Page 16 Figure 4-9. Programmed Start at DICONFIG ............... 4-14 Figure 4-10. Advant Controller 450 - Survey of Software System ......... 4-16 Figure 4-11. Survey of Processor Module and Operating System ........4-17 Figure 4-12. Example of PC Element: FUNG-1V ............4-20 Figure 4-13.
Page 17 ® Advant Controller 450 User’s Guide Table of Contents Figure 5-23. Adjustment of Current Output..............5-80 Figure B-1. RM500 Cabinet - Front View ...............B-1 Figure B-2. Mounting Cabinets together - Screw Position..........B-3 Figure B-3. Swing Radius for Door(s) and Hinged Frame..........B-3 Figure B-4.
Page 18 Situations which Cause Clearing of the RAM..........2-64 Table 2-16. Programmable Parameters ................2-67 Table 2-17. Cycle Times for Advant Controller 450 ............. 2-71 Table 2-18. Implementation of Functions in Systems Already Operating..... 2-82 Table 3-1. Backup of Application Program, Hardware and Software ......3-4 Table 3-2.
Page 19 ® Advant Controller 450 User’s Guide Table of Contents Table 3-8. Applied Communication, Used Links and Interface to Application Program .................. 3-25 Table 3-9. Calculation of RAM requirement............... 3-36 Table 3-10. Technical Data of CPU and Memory ............3-44 Table 3-11. Load from Process I/O Handling..............
Page 20 ® Advant Controller 450 User’s Guide Table of Contents Table F-1. Calculation of CPU-load from S100 and S800 Inputs........F-1 Table F-2. Calculation of CPU-load from S100 and S800 Outputs .......F-2 Table F-3. Calculation of CPU-load from User Defined Type Circuits......F-3 Table G-1.
Page 21 Figure 1-11. Location of Additional Program Cards ............1-26 Figure 1-12. Principle of Power Supply of an Advant Controller 450 (a.c. mains supply)..................1-38 Figure 1-13. Principle of Redundant Power Supply of an Advant Controller 450 (a.c. mains supply)..................1-39 Figure 1-14. Voltage Regulation in Controller Subrack..........1-42 Figure 1-15.
Page 22 Figure 1-49. Arrangement of Redundant I/O Modules ..........1-116 Figure 1-50. Cabinet, type RM500.................1-117 Figure 1-51. Typical Cabinet minimum Configuration, Redundant Power Supply..1-119 Figure 1-52. Advant Controller 450, Controller Subrack 9S ........1-120 Figure 1-53. Front of I/O Subrack................. 1-121 Figure 1-54. I/O Subrack Configuration ............... 1-122 Figure 1-55.
Page 23 Examples of Distribution Board Fusing, d.c..........3-9 Figure 3-6. Reduction Factors for Cabinets Installed in Groups........3-33 Figure 3-7. Advant Controller 450 Priority System............3-40 Figure 3-8. CPU Load Calculation Methods..............3-42 Figure 3-9. Load from Cyclic Functions, Overview ............. 3-45 Figure 3-10.
Page 24 Programmed Start at AUTO - ENTER............4-13 Figure 4-9. Programmed Start at DICONFIG............... 4-14 Figure 4-10. Advant Controller 450 - Survey of Software System......... 4-16 Figure 4-11. Survey of Processor Module and Operating System........4-17 Figure 4-12. Example of PC Element: FUNG-1V ............4-20 Figure 4-13.
Page 25 ® Advant Controller 450 User’s Guide Table of Contents Figure 5-16. Fault Finding, B..................5-44 Figure 5-17. First Guidance, Scenario C................. 5-46 Figure 5-18. First Guidance, Scenario D................. 5-47 Figure 5-19. Fault Finding, Mains Supply and 24 V Power Supply....... 5-48 Figure 5-20.
Page 26 ® Advant Controller 450 User’s Guide Table of Contents 3BSE 002 415R701 Rev A...
Page 27 ® Advant Controller 450 User’s Guide Table of Contents TABLES Table 1-1. Related Documentation - Configuration/Application Building ....1-6 Table 1-2. Related Documentation - Installation............1-7 Table 1-3. Related Documentation - Optional Functions ..........1-7 Table 1-4. Related Documentation - Tools ..............1-9 Table 1-5.
Page 28 Situations which Cause Clearing of the RAM ........... 2-64 Table 2-16. Programmable Parameters................2-67 Table 2-17. Cycle Times for Advant Controller 450 ............. 2-71 Table 2-18. Implementation of Functions in Systems Already Operating ....2-82 Table 3-1. Backup of Application Program, Hardware and Software......3-4 Table 3-2.
Page 29 ® Advant Controller 450 User’s Guide Table of Contents Table A-2. Pin Designation for Channel 1 and 2. Connector X4 and X5 ......A-7 Table A-3. DSSB 170, Operating Data................A-9 Table A-4. SA1xx, Individual Technical Data .............A-23 Table A-5. Fuses in SA1xx...................A-24 Table A-6.
Page 30 ® Advant Controller 450 User’s Guide Table of Contents 3BSE 002 415R701 Rev A...
Page 31 Remote Terminal Process I/O Advant Controller 450 is a large controller for mixed binary, regulatory and supervisory control. It can be used standing alone, or as an integrated controller in a distributed control system, communicating with other Advant OCS equipment (see Figure 1-1).
Page 32 Š Figure 1-2 shows the basic structure of the Advant System’s various documentation. Each document, whether it is describing and referencing hardware or software, is built around this one structure to make it easy for you to locate related information in any of the documents. Since this one structure is not completely applicable to both hardware and software, certain sections contain only very brief statements in some documents.
Page 33 A glossary defining terms frequently used in this manual. • A product and functional overview. Read this to get an idea of what the Advant Controller 450 can do and how it works. guides you through various installation activities: •...
Page 34 Š gives you detailed information about how to obtain a desired function. The main information is structured as follows: • Section 3.1, Design Considerations. You can find design guidelines, including design rules, in this section. Keywords include the following. – Limitations –...
Page 35 Advant OCS is used for Advant Open Control System, with Master software, throughout this manual. This manual is the main document of the system product Advant Controller 450. Many of the available options are briefly described in this manual. For additional detailed information about options, see the appropriate individual manuals.
Page 36 Š PC Elements Data for all PC elements in AC 410/450. AC 400 Series Data Base Elements Data for all data base elements in AC 410/450. AC 400 Series AMPL Application Building Basic manual covering the use of the application program language AMPL.
Page 37 Š Environmental Immunity for Description of the environmental immunity for ABB ABB Advant OCS Products Advant OCS products. Elektroniska Apparater Minimum requirements on electronic equipment used in power industry within EC and EFTA (in Swedish). Interference-free Electronics This book teaches how to design circuit boards,...
Page 38 MasterNet Manual describing how to configure, install and maintain MasterNet communication networks, MasterBus 300, MasterBus 300E and GCOM. For information about ABB MasterGate communication stations, see the manuals concerned. RCOM Contains technical descriptions, instructions for AC 400 Series configuration, installation, start-up and fault tracing of AC 410/450.
Page 39 Š Advant Station 100 Series Contains a description of the basic functions, Engineering Station connection and start-up and how to work with the main functions. AdvaBuild On-Line Builder This reference manual describes all common commands used in AS 100ES, AS 500ES and AS 500OS.
Page 40 , include: • Object oriented connection units • 8 or 16 Mbyte memory in Advant Controller 450 • Optical S100 I/O bus extension for distributing I/O boards up to 500 m from the controller • Ex-barriers adapted to the S100 I/O System by certain manufacturer •...
Page 41 Š ∗ New highlights in the , include: • Integration of the S800 I/O System • Twisted pair media for the Advant Fieldbus 100 • Number of Advant Fieldbus 100 increased • Backup of application program on flash card • More MMC_X instances •...
Page 42 Š ∗ New highlights in the , include: • LONWORKS Network Interface • INSUM Switchgear integration • PROFIBUS-DP, enhanced functionality • HART data routing support • Extended range of S800 I/O modules. • New S100 I/O bus extender, DSBC 176. For single S100 I/O bus. Regarding version designations, see Section 1.7.1, Product Versions.
Page 43 MasterNet is called a control network (DCN). It provides real time communication. stands for lectro tatic ischarge. A functional unit is an ABB Master specified denomination. It is a “package” of different software functions such as PC elements, data base elements and man-machine interface for an operator station.
Page 44 Š tegrated ystem for ser optimized otor control. An ABB proprietary, LONWORKS based system for switchgear and motor control systems. Intrinsically safe equipment and wiring is equipment and wiring which is incapable of releasing sufficient electrical energy under normal or abnormal conditions to cause ignition of a specific hazardous atmosphere mixture.
Page 45 Š , andom ccess emory Redundancy in general means the existence of more than one capability of an item (system, apparatus, component) to perform its intended function. A slot means: The place in the subrack where you put a The place in a where you put a submodule.
Page 46 Š Advant Controller 450 is a programmable system for control and supervision of processes and equipment in industrial environments. 1-16 3BSE 002 415R701 Rev A...
Page 47 MasterPiece 200/1 products, MasterView 800/1 products, SuperView 900 products and external computers in the network (see Figure 1-1). You can connect a local operator station and a printer to an Advant Controller 450 via standard serial channels. 3BSE 002 415R701 Rev A 1-17...
Page 48 Š The programmability of Advant Controller 450 covers a wide range of functions, such as logic and sequence control, data and text handling, arithmetic, reporting, positioning and regulatory control, including advanced PID and self-tuning adaptive control. A function-block language with graphic representation, you can use AMPL (ABB Master Programming Language), for configuration and application building.
Page 49 Š The software included, which is of modular character, is selected in accordance with the scope of the function and consists of a basic system program module and applicable function library program modules. All program modules are designated in principle in the same way, for example, QC07-BAS41 ∗2.0/0.
Page 50 Š ABB Master is a totally modularized system at all levels. The high level consists of a family of system products. An example of an advanced control system applying system products is illustrated in Figure 1-1. The system product is divided into HW modules and SW modules. In this way, the system shows: •...
Page 51 Š The process I/O dedicated to an Advant Controller 450 is available as one or several I/O subracks (for central location close to the controller) or I/O units (for distributed location). Also available are different distributed, autonomous units including I/O, for example PLC-type controllers.
Page 52 Š Figure 1-8 indicates broadly the functional relationship between main system utilities and how the hardware is structured. This is an example of a version of the Advant Controller 450. Communication for example: MasterBus 300, GCOM, EXCOM, MVI Advant Fieldbus 100, MasterFieldbus...
Page 53 The concepts of basic function and optional function are sometimes used in the documentation of the Advant Controller 450 system. A system can be provided with a number of optional functions which enable you to adapt each system for specific control tasks. Certain functions require extra software while others require both extra software and extra hardware.
Page 54 Please refer to relevant tendering and sales documentation for that information. The central processing unit of the Advant Controller 450 comes in two versions with 8 or 16 Mbyte dynamic RAM. The versions are both designated Processor Module PM511V. A label on module side states the RAM size (PM511V or PM511V ).
Page 55 Š The Processor Module PM511 contains the total amount of RAM (Random Access Memory), which is an 8 or 16 Mbyte dynamic RAM with error correction code. This memory holds the system program which is in use as well as the controller system configuration and application program, that is all memory executed in run time.
Page 56 In some applications this is a too time consuming procedure and it needs assistance of qualified maintenance people. As an alternative the Advant Controller 450 can be equipped with an optional flash card of similar type as the one used for the system program. The illustration in Figure 1-11 apply.
Page 57 Š The program function library, among others, contains PC elements and functional units. A functional unit is a package of different program functions such as PC elements and operator’s functions. This simplifies the realization of combined functions with both the control function and associated operator’s handling via a display screen and keyboard.
Page 58 Š Structure PC elements for structuring of PC BLOCK, CONTRM, elements programs, including breakdown of FUNCM, MASTER, sequences into steps. PCPGM, SEQ, SLAVEM, STEP Logic Logic gates and binary memory AND, AND-O, INV, OR, elements elements. OR-A, SR, SR-AA, SR-AO, SR-D, SR-OA, SR-OO, XOR Arithmetic PC elements for the four basic calcula-...
Page 59 Š Fault Handle groups of fault signals for lamp FAULT elements indication with flashing, acknowledgment and alarm. Printing and text Compose text strings and print reports. PRINT, TEXT generation elements Elements for Interface PC programs with GENBIN-I, GENBIN-O, functional units Advant Station 500 and MasterView 800 GENUSD-I, operator stations for control of motors,...
Page 60 Š Weighing Interface strain-gauge scales with PC SCALE, SCALE_DOS elements programs in Advant Controller 400 Series. Table handling Elements for handling data as tables. TBL-R, TBL-RG, elements TBL-W, TBL-WG Ramp Ramp generator with S-shaped output. RAMP-S1 generators Supervision Evaluate the load on Advant ANALYSE, COM-STAT elements Controller 400 Series and Advant...
Page 61 Valve controller The program module QC07-BAS41 is in principle composed by QMP240 in earlier releases of ABB MasterPiece 200/1. QC07-LIB41 extends the PC element library that is included in the basic system program module with PC elements to support the functions listed below.
Page 62 Š Time Square- and sine-wave oscillators. OSC-SQW, OSC-SIN controlled elements Function gen- Generate an output from one or two input FUNG-1V, FUNG-2V, erators variables according to a function described FUNG-T by data tables or as a function of time. Filter ele- Low-pass filters with one or two poles.
Page 63 The optional program module QC07-LOS41 extends the functionality given by the basic system program module with functions listed below. QC07-LOS41 adapts the Advant Controller 450 to a MasterView 320, a local operator station built up on a VT100 terminal. This provides dialog texts in the following languages: English, Swedish, Danish, Norwegian, Finnish, Dutch, German, French, Italian, Spanish and Portuguese.
Page 64 Advant Controller 450. After the user defined PC element is installed in the Advant Controller 450 it can be used freely in all PC programs as a normal PC element. These elements will appear in every sense as standard PC elements.
Page 65 MasterView 320. A slow, smaller adjustment in the interval ±100 s can also be performed with the programming unit. With Advant Controller 450 connected to MasterNet, as a part in a distributed control system, the synchronization occurs automatically with other stations via a network with an accuracy better than 3 ms.
Page 66 The PU535 also contains a simple User Test Interface for execution control and diagnostics, available through the service port (V24/RS-232-C). An Advant Controller 450 is normally delivered in one or several cabinets. Process I/O subracks are included as applicable. The equipment is designed, as standard, for connection to a 120/230 V single-phase or two-phase a.c.
Page 67 Š Common to all alternatives is an optional connection to a separate single-phase a.c. mains supply C. This network C feeds modems, which use a.c. power supply and a specific backup power supply SB510. The latter solution provides the feature to maintain battery charging and supply of the RAM while the power supply is otherwise switched off.
Page 68 Š 1-38 3BSE 002 415R701 Rev A...
Page 69 Š 3BSE 002 415R701 Rev A 1-39...
Page 70 Š Mains A and B SX540 SX540 SX555 SX555 SX550 SX540 SX540 SX555 SX550 Mains A and B SX541 SX541 SX555 SX555 SX551 SX541 SX541 SX555 SX551 (expansion) Mains C, category II SX542 SX542 SV543 SV542 Mains C, category III SV541 SV540 SV543...
Page 71 You use the power switch and distribution unit to connect and disconnect the Advant Controller 450 system to the mains and for distribution of voltage to different units in the cabinet. The power switch unit contains terminal blocks, miniature circuit breakers and power outlets for, for example, power supply units.
Page 72 Š All modules in the subracks are powered by 24 V unstabilized voltage and 5 V stabilized voltage. 24 V is converted to 5 V by voltage regulators. Each subrack has one or several dedicated voltage regulators. Different types are available which are adapted to mechanical, energy and special high-reliability/availability requirements.
Page 73 Š Regulator Output fuse Terminal blocks for connection of 24 V Input fuse F1 for the regulator Cable +24 V to DSSR 122 Fuse protected +24 V Cable 0 V to DSSR 122 and backplane to the backplane Rear of subrack Backplane DSBB 188 Regulator 1 - 3 Voting Unit...
Page 74 1 h per 1 Ah external battery capacity (redundant processor modules). The internal battery SB522 must be in position to get the normal diagnostics of the SB511. The fusing and electronic overload protection of the Advant Controller 450 and its main parts are illustrated in...
Page 75 Š An Advant Controller 450 communicates with the process through various types of sensors and actuators connected to process interface units. Three variants of the I/O system are offered, S100 I/O, S400 I/O and S800 I/O. The I/O systems are optimized for different use.
Page 76 Š The input and output signals can be in digital or in analog form (current or voltage signals). Figure 1-16 Figure 1-17 shows, in principle, the layout of the signal paths for the input and output signals for the different I/O systems. The signal paths are built up of the following units, which are described in principle below.
Page 77 Š Parallel data Processor Internal module system Bus extension Comm. (max 12 m (39 ft.) el. max 500 m (1640 ft.) opto) module S100 I/O DSBC 174/ interface DSBC176 Connection unit board 3BSE 002 415R701 Rev A 1-47...
Page 78 Š Processor module Internal Short distance bus system unit Comm. Modem Modem Modem module TC570 CI570 unit Long-distance bus (max 750 m (2460 ft.) el. max 3000 m (9842 ft.) opto) unit Processor module Internal Modulebus system Advant Fieldbus 100 Comm.
Page 79 Š The process cables are connected to screw terminals (terminal blocks) on the connection units or directly to the I/O units. The connection unit consists of a circuit board which is to be located on a mounting bar in the backplane of the cabinet.
Page 80 Š and valves utilizing both ordering and indicating signals are joined with the control system in a rational and uniform way. Figure 1-19 gives an example of application. Motor object Contactor Mounting bar Process cable Ready Fuses Plug-in Trip Terminals connector I/O boards Connection unit...
Page 81 Š I/O boards convert incoming electrical signals from the process controlled, so that they can be further processed in the processor module. Outgoing signals are adapted to their functions in the process. I/O boards are divided into the following groups: •...
Page 82 Š Hazardous applications may use barriers between the standard electronics and the equipment located in hazardous atmosphere. Certain barrier brands provide rational connection facilities adapted to the Advant Controller 400 Series thus making these brands especially advisable. The basic principle is to replace the connection units of the S100 I/O System with termination boards housing the intrinsically safe isolator modules.
Page 83 Advant Control Configurator tool version supporting HART and its integrated HART configuration tools are conditions for this function. HART specific data is not available in Advant Controller 450 which is acting as a router between the S800 I/O modules and the HART configuration tool. The principle is illustrated in Figure 1-21.
Page 84 Š S100 I/O is the group of input and output boards located in the I/O subrack. The I/O subrack communicates with the controller subrack using Bus Extension to S100 I/O. Single and redundant Bus Extension to S100 I/O are available. Redundant S100 I/O Bus Extension requires redundant processor module.
Page 85 Š DSDI 110A 32 (4 x 8) channels, 24 V d.c., controlled by Variants below provide scanning or interrupt various rated input voltages, all channels galvanically isolated: 24 V d.c., 4 x DSTD 195 DSTK 226L3 120 V a.c., 4 x DSTD 197 DSTK 226L3 230 V a.c., 4 x DSTD 198 DSTK 226L3...
Page 86 Š DSDI 120A 32 channels, 48 V d.c., controlled by DSTD 150A / DSTD 190 DSTK 221L3 scanning or interrupt. DSDI 120AV1 32 channels, 48 V d.c., controlled by DSTD 150A / DSTD 190V1 DSTK 221L3 scanning or interrupt. (1) Optionally, you can combine the connection units DSTD 195, DSTD 196, DSTD 197 and DSTD 198 for their respective board. (2) Optionally, you can combine the connection units DSTD 195, DSTD 196P, DSTD 197 and DSTD 198 for their respective board.
Page 87 Š Table 1-14 presents available digital output boards. DSDO 115 32 channels, 24 V d.c. DSTK 226L3 DSTD 108 / DSTD 108L These connection units pro- vide 8 relay outputs each, 24 - 250 V a.c./ d.c. max 3 A. DSDO 115A 32 channels, 24 V d.c.
Page 88 Š DSDO 115A 32 channels, 24 V d.c., short-circuit protected, DSTD 110A / DSTD 190V1 DSTK 221L3 transistor output, max. 150 mA DSDO 120A 16 channels, 24/48 V d.c, transistor output, DSTD 120A DSTK 220L3,2 max. 1 A (1) DSTD 108L is used for low-current loads (max. 200 mA). 8‚‡…‚yyr…...
Page 89 Š • Each board has built-in reference channels for automatic calibration and testing. • The data base is updated by scanning, with cycle times normally selected from the range 100 ms to 600 s. • The suppression frequency is selectable from 20, 30, 50 and 60 Hz. •...
Page 90 Š DSAI 130A 16 differential and eight directly grounded inputs DSTA 135 DSTK221L3 (single ended), transducer supply fused channel by channel, resolution 12 bits, 0 to ±10 V, 0 to ±5 V, 0 to ±2.5 V, 0 to ±1.25 V or 0 to ±20 mA, 0 to ±10 mA, 0 to ±5 mA, 4 to 20 mA (elevated zero obtained by SW) shunt 250 Ω...
Page 91 Š DSAI 155A 14 channels (+ two ref. channels + one comp. chan- DSTA 156 DSTK 225SL3 nel) for thermocouples, resolution DSTA 155 12/13 bits + sign, measurement range: B, C, E, J, K, R, S and T for insulate thermocouples DSAI 155A 14 channels (+ two ref.
Page 92 Š 8‚‡…‚yyr… TvthyÃhqhƒ‡h‡v‚Ãˆv‡ Q…‚pr†† †‚s‡h…r Analog input Connection board Data base Program unit Process transducer Test point (X3) With redundancy, the pair of boards is treated as an individual in the data base. A common connection unit connects the singular process object (transducer, actuator). Figure 1-25 illustrates an application with redundancy.
Page 93 Š • Analog outputs are available for standard voltage and current signals. • There are both isolated and non-isolated outputs. • Optional redundancy is featured, where one type of board can be duplicated to achieve increased availability. • A board is offered which combines analog inputs and analog outputs (loop dedicated I/O). •...
Page 94 Š DSAX 110 DSTA 001A DSTK 223L3 Eight channels, directly grounded inputs (single ended) resolution 12 bits unipolar 0 to + 10 V, 0 to + 20 mA, 4 to 20 mA (elevated zero obtained by SW) shunt 250 Ω 0.05% Eight channels, resolution 12 bits unipolar 0 to + 20 mA, 4 to 20 mA (elevated zero obtained by SW)
Page 95 Š 8‚‡…‚yyr… TvthyÃhqhƒ‡h‡v‚Ãˆv‡ Q…‚pr†† †‚s‡h…r e.g. Analog Connection Data base Program output unit board Test terminal (X3) (not all types of units) • Pulse counter units are available for pulse counting and frequency measurement, for 5, 12 or 24 V d.c. inputs and frequencies up to 2.5 MHz. •...
Page 96 Š Data base -bit Pulse Program Filter Pulse board counter Pulse Direction Discrimination level 5, 12 or 24 V Channel Frequency Function measurement Function Frequency selector calculation selector Signal adaptation Number of pulses Reading 16 bits Error counter calculation signal Error supervision Channel...
Page 97 Š For further information on positioning, see Section 1.7.8.3, Control Functions, under the heading and see the Table 1-18 presents the available board. DSDP 140A One positioning loop input for pulse DSTD 150A / DSTD 190 DSTK 225SL3 generator: three channels, ±15 mA, max.
Page 98 However, time-tagged events have comparatively reduced accuracy. If an S400 I/O unit loses its contact with Advant Controller 450 for any reason, it enters “local mode.” In this mode, it maintains its output signals at their most recent correct values or to a predetermined value, as selected by the user.
Page 99 Š DSDX 452 20 channels, DSDX 452L 24 V d.c. for DSDX 452 and DSDX 452L DSDX 454 48 V d.c. for DSDX 454 and DSDX 454L DSDX 454L 12 channels, relay output , expandable Supply: 120/220 (230)/240 (230) V a.c., 50/60 Hz DSDI 452 32 channels, DSDI 454...
Page 100 However, time-tagged events have comparatively reduced accuracy for modules without internal sequence of event handling. If an S800 I/O module loses its contact with Advant Controller 450 for any reason, it enters “local mode.” In this mode, it maintains its output signals at their most recent correct values or to a predetermined value, as selected by the user.
Page 101 Š A S800 I/O Station can consist of a base cluster and up to 7 additional I/O clusters. The base cluster consists of a Fieldbus Communication Interface and up to 12 I/O modules. I/O cluster 1 to 7 consist of an Optical Modulebus modem and up to 12 I/O modules. A S800 I/O Station can have a maximum of 24 I/O modules.
Page 102 Š The FCI provides 24V d.c. (from the source) and an isolated 5V d.c. power to the base cluster’s I/O modules (12 maximum) by way of the ModuleBus connections. There are three types of FCIs one for single Advant Fieldbus 100 configurations, one for redundant Advant Fieldbus 100 configurations and one for single PROFIBUS configurations.
Page 103 Š All I/O modules are supervised at system start-up as well as under normal operation. The status of a module is indicated with front mounted LEDs; RUN (R), green, normal operation, FAULT (F), red, when a fault is detected, WARNING (W), yellow, when a channel fault is detected and OUTPUT SET AS PREDETERMINED (OSP), yellow, when the module has lost communication.
Page 104 Š DO814 Digital Output 24 V d.c. 0.5 A short circuit proof, 2 x 8 channels, Current sinking. Rated isolation voltage 50 V. DO815 Digital Output 24 V d.c. 2 A current source short circuit proof, 2 x 4 channels. Rated isolation voltage 50 V.
Page 105 Š The analog I/O modules all have galvanic isolation relative to chassis ground in a group of 4 or 8 channels. The modules have the standard set of module status indicators. Open circuit detection is available for inputs and outputs configured for 4…20 mA and for the RTD and TC inputs.
Page 106 Š AO890 Analog Output, with Intrinsically safe interface 1 x 8 ch. 0(4)...20 mA, 12 bit, 0.1% Rated isolation voltage 50 V. AO895 Analog Output, with Intrinsically safe and HART interface 0(4)...20mA, 12 bit, 0.1% Rated isolation voltage 50 V. The Pulse Counting / Frequency Measurement modules DP820 is a two-channel pulse counter module in the S800 I/O series.
Page 107 Š Compact MTUs are 58 mm (2.3”) wide and extended MTUs are 120 mm (4.72”) wide. The two MTU types can be mixed and matched within an I/O-station to fit a user’s needs. Choice of compact MTU or extended MTU can be made freely trading space versus termination needs. Compact and extended MTUs are available with rated isolation voltages 50 V and 250 V.
Page 108 Š TU836 Extended MTU, 120 mm wide. Two isolated groups with one row of 4 uncommitted terminals individually fused (3 A), one row of 4 uncommitted terminals, 2 pcs L and 2 pcs N- terminals. Rated isolation voltage 250 V. Conductor area: 0.2-2.5 mm , AWG 24-12.
Page 109 Š SD811 SD811 Power Supply 100-240 V a.c./185-250 V d.c. 24 V d.c. 2.5 A. Rated isolation voltage 300 V. SD812 SD812 Power Supply 100-240 V a.c./185-250 V d.c 24 V d.c. 5 A. Rated isolation voltage 300 V. The Modulebus can be expanded by using a Modulebus Optical port module on the Fieldbus Communication Interface module and communicates via an optical cable with the Optical Modulebus modem in the I/O cluster.
Page 110 The configurator sets network and node identity on hardware. There is a low-load version of MasterBus 300/MasterBus 300E for the Advant Controller 450 which uses special hardware. The low-load version has dedicated CPU support, so it causes a lower load in the main CPU of the controller.
Page 111 CCITT recommendation X.25.2 LAPB with transmission rate 19.2 or 50 kbits/sec • ADLP-10 (ABB Data Link Protocol), an asynchronous protocol based on ECMA 16 and ECMA 24, with transmission rate of 9.6 kbits/sec. You can duplicate GCOM to achieve full redundancy.
Page 112 MasterPiece 90, MasterPiece 51 and converters for motor drives (TYRAK L or SAMI) to Advant Controller 450. You can connect several buses to one Advant Controller 450, and each bus can take up to 16 remote units.
Page 113 Š You can disconnect remote units from the bus and replace them without disturbing other units or their communication with Advant Controller 450. Communication with a reconnected unit is resumed automatically. MasterFieldbus operates at 2 Mbits/s. For distances up to 25 m (82 ft.), use MasterFieldbus with twisted pair cable and without modems.
Page 114 Š Advant Fieldbus 100 is a high-performance bus specially designed for real-time applications. A number of different products are connectable to Advant Fieldbus 100, that is Advant Controller 410/450, Advant Controller 110, distributed S800 I/O stations, ACV 700 Converter, and so on. It features reliable, cyclic data transfer as well as event-driven background transfer of service data.
Page 115 Š With modem TC515V2 you can extend the bus length up to 1400 m. AC 450 CI522A TC516 Advant Fieldbus 100 External PM810V1 Device AC 70 TC515V2 S800 I/O Station Grounded twisted pair termination Twisted pair termination AC 70 Together with the opto-modem TC630 or TC514V2 and opto-fibre cable, you can extend the bus length up to 1700 m.
Page 116 PA device PROFIBUS-DP PROFIBUS-DP device device Figure 1-37. PROFIBUS-DP configuration example Up to 125 slave nodes can be connected to one bus. Up to eight buses can be configured in an Advant Controller 450. 1-86 3BSE 002 415R701 Rev A...
Page 117 Up to 128 supervised devices can be connected to one bus. Meaning that more devices can be connected to the bus, but can not be supervised by the Advant Controller 450. Up to eight buses can be configured in an Advant Controller 450.
Page 118 Š EXCOM (EXternal computer COMmunication) permits the external computer to read or write in the Advant Controller 450 data base with the help of simple commands and an asynchronous serial communication link V.24/RS-232-C. The communication is controlled by the external computer.
Page 119 Š RCOM functions in accordance with the master-slave principle. The communication is performed via point-to-point or multi-drop connection. You can also connect a dialing modem on telecommunication authority lines. The modem must have command-initialized dialing and an automatic reply function. Redundancy is possible at different levels by optional duplication of communication boards, modems and cables.
Page 120 Š Advant Controller 450 communicates with a wide range of products, as indicated in Table 1-28. The links used are shown. RCOM is, in some cases, an alternative for long-distance or low- cost/less-performance applications. The main functionality obtained is given. Additionally, there are diagnostics generally included as a basic link function.
Page 121 Events are defined and time-stamped in the central I/O of Advant Controller 450 or in distributed units of the type Advant Controller 110 and Advant Controller 70. Advant Controller 450 sends the information to operator stations for presentation in lists.
Page 122 For a detailed description of Data Set and Text Set, see the reference manual Advant Controller 450 offers powerful features covering all aspects of process control in most application areas. For information on the application language used, the principles of configuration/application building and the functional resources, see the following sections.
Page 123 Š When a dedicated station is used for programming, it can be connected, either directly to the controller to be programmed, or indirectly via another controller in the communications network. For remote access, the public telephone network can be used. Signals are represented in engineering units throughout the whole application program.
Page 124 Š Another way to implement your frequently used control solution and ensure a fully integrated engineering environment is to make use of the option User Defined PC Elements. A user defined PC element appears in every sense as a standard PC element. Actually the control solution of a user defined PC element is defined by other PC elements.
Page 125 Š Figure 1-42 illustrates how process signals available in the data base are linked to the AMPL application program. DB element defining board, signals DSDO 120 TYPE DI 1 DO 1.1 DSDI 110 TYPE START M1 NAME DI1.1 NAME START PC program PC element Switch gear...
Page 126 Š Besides the PC elements, the function library consists of functional units. Functional units are available to supplement the library for more complex functions. A functional unit is a package of different program functions such as PC element, data base element and operator’s functions. This simplifies the realization of combined functions with both the control function and associated operator’s handling via a display screen and keyboard.
Page 127 Most of the functions are supported by PC elements, that is the PC elements are the base of the functionality of the Advant Controller 450. For a listing of those PC elements included in the basic system program module and the different optional program modules, see Section 1.7.3.3, Program Module...
Page 128 – Three pulse inputs adapted for the ABB pulse generator QGFA 110: A channel, B channel and STROBE. Maximum frequency 80 kHz. Analog output for speed reference, 11 bits + sign. 0 to ±10 V or 0 to ±20 mA.
Page 129 Š The report function permits you to connect a printer to the Advant Controller 450 system to print out simple reports. Figure 1-44 shows an example of a simple report which is “edited” with the help of data base and PC elements. Values, date and time are transformed into text strings.
Page 130 For further information regarding report generation in operator stations, see the appropriate separate documentation. Process supervision has an important role in a control system like Advant Controller 450. Any logic state transition in the process or application program, or any limit transition of a process variable or complex calculated variable, can be defined as a point of event.
Page 131 Š Powerful functions for feedback control are provided with a great number of PC elements and functional units. Examples of applications are: • Basic PID control • Cascade-coupled controllers • Ratio control • Manual control from central/local operator’s workplace • Controlling final elements with two- or three-position action •...
Page 132 MOTCONI controls INSUM Motor Control Units (MCU) over the LONWORKS Network. For large control systems, built on Advant Controller 450, the connection to ACS 600 drive systems is made via Advant Fieldbus 100. Each fieldbus node connects up to 24 drives through an optical ring.
Page 133 • System Status List. Advant Controller 450 offers a range of interfaces to operators of different categories. A short presentation is given below. For detailed information, see separate documentation. The main purpose of this type of interface is to support fault tracing and backup handling of the application program.
Page 134 An Active Mimic Controller module makes it possible to control active mimic panels from an Advant Controller 450 via one or more RCOM links. You can use the module for local collection of inputs from push-button switches (PBs), for updating of LEDs or lamps, and for control of an alphanumeric text display.
Page 135 • Presentation of trend curves. The central operator station communicates with the application program and the process is controlled via the signal and object files in the data base of the Advant Controller 450. 3BSE 002 415R701 Rev A 1-105...
Page 136 (see Figure 1-47 below). Operator Station Presentation Dialog MasterBus 300 Advant Controller 450 Program module QC07-OPF41 Data base PC program Obj. file Process You can obtain printouts of reports, generated in the report function, or paper copies of event lists when a MasterView 320 is included, with a printer connected to an Advant Controller.
Page 137 Fault in parallel bus communication (backplane bus on CPU and I/O subrack). In spite of the fact that an Advant Controller 450 is a very reliable system, reset of outputs to zero cannot be guaranteed during all conditions. Always assume a combination of errors or an incorrect system handling which can cause an output to behave in an unexpected way.
Page 138 The diagnostics support the maintenance philosophy of fault isolation and replacement down to module or subassembly level. A survey of the fault announcement in Advant Controller 450 follows. The diagnostics built in to different modules and system functions are mentioned briefly. You can also find more information on LED indications and so on, in connection to module descriptions.
Page 139 Š Most of the replaceable hardware modules are equipped with LED indicators. A green LED indicates running. A red LED indicates fault. Some modules provide additional yellow LEDs for increased maintainability, for example send and receive information on communication modules. Diagnostics information is available in the data base and in PC elements, which means it is possible to build up, for example, different control strategies with respect to the status of relevant functions and hardware modules.
Page 140 Š Execution check by “watchdog” is carried out with respect to three priority levels. Task reference, supervision time and consequences at exceeded time are given below: • Timer task - 100 ms - safety shut-down • Application program - 5 s - safety shut-down •...
Page 141 Š In general, the following subsystems and functions are available with redundancy: • Mains distribution network • Voltage supply, 24 V • Voltage regulation, 5 V • Battery and charger • CPU and memory • Network communication • GCOM • MVI (Multi Vendor Interface) communication •...
Page 142 In the event of a single failure, the full responsibility is bumplessly taken over by the remaining equipment. The n is equal to 1 in the standardized Advant Controller 450. The 5 V supply is distributed as single supply to each module.
Page 143 Š The principle of fault tolerance in the redundant processor modules is based on continuous updating of the backup unit to the same status as the primary unit. This enables the backup unit to assume control without affecting surrounding systems in a bumpless manner. This principle involves dynamic division of the program execution into execution units and the creation of rollback points at which the processor module’s status is completely defined.
Page 144 Š There are two alternatives for network communication redundancy available. Normally, the duplicated submodules are distributed to separate carrier modules, an arrangement which provides maximum availability. See Figure 1-48. You can also mount duplicated MasterBus 300 communication submodules in a common carrier module.
Page 145 Š The Advant Fieldbus 100 redundancy concept comprehends: • Media redundancy • Communication interface redundancy. Media redundancy includes redundant cables and redundant modems. Communication interface redundancy is achieved by using two interface modules CI522A connected to a media redundant bus. S100 I/O Bus Extension redundancy is available.
Page 146 For example, analog inputs use hot stand-by. Analog outputs use parallel operation. An Advant Controller 450 is normally installed in one or several cabinets, depending on the number of centrally connected process I/O signals. The cabinet type is RM500 and it is available in two versions with different dimensions (RM500V1 and RM500V2).
Page 147 Š Figure 1-50 shows a cabinet of the RM500 type. Features and applications are listed below: • RM500 is prepared for installation of subracks, process connection units and terminal blocks. Subracks are used to house circuit boards and other plug-in units. •...
Page 148 ”. Depending on the number of circuit boards necessary to control the process, an Advant Controller 450 installation can contain up to one controller subrack plus five I/O subracks located in up to six cabinets. The controller subrack is always installed in the left-hand cabinet.
Page 149 Š An I/O subrack is mounted in a hinged frame while the connection units for the different I/O boards are mounted in the rear backplane. Use the 24-inch installation width for the connection units in RM500V1. Figure 1-51 shows a cabinet configuration in a RM500V1 cabinet.
Page 150 Š Many of the Advant Controller 450 components are installed in subracks. Subracks are fitted with guide bars for circuit boards and other plug-in units. Each unit is connected to the backplane of the subrack. There are two variants of subracks, both based on a 19-inch standard: a controller subrack which houses the processor module and the various communication modules and an I/O subrack which houses the S100 I/O.
Page 151 Š ..20 21 Pos: 1 2..Position referred addressing is not used in S100 I/O A locking bar at the upper front edge fixes the I/O boards once they are inserted. An I/O subrack can be powered by a single 5 V regulator unit or redundant 5 V regulator units located at the rear of the subrack.
Page 152 Š Mounting bar for connection units Connection to the process Connection cable Backplane for parallel communication bus Plug-in units The rear side of an I/O subrack must be accessible. This is achieved by mounting the I/O subrack in a hinged frame. 1-122 3BSE 002 415R701 Rev A...
Page 153 The submodule carrier is a single point of failure. Damaging the carrier module may affect one or both submodules. Replacing the carrier module, however, obviously affects both submodules. Mechanically, any submodule fits into any submodule position on Advant Controller 450. The software does not, however, necessarily support all combinations. 3BSE 002 415R701 Rev A...
Page 154 Š A normal controller installation uses different operator’s interfaces. A division into two main categories can be seen with respect to their applications: • Operator’s interface for process control. – Operator stations – Mimic panels – Printer. • “User interface” for the controller seen as a computer resource. –...
Page 155 This chapter contains guidelines for planning the installation of your Advant Controller system, Section 2.1, Site Planning Environment. In addition, this chapter also describes the concrete installation procedures on site, specific to Advant Controller 450, see Section 2.2, Setup. This chapter does not, however, provide a complete list of measures to take with respect to environment and other conditions on site.
Page 156 ® Advant Controller 450 User’s Guide Chapter 2 Installation • The free space in front of cabinets. Also reflect on how much space is required to fully open either a left-hand or right-hand hinged cabinet door (both exist). There must always be space left for safety reasons even with open doors.
Page 157 Under these conditions, the temperature in a cabinet must not exceed 70°C. For further information about the environmental immunity, please refer to the data sheet “ABB Master Environmental Immunity”. Temperature It is important to note the temperature within cabinets and in the surrounding environment and atmosphere.
Page 158 The floor cover plates may be mounted by any other reason determined in the particular project. Cabinetry According to information given in the ordering documentation, Advant Controller 450 shall be located in a EMC-proof cabinetry. Please note that the requirement is valid to controller cabinet, I/O cabinet and connection unit cabinet, if separated.
Page 159 The complete list of rules are presented in ordering documentation. General • An Advant Controller 450 with I/O, ordered on one set of price lists, is designed with cabinets that are to be placed side by side (no plates between the cabinets). •...
Page 160 ® Advant Controller 450 User’s Guide Chapter 2 Installation • Normal start configuration is a double cabinet (Nos. 1 and 2). • With the controller cabinet to the left, the building direction is to the right. • I/O subracks cannot be placed in cabinet 6 or 7, the bus extension cable exceeds 12 m. •...
Page 161 ® Advant Controller 450 User’s Guide Section 2.1.4 Standard Layout and Disposition of Cabinets S100 I/O with Object Oriented Connection Units A variant of cabinet configuration is offered for this type of connection units. See illustrations in Figure 2-3. Ex., 1 subrack Bus Extension, El.
Page 162 ® Advant Controller 450 User’s Guide Chapter 2 Installation 2.1.5 Grounding Grounding in General The signal processing electronics in Advant OCS, as well as all interference suppression for external signals, are normally directly grounded to chassis and plant earth. The plant earth potential must be stable and well defined, even in the event of ground fault in low- and high-voltage equipment or lightning stroke.
Page 163 ® Advant Controller 450 User’s Guide Section 2.1.6 Cables hinders the use of connection units for voltage distribution. In such cases, you can use a bar with the terminal block and fuse equipment required by the application. If the transducer has galvanic isolation of the supply from the electronics otherwise, you can ground its signal zero freely and where it is most suitable for measurement accuracy without special voltage supply requirements such as group division, fusing and grounding.
Page 164 ® Advant Controller 450 User’s Guide Chapter 2 Installation Safety Switch Close to the controller installation, there should be a safety switch enabling total power supply disconnection of the equipment. This means a common switch for all supply voltages, for example networks A, B and C discussed above. The main use of the safety switch is to disconnect the power supply in a clear and safe way during work in the cabinet.
Page 165 An open compartment is not CE-marked. For further information: using ABB standard cabinets, see adequate sections in this installation chapter and the referred document below for further details if necessary. using non-ABB cabinets, see Advant OCS Installation Rules User’s Guide for compliance with the EMC requirements or the general document Interference-free Electronics Design and Applications.
Page 166 ® Advant Controller 450 User’s Guide Chapter 2 Installation Consider such an alternative at an early stage in the design to ensure that it is located in the cabinet to give optimum cable lengths. Wiring is routed to different transducers and loads in the installation from the marshalling. It is important that the leads to and from a transducer for an electric signal be in the same cable.
Page 167 ® Advant Controller 450 User’s Guide Section 2.1.9 Hazardous Applications 2.1.9 Hazardous Applications Always combine standard process I/O boards and I/O units with barriers for ex-environment in an application-adapted way. You may use any of the available barriers on the market which meet your requirements.
Page 168 ® Advant Controller 450 User’s Guide Chapter 2 Installation degree of interference (for example electromagnetic relays with no interference suppression). Consider this when you are ordering the equipment. Figure 2-6. Minimum Distance to the Walls and the Ceiling To ensure adequate ventilation, there should be a free space, 150 mm high, between the top of the cabinet and the ceiling or the underside of any beam, duct or similar structure over the cabinet.
Page 169 ® Advant Controller 450 User’s Guide Section 2.1.13 Transportation and Storing The free space in front of the cabinet should be the width of the door plus the width of the aisle. If a double door alternative is used, reflect the space required for any hinged frame. There must always be space left for safety reasons even with open doors or frames bent outwards.
Page 170 • Make sure that everyone working on the installation knows the location of the safety switch and the main power supply switch to the Advant Controller 450 equipment and how to use it. •...
Page 171 ® Advant Controller 450 User’s Guide Section 2.2.1 Safety Regulations 2.2.1.2 Machine Safety CAUTION Observe the following safety rules: • Avoid discharges of static electricity by grounding both yourself and tools before handling circuit boards and other parts of the equipment. •...
Page 172 ® Advant Controller 450 User’s Guide Chapter 2 Installation 2.2.2 Unpacking and Storing If the packaging is opened for a delivery check, reseal it if the cabinets are not to be installed immediately. Store cabinets in a dry place, protected again dust. Avoid fixing labels on painted surfaces.
Page 173 ® Advant Controller 450 User’s Guide Section 2.2.5 Grounding 2.2.5 Grounding This section shows you where to ground in an Advant Controller cabinet. If necessary, it also shows you how to ground. You should be aware of the common Advant OCS Installation Rules, which establish the principles of grounding and answer the questions of when a piece of equipment, a circuit or a cable shield should be grounded and why it should be grounded.
Page 174 ® Advant Controller 450 User’s Guide Chapter 2 Installation By different reasons other field cables may be shielded too. For example following a company/plant standard. There is no requirement from the controller viewpoint. These field cables are denoted category B. Unshielded process I/O cables can be mixed with shielded process I/O cables.
Page 175 ® Advant Controller 450 User’s Guide Section 2.2.5 Grounding Not CE-marked Design If a conventional cabinet is used the attachment of the cable shield and anchoring of the cable is co-ordinated by using the horizontal mounting bar, see Figure 2-9. The shield of a category A cable must furthermore be run all the way up to the relevant connection unit.
Page 176 ® Advant Controller 450 User’s Guide Chapter 2 Installation CE-marked Design I addition to the general instruction found above, further interference suppression of the cable shield is made at the enclosure port by individual methods adapted to the different types of communication.
Page 177 ® Advant Controller 450 User’s Guide Section 2.2.5 Grounding Attachment Communication of the Cable Cable Capacitive Decoupling Unit, TX507 Expose shield 20-30 mm (0.8-1.2”) Cabinet Floor Split Ferrite Coil Figure 2-11. Communication Cable Shield Grounded by Capacitor and Ferrite Coil Each unit takes up to four communication cables and it also provides the mechanical anchoring of the cable.
Page 178 ® Advant Controller 450 User’s Guide Chapter 2 Installation Table 2-1. Methods of Handling Communication Cable Shields (Continued) Grounding of Shield Grounding of Shield Type of Communication Directly via Capacitor LONWORKS Communication Twisted Yes, on one end pair PROFIBUS-DP V24/RS-232-C, for example for a printer Bus Extension to S100 I/O Refer to...
Page 179 ® Advant Controller 450 User’s Guide Section 2.2.5 Grounding CE-marked Design A EMC-proof cabinet must be used for the I/O subrack and the connection units as well. The cable shield shall be grounded in both ends according to Figure 2-12. Not CE-marked Design The description given under the heading General is adequate.
Page 180 ® Advant Controller 450 User’s Guide Chapter 2 Installation You must follow the main rule: Do not ground a signal at different points in the plant. Sheet cable lug and Self-tapping Point of grounding screw (used for certain cable shield connection too) 0 V lead ST 3.5x9.5 (B6x9.5)
Page 181 ® Advant Controller 450 User’s Guide Section 2.2.6 Cable Routing in Cabinets Cabinet seen from above Internal 24 V, battery supply, and so on. Space for cables joining connection units and I/O boards mounted in the same cabinet Front Enclosure port in the floor Mounting bar Indicates contours of subracks (controller, I/O) and bar with connection units...
Page 182 ® Advant Controller 450 User’s Guide Chapter 2 Installation Cabinet seen from above Internal 24 V and so on Space for cables joining connection units and I/O boards mounted in the adjacent cabinet Front Enclosure port in the floor Mounting bar Indicates contours of bar with connection units Indicates space for plant cables Category 1-3 acc.
Page 183 ® Advant Controller 450 User’s Guide Section 2.2.7 Power Supply Connection Cabinet 2 Cabinet 1 Cabinet 3 Controller Power Supp. Power Supp. Power Supp. Mains net filter Power Switch (CE-marked design) Supply 3-wire cables Protective earth Figure 2-16. Main Principle of Power Supply Connection and Distribution 3BSE 002 415R701 Rev A 2-29...
Page 184 ® Advant Controller 450 User’s Guide Chapter 2 Installation 2.2.7.2 Installation General Ordering documents show which power supply alternative is applied. An a.c., d.c., redundant or non-redundant supply is connected to the controller in the same way, in principle. A terminal diagram form enclosed at delivery shows the relevant physical item designations and connection points in the cabinet.
Page 185 ® Advant Controller 450 User’s Guide Section 2.2.8 Controller 2.2.8 Controller Assembly All equipment included in the controller is factory assembled. Cabinet arrangement and similar questions are dealt with in the general setup instructions above. Electric Installation Apart from the process I/O connections and communication connections, which are treated separately, there is little electric installation.
Page 186 ® Advant Controller 450 User’s Guide Chapter 2 Installation External Clock Synchronization AC 450 External clock TC520 SYNCIN COMM.SYNC Description/Configuration: DB element Clock Synch Figure 2-18. Connection of External Clock Synchronization Additional Supervisory Inputs AC 450 TC520 Diagnostics at redundancy System status (normally factory installed) display in...
Page 187 Section 2.2.9 Bus Extension to S100 I/O The status information is available: • On the Advant Controller 450 data base element for use in any application program. • On the Advant Controller system status display presented on central operator station display screen.
Page 188 ® Advant Controller 450 User’s Guide Chapter 2 Installation Use these cables! It is important not to exceed the maximum bus length 12 m, that is, the total length of the cables used may not exceed 12 m. Check that a plug-in termination unit DSTC 176 is located only on the last bus extender slave board in the chain.
Page 189 ® Advant Controller 450 User’s Guide Section 2.2.10 S100 I/O If for some reason the cabinets are not arranged side by side then the bus extension cable must be routed separated from other cables (>100 mm). A CE-marked design put the requirement that the extension cable shield is additionally grounded by the cable clamp in the cabinet floor.
Page 190 ® Advant Controller 450 User’s Guide Chapter 2 Installation Electric Installation Distributed Connection Units Distributed (3 m - 15 m) connection units are joined to the I/O boards by adapted shielded cables with plug-in connectors. The following instructions apply: • Outside the I/O cabinet, route the cables separately from other cables.
Page 191 ® Advant Controller 450 User’s Guide Section 2.2.10 S100 I/O Table 2-3. Functional Jumpering Board/Connection Unit Function DSAI 146, 155A Mains frequency DSTA 001, 001B, 002, 002B Current/voltage DSTA 131, 133, 135 Current/voltage, grounded/floated supply DSTA 155, 155P, 156, 156B Grounding DSAO 110 Current/voltage, 10/20 mA, gain factor...
Page 192 ® Advant Controller 450 User’s Guide Chapter 2 Installation most effective to maintain the check from the automatically generated process I/O object displays. The application data base must be loaded. CAUTION When you use a somewhat tougher method, be aware of the risk of “accidents.” Short-circuiting and over-voltage can damage a limited part of the equipment, for example, a process I/O board.
Page 193 ® Advant Controller 450 User’s Guide Section 2.2.12 Peripheral Units Advant Controller Printer/ Video terminal a.c. powered system N L PE a.c. mains supply (C) socket Advant Controller Printer/ Video terminal d.c. powered system a.c. is available N L PE a.c.
Page 194 ® Advant Controller 450 User’s Guide Chapter 2 Installation 2.2.12.1 Printer Assembly/Location See instructions enclosed with the actual printer. Electric Installation (including Power Supply) Short-Distance Connection At distances shorter than 15 m (49 ft.), join the printer with the communication module in the controller subrack with a standard cable TK520V150.
Page 195 ® Advant Controller 450 User’s Guide Section 2.2.12 Peripheral Units From the viewpoint of the Advant Controller, there are no restrictions on the mains power supply of the printer, for example, no requirement for earthing and same supply. The controller and the printer are galvanically isolated from each other by the communication modems.
Page 196 ® Advant Controller 450 User’s Guide Chapter 2 Installation Functional Measures, General The following instructions apply. Communication module CI531: No measures needed. Modem: X protocol utilized and the factory settings of the modem TC562 or DSTC X008 (jumpering) are adequate. If a.c. 230 V is not desired, please reconnect to a.c.
Page 197 2.2.14 Engineering Station The following apply to an engineering station type Advant Station 100 Series ES when connected directly to the Advant Controller 450. Electric Installation (including Power Supply) Plug the communication cable enclosed with the engineering station into the X10 SERVICE connector on the processor module front.
Page 198 ® Advant Controller 450 User’s Guide Chapter 2 Installation 2.2.15.2 Process Cabling, Shielding, Grounding, Maximum Length Table 2-6. Process Cabling, Shielding, Grounding, max. Length Item Concerning Action Cables Prescribed type Communication cables Pulse transducer cables Shielded for AI ≥12 bit and for Low level AI (Pt, thermocouple) Same signal types in same cable (low level/d.c./a.c./ communication/power supply)
Page 199 Using of interference- Special isolation transformer for electronics supply sensitive power supply must be used units not manufactured by ABB Internal distribution Incoming power supply (120/230 V) must be separated from other cables by 5 cm or more d.c. Earthing, supply...
Page 200 ® Advant Controller 450 User’s Guide Chapter 2 Installation 2.2.15.5 Subrack, Connection Unit, Circuit Board Table 2-9. Subrack, Connection Unit, Circuit Board Item Concerning Action If problems, check R < 100 mΩ, Mounting rail Ground connection to cabinet chassis via measured with equipment switched off and (for connection mounting screws...
Page 201 ® Advant Controller 450 User’s Guide Section 2.2.15 Checklists 2.2.15.6 Cabinets, Internal Cables Table 2-10. Cabinets, Internal Cables Item Concerning Action Row of cabinets Electrical connection Through short 35 mm copper conductors or (grounding) horizontal copper rail joining the PE terminals in each cabinet.
Page 202 ® Advant Controller 450 User’s Guide Chapter 2 Installation 2.2.15.8 Communication, Communication Cables Table 2-11. Communication, Communication Cables Item Concerning Action ≤50 mm (1.9 inch.) Communication Electrical connection cables with shield (not to chassis coaxial cables) Max. permitted length Max. specified length must not be exceeded Coaxial communica- Electrical connection Not to be directly earthed or earthed at one...
Page 203 ® Advant Controller 450 User’s Guide Section 2.2.16 Final Procedures Before Start-up 2.2.15.9 Miscellaneous Table 2-12. Miscellaneous Item Concerning Action Relays and contactors Suppression Cabling to non-suppressed inductive loads in in cabinets Advant OCS cabinets must be kept more than 100 mm away from internal cables. Thermo-couples Supply connection Power supply for compensation of cold junc-...
Page 204 ® Advant Controller 450 User’s Guide Chapter 2 Installation 2.3.2 Controller and I/O Emergency Shut-down An emergency stop should always be available. Adapt it to local statutory regulations. This is an obligation of those responsible for the plant design and construction. The controller system does not supply this specially arranged function.
Page 205 ® Advant Controller 450 User’s Guide Section 2.3.2 Controller and I/O Regardless of the shut-down method, the result and consequences are: • Application program execution immediately stops. • There is zero output to the process objects. • Output relays are de-energized. •...
Page 206 ® Advant Controller 450 User’s Guide Chapter 2 Installation The result of a stop and its consequences are compatible for the two manual stop methods: • Application program execution immediately stops. • There is zero output to the process objects. •...
Page 207 ® Advant Controller 450 User’s Guide Section 2.4.1 Safety Regulations Necessary Outfit The following kit is a minimum requirement: • Ordinary hand tools. • Universal instrument, for example a digital multimeter. • Test leads with 4 mm banana contacts and reducer contacts for a 2 mm test jack. •...
Page 208 ® Advant Controller 450 User’s Guide Chapter 2 Installation 2.4.2.1 Power-up If, for some reason, you desire a limited power-up, the minimum equipment necessary is: • Processor Module PM511 including a program card • Submodule Carrier SC5x0. Check that the circuit breakers on the power switch units are switched off. There is one circuit breaker for mains A (labeled S1) and one for mains C (labeled F1).
Page 209 ® Advant Controller 450 User’s Guide Section 2.4.2 Controller and I/O processor module will be PRIMARY while the right processor module will be BACKUP. Chapter 4, Runtime Operation explains alternative ways of starting. Figure 2-25. There are also some negative indications, for example: –...
Page 210 AMPL Configuration Advant Controller 400 Series. If the actual Advant Controller 450 is a node in a LAN, you can connect the engineering station to any of the nodes included in the network. You can perform remote configuration in that way.
Page 211 ® Advant Controller 450 User’s Guide Section 2.4.2 Controller and I/O Additional Information for Redundant Processor Modules Connection to Primary Unit Connect the engineering station to the processor module which is PRIMARY (“P1” or “P2” on the number display). The operation of the engineering station/target system does not differ from its operation in a system without redundancy.
Page 212 ® Advant Controller 450 User’s Guide Chapter 2 Installation You can redimension in a later stage, but it is time-consuming work. The general rule is to plan well from the start. Always dimension the spares! Application analyses System definition Controller system configuration Dimensioning...
Page 213 CI543 MVIx Demand Bus extension to S100 I/O Autom. (DSBC_174) Demand Also valid for DSBC 176 S100 I/O boards CRDB Misc. Misc. Demand ABB MasterFieldbus CRDB CI570 Demand S400 I/O units CRDB Misc. Misc. Demand Advant Fieldbus 100 CRDB CI522A...
Page 214 ® Advant Controller 450 User’s Guide Chapter 2 Installation Table 2-13. Function List with an Outline of Controller System Configuration Information. (Continued) Data Base Element Data Function/ Dimen- Creating Item. design. entry Comments Call name occurrence sioning (default name) Data Set Peripheral CRDB DSP_x Demand Basic cycle time can be...
Page 215 ® Advant Controller 450 User’s Guide Section 2.4.2 Controller and I/O Dimensioning and Disposition of RAM To show the total requirement for dimensioning and disposition of the RAM when the controller is started for the first time, a list of functions/occurrences to be dimensioned is given below. The information is structured as it will appear in the engineering tool.
Page 216 ® Advant Controller 450 User’s Guide Chapter 2 Installation MasterView 300 Number of DISPLAYS Number of VARIABLES Data Tables & Trend Data Number of TTD_LOGS Number of TTD_VARIABLES Number of TBL_CLASSES Number of TABLES Number of TBL_PARAMETERS Size of DATA TABLES (kB) Number of FILE ELEMENTS Size of FILE DATA (kB) Functional Units &...
Page 217 ® Advant Controller 450 User’s Guide Section 2.4.2 Controller and I/O Redimensioning of Space for PC Program You can redimension at a later stage. Make a copy of the PC program. Use the command DUTPT. This copy includes the DIMPC information. Load the copy.
Page 218 ® Advant Controller 450 User’s Guide Chapter 2 Installation Table 2-14. Dump and Load Facilities (Continued) Description of use Dump command Load command DUDBS TRDBS Source code of data base DUmp Data Base Source TRanslate Data Base Source Source code of PC program DUPCS TRPCS See text below...
Page 219 ® Advant Controller 450 User’s Guide Section 2.4.2 Controller and I/O 2.4.2.7 Summary of the Controller Start-up and Verification of the Start The following summary is a basic “from scratch” step-by-step instruction explaining how to start up. Other working schedules exist, especially in connection to revisions and system enlargement.
Page 220 ® Advant Controller 450 User’s Guide Chapter 2 Installation Significant engineering tool commands to use are: DIsable Build Mode, DIBM PCx DeBLock, DBL NOTE DIMPC must be performed to get update of I/O signals. Indications of an operating system with a started application: •...
Page 221 To check the parameters, please refer to the user’s manual of the printer in question. The basic settings correspond to the settings of the unit when delivered by ABB Automation Products AB. The language parameter is pre-set for English printout.
Page 222 Advant Controller 450 User’s Guide Chapter 2 Installation Configuration, Advant Controller 450 With an engineering station, you can implement a printer communication in the Advant Controller 450 using the hardware-related data base element CI531 and the data base element PRINT. The default parameter values are adequate, except the time-out value in the PRINT element, which is to be changed from 15 to 30 seconds to better comply with the usual printers.
Page 223 ® Advant Controller 450 User’s Guide Section 2.5.1 Safety Regulations 2.5.1 Safety Regulations The instructions given in Section 2.2.1, Safety Regulations are applicable in all situations when you work with an Advant Controller and associated equipment. Please read the instructions carefully.
Page 224 ® Advant Controller 450 User’s Guide Chapter 2 Installation 2.5.3.3 Modify Permission Executing units such as control module headers, see Figure 2-27, have built-in protection against inappropriate attempts to change their contents. When the condition “Modify Permission” (MODP) is deactivated for a control module, all attempts, from the engineering unit, to change anything in the complete PC program are prevented.
Page 225 The value is specified in ms. You can change the value inside an interpreter with, for example, the command MV, for example, MV PC1.1:C1. Normally, you can select the following values. Table 2-17. Cycle Times for Advant Controller 450 A(ms) B(ms)
Page 226 ® Advant Controller 450 User’s Guide Chapter 2 Installation Table 2-17. Cycle Times for Advant Controller 450 A(ms) B(ms) C(ms) 1000 2000 A, B and C constitute interpreters. If an attempt is made to set a time outside the limits specified or to another interpreter, a system message is presented.
Page 227 ® Advant Controller 450 User’s Guide Section 2.5.3 Commissioning 2.5.3.8 Listing of Executing Unit Status List the status of all executing units with the command LSS (List Special Status). The following are examples of status listed. • If an executing unit is in the build mode. •...
Page 228 ® Advant Controller 450 User’s Guide Chapter 2 Installation Input Signals Figure 2-28 shows in principle where to check an input signal in an S100 I/O application. DI boards provide X90 connector and DI channel LEDs. AI boards provide X90 connector, a test terminal X3 and a common-to-all-channels A/D conversion indicating LED.
Page 229 ® Advant Controller 450 User’s Guide Section 2.5.3 Commissioning and that the change is registered by the property VALUE on the display screen in the engineering station. For MDB, use GVD for dynamic updating of the values on the display screen. –...
Page 230 ® Advant Controller 450 User’s Guide Chapter 2 Installation Engineering station DB elements Board Signal TYPE Operator station NAME VALUE - Object display - Trend curve AC 450 sw interface S100 I/O hw interface Process Connection unit Output Process PC program Data base board object...
Page 231 ® Advant Controller 450 User’s Guide Section 2.5.3 Commissioning • Analog Output Signals Figure 2-29 shows typical analog output channels and where you can test the signals. Analog output signals in a specific plant are shown in the connection diagrams for the plant.
Page 232 ® Advant Controller 450 User’s Guide Chapter 2 Installation COMMON IDENTITY: ABB INDUSTRIAL SYSTEMS 1994-02-01/18:04:15 PCPGM (20,1) CONTRM (20,2,0) >SINGLE MODP OSC-SIN 1-PC1.1:RUN D=1.0 TC ERR D=2.000 Figure 2-30. Graphic Diagram PCD PAGE: ABB INDUSTRIAL SYSTEMS NAME TYPE SOURCE PAGE...
Page 233 ® Advant Controller 450 User’s Guide Section 2.5.4 Final Control 2.5.4 Final Control When the control system testing is complete and the plant is functioning satisfactorily, take the following actions: • Check that all circuit boards are properly inserted in the bus backplane and that no screws are loose.
Page 234 ® Advant Controller 450 User’s Guide Chapter 2 Installation 2.6.1 Servicing Tool Section 2.4.2.3, Connection of Engineering Station for a description of installing an engineering station, the main servicing tool. For detailed information about its use, see separate documentation. 2.6.2 Safety Regulations The instructions given in Section 2.2.1, Safety Regulations are applicable in all situations when...
Page 235 ® Advant Controller 450 User’s Guide Section 2.6.3 General Guidelines Disconnection of the mains supply may have impact on dynamic information stored in the application program. For example counter/register content, integrator content and so on, will be lost if not secured by special considerations in the application program design. However this is general design considerations.
Page 236 ® Advant Controller 450 User’s Guide Chapter 2 Installation Summary of Aspects Table 2-18. Implementation of Functions in Systems Already Operating Enlargement/Addition Dimensioning Function/Equipment Comments of Data Base On-line Off-line System software I/O module (S100, S800 I/O) I/O subrack (S100 I/O) (Yes) I/O unit (S400 I/O) Redundant processor module...
Page 237 ® Advant Controller 450 User’s Guide Section 2.6.4 Additional I/O Boards 2.6.4 Additional I/O Boards An I/O board which is not replacing a faulty board is delivered with a connection unit and connection cable. Replacement of faulty boards is described in Chapter 5, Maintenance.
Page 238 ® Advant Controller 450 User’s Guide Chapter 2 Installation Provide access to the desired position in the subrack by loosen the locking bar in front of the boards. Insert the I/O board carefully in the subrack without reaching the rear plane contacts. Ensure that the board slides in the guides in the subrack.
Page 239 ® Advant Controller 450 User’s Guide Section 2.6.4 Additional I/O Boards Mounting bar for connection units Connection to the process Connection cable Back plane for parallel communication bus Plug-in units Figure 2-33. I/O Subrack Start-up The start-up is carried out in different ways, depending on the main working mode, on-line or off-line.
Page 240 ® Advant Controller 450 User’s Guide Chapter 2 Installation If the board is added off-line because REDIMENSION of the data base was necessary (no spares available), the following start-up sequence is applicable. A data base dump DUTDB and a PC program dump DUTPT are presupposed. Follow the general instructions in Section 2.6.7, Power-up Ahead of Program Loading.
Page 241 ® Advant Controller 450 User’s Guide Section 2.6.5 Extension with Redundant Processor Module 2.6.5 Extension with Redundant Processor Module You can install an additional processor module at any time for redundancy. Normally, a dedicated slot in the controller subrack, module position 2, should be spare. The processor modules must be coordinated.
Page 242 ® Advant Controller 450 User’s Guide Chapter 2 Installation Extension Off-line Shut down the system by setting the start mode selector on the existing processor module in STOP position. The display shows -3. The entire process control is shut down! Check module identities.
Page 243 ® Advant Controller 450 User’s Guide Section 2.6.6 Enlargement of the System Software 12. Set the start mode selector on the new processor module in the same position as the existing processor module. 13. Push the ENTER button on the new module. Check the display.
Page 244 ® Advant Controller 450 User’s Guide Chapter 2 Installation Make a suitable dump of the application program: – Always make a source code dump of the PC program (DUPCS). – If there is no change in the system software compatibility code, make a dump of the total data base (DUTDB).
Page 245 ® Advant Controller 450 User’s Guide Section 2.6.7 Power-up Ahead of Program Loading The processor module changes over and indicates P1 (working mode OPERATION). The system is now started and ready for operation. Perform the final stages, including start of application program execution, successively. WARNING When the application program is started, the process being controlled is influenced.
Page 246 ® Advant Controller 450 User’s Guide Chapter 2 Installation There are also some negative indications, for example: – S100 I/O boards red LED F (Fault) (Indicating that the boards are not implemented.) – S100 I/O Bus Extenders DSBC 174or DSBC 176 yellow LEDs INIT and INHIB (Indicating that the boards are not implemented.)
Page 247 Š This section tells you some of the things you need to think about during configuration and application building. This follows the primary structure outlined in Section 1.7, Product Overview, however, some subsections have been added. The information is given as concisely as possible under the following headings, as relevant.
Page 248 Š No extra hardware or software is needed. To achieve external synchronization, the “minute pulse” is connected to the System Status Collector TC520, see Figure 3-1. Synchronization input electrical data is given in Section 3.2.1.4, System Clock. SYNCIN COMMON SYNC Configuration: DB element Clock Sync No extra hardware or software is needed.
Page 249 Š No extra hardware or software is needed. The Supervision Unit TC520 is used according to Figure 3-3. Electrical data: see the module description in Appendix A, Hardware Modules. Application: see Section 2.2.8, Controller, heading Electric Installation. System status display in operator station STATUS A1 Reserved for...
Page 250 Š Backup of application MB510 QC07-BAS41 A PCMCIA card of program suitable memory size must also be used • No restrictions in location of submodule and submodule carrier in controller subrack. Use leftover slot on a submodule carrier if possible. •...
Page 251 Š – the need for current is small – there is idle capacity in the available power supply units (see – the transducer is grounded directly in the control system chassis. Table 3-2, you can find six alternatives for equipment configuration. Power supply needs are divided up into available power supply units rated 25 A and 10 A.
Page 252 As a rule, an SA168 (25 A d.c.) supply unit is used to supply equipment with one I/O subrack. If the Advant Controller 450 has another I/O subrack, it is equipped with another SA162 (10 A d.c.) in cabinet 2. If the system has three I/O subracks, the extra supply unit is replaced by an SA168.
Page 253 Š The system is protected with adequate internal fusing. In addition to fusing distributed to different apparatus, there are common miniature circuit breakers in the power switch and distribution units in the cabinets (see the terminal diagram form for the actual power supply system).
Page 254 Š With respect to the actual power supply distribution within the Advant Controller installation and planned distribution board fusing, please use the figures in Table 3-4 to calculate a suitable distribution board fusing. The fuse dimensioning current in the table is settled with respect to: •...
Page 255 Š Some application examples for the d.c. mains supply are given in Figure 3-5. Advant Controller 450 Distribution board Power switch and distribution unit Power supply Controller subrack (min. value) 50/25A 50/25A I/O subrack 1 Advant Controller 450 Distribution board...
Page 256 Š In the event of a power failure, the controller is shut down safely. During the dead time, the current supply of the RAM and the system clock is backed up by a battery package. To prevent shut down, you can feed the controller by a UPS. In addition, make the actual load (VA, W) considerations with respect to information given in Table 3-5 Table 3-6...
Page 257 Š Each board/unit/module is normally represented by a . The same applies to the individual channels of the board/unit/module. For a digital input board in the S100 I/O, there is a superior DI board element and 32 Digital Input (channel) elements. For an S400 I/O unit or S800 I/O module, there is a corresponding superior element defining the unit (AX unit, DX unit) or module.
Page 258 Advant Controller 450 and a distributed I/O unit and have separate signal leads only between the I/O unit and the process. The wider the process is dispersed geographically, the more profitable distributed I/O becomes.
Page 259 Š There are certain restrictions in number of I/O subracks, number of I/O boards and number of signals of different categories. Please see Section 3.2, Technical Data Including Capacity & Performance. There are no restrictions on location and mixing of boards of different categories in an I/O subrack.
Page 260 Š DSAI 130A DSTA 138, DSTK 221L5 DSTA 138 provides object oriented connection to DSAI 130A and DSAO 130A. Regarding input features please refer to DSAI 130A using DSTA 131 above. No fusing of power supply distribution. However, individual protection per channel is available by means of a PTC resistor. DSAI 133 2x DSTA 002A, DSTK 222L3 DSAI 133A...
Page 261 Š DSAX 110 DSTA 001A, DSTK 223L3 DSAX 110A DSTA 001B, DSTK 223L3 Eight single ended, unipolar current inputs and eight supervised current outputs, which means that transducers or their power supply can be grounded only within a geographically limited area, where the ground potential is the same as the system ground.
Page 262 • Interrupt-controlled inputs The data base in Advant Controller 450 is only updated when the values at the inputs are changed. This gives more exact time-tagging with event handling of the inputs. Interrupt- controlled inputs also mean a lower load with low to moderate frequency of change.
Page 263 Scanned or interrupt-controlled 48 V d.c. inputs, otherwise similar to DSDI 110A/DSDI 110AV1. Advant Controller 450 can be equipped with digital outputs of static type (semiconductor) and with a relay contact. The different output types have partially different properties. Certain significant properties are presented below: •...
Page 264 Š over the capacitor. This voltage is induced over the open control function and can result in the maximum permitted voltage being exceeded. This can be a problem with a.c. 230 V and with the use of DSTD 108P. DSDO 115 4xDSTD 108/DSTD 108L, DSTK 226L3 With these connection units four times eight closing relay outputs, 24 - 250 V a.c./d.c.
Page 265 Š DSTD 108LP Same as DSTD 108P but for maximum load current on it is 200 mA. DSTD 109P Connection unit with eight static outputs, 24 V 2 A with common power supply. Each connection unit (DSTD 109P) is 120 mm long. With pluggable screw terminals. DSDO 120 DSTD120A, DSTK 220L3.2 Static outputs for 24 V - 48 V d.c.
Page 266 Š Both inputs and outputs can suppress moderate CMV in the range ±10V for voltage input and ±20 V for current input. This means, in practice, that you can ground the transducer and load freely within a geographically limited area in which the difference in ground potential is within the specification.
Page 267 Š The general information given by way of introduction in Section 3.1.4, Process Interface adequate for an S800 I/O system. Otherwise you are referred to the From the hardware viewpoint, the concept of submodule and submodule carrier is used to build a function.
Page 268 Š (1) (2) MasterBus 300 CS513 QC07-BAS41 See separate executed in main CPU documentation (Basic) (1) (2) MasterBus 300 executed in slave CPU (1) (2) MasterBus 300E executed in main CPU (1) (2) MasterBus 300E executed in slave CPU GCOM CI543 Bus extension to S100 I/O...
Page 269 Š Communication among different computers gives rise to a load divided among the communication link itself and the main CPU of the involved computers. This must be considered when you design a distributed control system. A basic rule, always relevant, is to limit the frequency of the information transfer to what is really needed by the application.
Page 270 Š • You cannot mix MasterBus 300E (executed in slave CPU) and MasterBus 300E (executed in main CPU) within the same controller. • S100 I/O Bus Extension is included on the Processor Module PM511. • See separate hardware manuals for important restrictions on the distribution (cable lengths, location, and so on) of the communication bus.
Page 271 Š Advant Controller 410/450 MasterBus 300/300E CS513 DS, DAT (RCOM is an alternative) Advant Station 500 Series OS MasterBus 300/300E CS513 Advant Station 500 Series IMS MasterBus 300/300E CS513 Advant Station 500 Series ES MasterBus 300/300E CS513 MasterPiece 200/1 MasterBus 300/300E, RCOM CS513 DS, DAT MasterView 800/1...
Page 272 Š ACV 700, DCV 700 Convertor Advant Fieldbus 100 CI522A DSP (Data Set Periph.), Advant Station 100 Series ES Internal bus ABB Prologger, DCS Tuner EXCOM CI531, CAPXCOM DS, DAT, Read DI, DO, AI, AO Printer V.24 / RS-232-C CI531, CAPPRI...
Page 273 Data Sets generate more load than transmitting Data Sets. To minimize the load, you can create data base elements for receiving Data Sets in an Advant Controller 450 before transmitting. Place data base elements for the Data Set which receives data most frequently at the beginning.
Page 274 Š This section is not intended to be a formal guide to application programming but rather a collection of suggestions and ideas for program design and structuring. The following are general rules for program design: • Structure the application program (see below). •...
Page 275 Š Writing to the data base continues while the blocking is active. Use a simple pin diagram when you are structuring the application program. The main purpose of the division of the application program into PC programs is to divide the application into independent parts which have no signal exchange with each other.
Page 276 Š Control system availability is often discussed in relation to industrial processes, power generation systems, machines, and so on. Redundancy is one instrument to reach high system reliability and availability. The advantages of such redundancy include: • Improved personnel safety •...
Page 277 In the most critical applications, a special design of the Advant OCS, the Advant Safety System, is then applicable. Redundancy is achieved by duplication of actual hardware modules. Options for redundancy in Advant Controller 450 are described in Section 1.7.10.2, Redundancy. It is not necessary to order extra software to support a duplication of hardware.
Page 278 Š To avoid overheating, when ambient temperatures are high, take into consideration the heat dissipated in the electronics cabinet. This is particularly important for cabinets with protection degree (IP41, IP54) with considerable circuit board equipment and ambient temperatures at levels approaching 40°C. The frequency of faults is estimated to be doubled for each 20°C increase in temperature.
Page 279 Appendix E, Current Consumption and Heat Dissipation for the power dissipated as heat by hardware modules in Advant Controller 450 and the available I/O system. It is assumed that 70% of the channels of an I/O board are active simultaneously.
Page 280 Your solutions must make sense to the maintenance people in the event of disturbances and following trouble-shooting. You can connect a new Advant Controller 450 to an existing control network (MasterBus 300) without affecting other stations and controllers. The new controller is automatically incorporated in the communication system.
Page 281 Š Advant Controller 450 provides sufficient RAM for most applications (Table 3-9). Other practical limits are normally attained before RAM is used up. A combination, however, of huge PC programs, thousands of I/O points and a large number of logs with the shortest possible log interval requires a lot of RAM.
Page 282 20 operations with six recipe variables each. Included only if you choose the user diskette as a backup option in Advant Controller 450. The memory space can be dimensioned. 100 kByte is a space suitable for most requirements. Reserve RAM capacity is required because information about memory requirements of the different functions is generalized and inherently uncertain.
Page 283 Š PIDCON Excluding I/O signals x 1.50 PIDCONA Excluding I/O signals x 8.5 MANSTN Excluding I/O signals x 0.80 RATIOSTN Excluding I/O signals x 1.00 GENCON Excluding I/O signals x 0.50 GENBIN Excluding I/O signals x 0.50 GENUSD Excluding I/O signals x 0.50 VALVECON Excluding I/O signals...
Page 284 Š LONWORKS No. of LONWORKS Communication x 65 Network modules (CI572/CI573) No. of LONWORKS devices x 0.2 No. of LONWORKS variables x0.06 (input and outputs) No. of LONWORKS multiple network x 0.33 variable No. of LONWORKS Event Treat x 0.14 No.
Page 285 “What can I expect the load generated by my application to be?” It also provides a survey of how the software functions in an Advant Controller 450. In conclusion, you can find recommendations for the reduction of system load.
Page 286 30-minute period. This protection is provided to guarantee that all functions in an Advant Controller 450 have sufficient time to perform their tasks. The user is not normally concerned with priority levels since these are managed automatically by the system, but the user should be aware of the priority system and stall level if the system is heavily loaded.
Page 287 Š With certain heavy load situations in an Advant Controller 450, or if you want to determine if one controller is sufficient for a particular application/load, it may be valuable to perform a CPU load calculation. In the development of standard solutions, including type circuits of different scales, other working methods are strongly recommended.
Page 288 Š Approx. 4 % + Approx. 4 % + Base load PC and Process I/O Detailed analysis and calculation Use of EAF load data (Application) Detailed analysis Typical 4% Subscription, Command, Events Detailed analysis Typical 4% Data Set, EXCOM Detailed analysis Typical 3% Master View 320 Detailed analysis...
Page 289 Š First analyze the application to determine where you can take the most effective optimization action. Primarily, you can take optimization action in three areas, I/O, PC and communication. As usual with optimization, it is most profitable to optimize the part which uses the most CPU- power.
Page 290 Š This section provides technical data that is relevant from a controller viewpoint. Much of the detailed technical data about hardware modules is given in Appendix A, Hardware Modules. This appendix gives a summary of the supported hardware modules. You can find references to technical information either included in Appendix A or separately ordered.
Page 291 Š The load from cyclic functions in Advant Controller 450 is built up as shown in Figure 3-9. Base load fix (variable see below) PC and Process I/O (Application) Subscription, Command and Event Handling Data Set and EXCOM Master View 320...
Page 292 Š In addition to the base load, the following handling times apply to the various I/O channels. All times are in msec and per channel, where not otherwise indicated. (each execution) (VALUE changed) 0.20 0.15 DI scanned 0.20/board 0.05 DI interrupt 0.60 0.02 0.18...
Page 293 Š Use the following execution times and load figures when the shortcut method of CPU load calculation is applied: • One feedback control loop takes approximately 0.8 ms. Thirty feedback control loops with the cycle time 1000 ms thus give approximately 2.5% load.
Page 294 Š 0.02 Hz (50 s) 0.3% Interrupt, low change frequency 0.1 Hz (10 s) 0.8% 0.5 Hz (2 s) 3.2% Interrupt, high change frequency 1 Hz (1 s) 6.2% (This design should be avoided) 0.02 Hz (50 s) 0.4% Cyclic, low change frequency 0.1 Hz (10 s) 0.5% 0.5Hz (2 s)
Page 295 First an example and some general comments: A display with 100 objects from one Advant Controller 450, with an update cycle of 3 sec, generates a load of approximately 1% in the controller. Use of 7 different object types and communication module CS513 with a slave CPU is presupposed.
Page 296 Š Load (%) 1 s Update time 110 Number of objects Load (%) 110 Number of objects Load (%) (utilization of slave CPU) 110 Number of objects Load (%) (utilization of slave CPU) 110 Number of objects 3-50 3BSE 002 415R701 Rev A...
Page 297 (DI) or LIMIT exceeded (AI). However this is taken care of by having the stipulated reserve capacity. Full data sets (that is with 24 DAT values) are assumed. However the length of the data sets has little effect on the load in Advant Controller 450. Figure 3-11, sending data sets and...
Page 298 Š Load [%] SC510 SC520 (utilization of slave CPU) Number of DS / sec. The resulting CPU load in Advant Controller 450 from one MasterView 320 is given in Figure 3-13. Load [%] See text Number of variables/sec max. 48 On the X-axis you can find the update requirement from a display, which is .
Page 299 Š The load caused by each individual log can be estimated from the diagrams and models below. Finally make an addition. The lowest configured value of sampling interval or log interval for an actual log is used when entering the diagrams. In that way the different load caused by a momentary log and a mean value log is practically considered.
Page 300 Data set peripherals (DSP) are cyclically transmitted to their respective destinations, with a cycle time selectable in the range 32 ms to 4096 ms. The Advant Controller 450 CPU load from data set peripheral communication can be estimated from the curves given in...
Page 301 Š R = Receiving S = Sending Load (%) No. of DSP/ sec The basic cycle time for the DSP scan task is set to 32 ms with the APP command. Add the basic link load = 0.2 % (no sending/receiving). R = Receiving S = Sending Load (%)
Page 302 Š The load in an Advant Controller 450 caused by a communication with an external computer using EXCOM is approximately the same irrespective of if the actual controller is a transit node or a slave node in the communication. The computer is always master.
Page 303 Š 2 signals / message 4 signals / message 8 signals / message Load (%) (50) Messages / sec 2 signals / message 4 signals / message 8 signals / message Load (%) (70) Messages / sec This is a matter of the disposition of the total CPU load. A reserve of 15 to 20% is recommended.
Page 304 Š The performance of redundant processor modules is reduced to 95% in relation to a single system. Divide all load figures by 0.95. Time required to upgrade the system from SINGLE to DUAL status. <90 s With 8 Mbyte RAM Typical 5 - 10 ms Maximum...
Page 305 Š Use empirical formulae to permit practical estimation of the memory requirement of the different functions. Please refer to Section 3.1.13, Memory Calculation. For detailed information regarding the memory requirements of different PC elements, see the reference manual Inaccuracy expressed as drift in time max.
Page 306 Š Current consumption is a complex matter when it comes to a flexible control system concept. For rules for calculation of current consumption and dimensioning of distribution board fusing, Section 3.1.3, Power Supply. A quick guide of power consumption to use in a very preliminary phase of work on a project or anytime you need estimated figures for planning purposes follows.
Page 307 = scan cycle time of the Fieldbus Communication Interface 5 - 100 ms, not configurable b = Cycle time of Advant Fieldbus 100 (set by the user, terminal INSCANT) c = scan cycle time of the process data communication in Advant Controller 450 (set by the user, terminal SCANT).
Page 308 Š • It is also possible to receive events from Advant Controller 70/110 using Advant Fieldbus 100, or from Advant Controller 55/110 using RCOM/RCOM+. The relative time error between events for different configurations are given in Table 3-16. A condition for the table is that all events are connected to one Advant Controller 410/450.
Page 309 Š Please note that you must consider practical limits when the data below is applied: • Space in the used cabinet • CPU load • Integrity aspects • Availability aspects. No. of buses (bus extension) Near side bus No. of ”nodes” (I/O subrack and/or optical modems) max.
Page 310 Š Please note that you must consider practical limits when the data below is applied, for example: • Space aspects • CPU load • Integrity aspects • Availability aspects. No. of buses max. 7 No. of I/O units per bus max.
Page 311 Š No. of I/O modules per cluster No. of DI signals max. 2300 No. of DO signals max. 1489 No. of AI signals max. 910 No. of AO signals max. 963 No. of DP820 Pulse Counter channels ca. 1700 (1) 32 is valid for a twisted pair communication media within a segment. (2) If other stations than S800 I/O stations are used on the same Advant Fieldbus 100, the maximum number of S800 I/O stations must be reduced with corresponding number of stations.
Page 312 Normally there are no limits in capacity beyond the limits placed by the actual link for the application. Extended information for certain applications are found below. Regarding the maximum number of links available in Advant Controller 450, you can find information in Section 3.2.4.1, Provided Link Types above.
Page 313 Š Primarily, an application program for process control is “softly” limited by different considerations like: CPU load, integrity, availability, security, and so on. You can find information on these topics in part elsewhere in this manual. Some key data put “hard” limits on an application program for process control.
Page 314 Structuring/function element Maximum 255 structure elements per AMPL cycle time can be used. The following table shows the logging capacity of Advant Controller 450. Note, however, that the CPU load and the RAM requirement must also be considered. Max. no. of logs Max.
Page 315 The number of local operator stations is limited to 4. The number of operator stations of the types Advant Station 500 Series and MasterView 800/1 is limited to 16. You can use printers which satisfy the following requirements with Advant Controller 450. 3BSE 002 415R701 Rev A 3-69...
Page 316 (RI) (Ring Indicator) The reliability and availability of an Advant Controller 450 and its I/O can be calculated on request. Such a calculation can be adapted to the actual application and it can be extended to include all Advant OCS equipment in an automation system.
Page 317 Š Not applicable. See Chapter 2, Installation. The aim of this section is to give those who are inexperienced in this area a through the different phases of a controller design project. There are methods and tools developed to make such project work effective in a variety of aspects. No references are made to methods and tools in this section because that is beyond the scope of this product manual.
Page 318 Š The following four main stages can be identified in the control system design procedure: • Based on process control application analyses, a definition of the equipment must be made. The system definition phase is supported by this manual, especially Chapter 1, which gives an overall introduction from the functional and available resources viewpoints and, of course, Section 3.1, Design...
Page 319 Š Main points in the definition of a particular controller are: • Type of controller to be used, reflecting – Security questions such as Hazardous applications, Emergency situations, Abnormal operating situations, Consequences in the event of a failure, Behavior at start/stop, Behavior at maintenance, Manual control.
Page 320 Š All global objects are identified (and accessed) by unique names which you define within an application project. Certain objects are given default names by the system, which you can change later. From the system’s point of view, the name structure is flat. However, since a name is a visible ASCII string, you can implement any kind of structure in naming objects.
Page 321 Š Type circuit building is a very important aid in the configuration procedure. A type circuit is the largest common collection of PC elements which occurs at several places in the application program. A type circuit can be, for example, a certain type of feedback control loop or a panel control unit with push buttons and lamps.
Page 322 Š This phase mainly comprises the interactive work carried out with the help of an engineering station, for example Advant Station 100 Series ES connected to the target system. It is supported by separate documentation as well, mostly the reference manual, A recommended procedure is “cut”...
Page 323 During the boot phase and during the time of transition between certain working modes the display will indicate intermediate states with the help of a sequence of special codes. These codes are relevant at fault finding and system analyses by ABB personnel only. Additional Information for Redundant Processor Modules Redundant processor modules are two individual processor modules PM511.
Page 324 ® Advant Controller 450 User’s Guide Chapter 4 Runtime Operation The backup unit functions in parallel with the primary unit in any of the following working modes: STANDBY, UPGRADING, STOPPED and OFFLINE. The LED display on the BACKUP processor module front indicates the working mode with the codes b1, b2, -3 or -4.
Page 325 ® Advant Controller 450 User’s Guide Section 4.1.4 Primary and Backup Processor Module 1 (AUTO): Warm start, that is the application program is restarted. If the controller was in the working mode CONFIGURATION, it remains in the working mode CONFIGURATION. If the controller was in the working mode OPERATION, it remains in the working mode OPERATION.
Page 326 ® Advant Controller 450 User’s Guide Chapter 4 Runtime Operation Manual Selection In order to ensure manually that a given processor module will be PRIMARY, you can follow the sample procedure below: Set the other processor module’s start mode selector to 2 (STOP) before initialization. Press the initialization button on the desired primary unit (ENTER).
Page 327 ® Advant Controller 450 User’s Guide Section 4.1.5 Relations between Start Modes and Working Modes 4.1.5.1 First Power-up Starting-point: Uninitialized controller, for example newly delivered controller, or controller without memory backup voltage. Event : Power-up Start mode selector: (STOP) (CLEAR) (OFFLINE) (AUTO) 1 (Compulsory...
Page 328 ® Advant Controller 450 User’s Guide Chapter 4 Runtime Operation 4.1.5.2 Power-up and Initialization of Controller which Contains Application Controller containing an application, Starting-point: in working mode OPERATION or CONFIGURATION. Event : --Power fail/power disconnection and subsequent power-up --User presses ENTER button Start mode selector: (STOP) (CLEAR)
Page 329 ® Advant Controller 450 User’s Guide Section 4.1.6 Relations between Engineering Station Commands and Working Modes Table 4-1. Working Modes at Power Up of Redundant Processor Modules Start mode selection Resulting working mode Primary Backup Primary Backup 1 (AUTO) 1 (AUTO) Figure 4-3 The backup unit starts in UPGRADING mode (b2) and switches over to STANDBY (b1), <90 sec.
Page 330 ® Advant Controller 450 User’s Guide Chapter 4 Runtime Operation 4.1.6.1 DICONFIG Starting-point: Controller executing in working mode CONFIGURATION Event : User enters engineering station command DICONFIG (Compulsory Start mode selector: setting) (STOP) (CLEAR) (AUTO) 1 (OFFLINE) Actions executed - Initialize and by the controller start application...
Page 331 ® Advant Controller 450 User’s Guide Section 4.1.6 Relations between Engineering Station Commands and Working Modes 4.1.6.2 ECONFIG Controller executing in working mode Starting-point: OPERATION Event : User enters engineering station command ECONFIG (Compulsory setting) (STOP) Start mode selector: (CLEAR) (OFFLINE) (OFFLINE) (AUTO) 1...
Page 332 ® Advant Controller 450 User’s Guide Chapter 4 Runtime Operation 4.1.6.3 RECONFIG Controller executing in working mode Starting-point: CONFIGURATION Event : User enters engineering station command RECONFIG (Compulsory Start mode selector: (CLEAR) (STOP) setting) (OFFLINE (AUTO) 1 Actions executed - Install by the controller system SW - Erase...
Page 333 Section 4.1.7 Programmed Start 4.1.7 Programmed Start In Advant Controller 450, you can determine how the process control is to start up and how the system is to start after a mains voltage failure. You can make these determinations with parameters in a data base element (START) and with a PC program for programmed start-up.
Page 334 ® Advant Controller 450 User’s Guide Chapter 4 Runtime Operation Programmed Start at Power-fail - Power-up Starting-point: Controller containing an application and executing in working mode OPERATION or CONFIGURATION Event : Power-fail - Power-up (Recommended Start mode selector: setting) (STOP) (CLEAR) (AUTO) 1 (OFFLINE)
Page 335 ® Advant Controller 450 User’s Guide Section 4.1.7 Programmed Start Programmed Start at AUTO - ENTER Starting-point: Controller executing in working mode OPERATION User presses ENTER button Event : (Recommended Start mode selector: setting) (STOP) (CLEAR) (OFFLINE) (AUTO) 1 Actions executed Programmed start -Install by the controller...
Page 336 ® Advant Controller 450 User’s Guide Chapter 4 Runtime Operation Programmed Start at DICONFIG Starting-point: Controller executing in working mode CONFIGURATION User enters engineering station Event : command DICONFIG (Compulsory Start mode selector: setting) (CLEAR) (STOP) (OFFLINE) (AUTO) 1 Actions executed Programmed start by the controller Initialize and start...
Page 337 Section 4.1.8 System Program 4.1.8 System Program You can divide the software in an Advant Controller 450 into system programs and application programs (PC programs). A system program provides internal program functions and links together the application program with the system hardware.
Page 338 CS513 CI543 CI535/CI538 CI532Vxx CI531 CI532V01 CI534Vxx MasterBus free-pr. GCOM RCOM RS-232-C comm. System Program EXCOM Printer Handlers MV 320 RS-232-C Applic. Program Data Set comm. Data Base Dialog Console Engineering Pres.,TTD Station comm. Data Area PC program DSA__ Process PM511 Interpreter comm.
Page 339 ® Advant Controller 450 User’s Guide Section 4.1.8 System Program 4.1.8.1 Operating System Figure 4-11 shows in more detail the internal interrelation between the processor module parts and the operating system. The part of the program in the operating system which is responsible for all allocation of priority, start and supervision of the different program functions is called the kernel.
Page 340 Chapter 4 Runtime Operation 4.1.8.2 Process Communication An Advant Controller 450 normally exchanges signals with a process via inputs and outputs. Current data for these units is stored in the data base. Data consists of parameters for each board such as board address. The PC program can read, for each channel on a board, information such as the channel value, if there is any blocking of the data value, and so on.
Page 341 The application program consists of one or more PC programs and the data base. 4.1.9.1 Data Base The data base in an Advant Controller 450 is a structured storage form for data which can be used by several different internal program modules. For example, for all analog inputs, there is structured data which stores the value, scale factors, limits, unit, deadband, and so on.
Page 342 ® Advant Controller 450 User’s Guide Chapter 4 Runtime Operation 4.1.9.2 Data Area for PC Programs Each PC program is provided with a local data area for storage of variable values. 4.1.9.3 PC Program You can divide a control task into a number of functional sections. The division is performed primarily in accordance with the functional structure of the control task and can also be in accordance with the requirement of different cycle times in the process.
Page 343 The interpreter also checks if any unit is blocked, if the RESET of any unit is activated, and so on. In an Advant Controller 450, there is a large difference between the shortest and the longest possible cycle times.
Page 344 ® Advant Controller 450 User’s Guide Chapter 4 Runtime Operation The standard cycle times obtained are given in the figure. For a more detailed description of the configuration of cycle times, see the manual AMPL Configuration. Interpreter Interpreter Interpreter 10ms 20ms 40ms 50ms...
Page 345 ® Advant Controller 450 User’s Guide Section 4.1.10 Execution 4.1.10.2 Execution Sequence within an Execution Unit When the cycle time and the start conditions for an execution unit are satisfied, the following takes place: • All input data stored in the data base for the PC element included in the execution unit is read into the local data area.
Page 346 ® Advant Controller 450 User’s Guide Chapter 4 Runtime Operation 4.1.10.4 Execution Sequence for an Individual PC Element The execution sequence within a PC element is illustrated in Figure 4-16 by an AND-gate with two inputs. & AND function Address to data for input 1 Memory map Address to data...
Page 347 ® Advant Controller 450 User’s Guide Section 4.1.10 Execution 4.1.10.5 Execution Sequence of PC Elements After the execution of the function of a particular execution unit and after the reading-in phase, the execution of the PC elements included begins. This is performed, element by element, in the order in which they are entered at program entry, which also corresponds to the order of documentation.
Page 348 ® Advant Controller 450 User’s Guide Chapter 4 Runtime Operation you can select interrupt-controlled scanning of digital inputs by selecting the parameter SCANT to INTERRUPT. You can select different values of SCANT in the range 10 ms to 600 s. See the reference manual Data Base Element for available standard scanning times.
Page 349 ® Advant Controller 450 User’s Guide Section 4.1.11 Data Transport 4.1.11.2 Reading-out Phase The execution of all execution units is concluded with a reading-out phase. This means that output data from the execution unit is obtained from the executions of all of the PC elements in the unit.
Page 350 ® Advant Controller 450 User’s Guide Chapter 4 Runtime Operation 4.1.11.3 Data Transport between Execution Units Figure 4-20 shows how data is exchanged between different executing units. PC 1 PCPGM (20,1) PUT element for Control module executed data to under interpreter A data base CONTRM (40,2)
Page 351 ® Advant Controller 450 User’s Guide Section 4.1.12 Initialization of Process Communication Note the following regarding data exchange. • Input signals from the data base: The reading-in element (GET element) is created automatically by the engineering station. • Output signals to the data base: The reading-out element (PUT element) is created automatically by the engineering station.
Page 352 4.2 Operating Overview An Advant Controller 450 is an autonomous station which normally is not handled by an operator. Of course, it is started and sometimes stopped manually. This is done, however, in specific situations such as at the time of installation work and maintenance.
Page 353 Remember that an Advant Controller 450 starts automatically when voltage is applied if this is not prevented by means of the data base element START. You can also prevent start- up of an Advant Controller 450 by setting the START MODE selector in the STOP position.
Page 354 Remember that an Advant Controller 450 starts automatically when voltage is applied if this is not prevented by means of the data base element START. You can also prevent start- up of an Advant Controller 450 by setting the START MODE selector in the STOP position.
Page 355 ® Advant Controller 450 User’s Guide Section 5.2.1 Safety Regulations 5.2.1.2 Machine Safety CAUTION Observe the following safety rules: • Avoid discharges of static electricity by grounding both yourself and tools before handling circuit boards and other parts of the equipment. •...
Page 356 5.2.5 Air Filter The fan unit located beneath the controller subrack (Advant Controller 450) always includes an air filter. Wash the air filter included with the equipment in warm water with a mild detergent at regular intervals determined by environmental conditions.
Page 357 Only system messages which are of particular interest to the final user are included. That is messages which point out possible malfunctions which can be easily corrected by the user himself. System messages not described here are to be noted and forwarded to ABB Automation Products AB to determine if any action is necessary.
Page 358 Diagnostics are available in different forms for rapid localization of the source of the equipment malfunction. Hardware error is usually corrected by replacing the faulty unit, which is returned to ABB for repairs. The least replaceable unit is normally a circuit board or an apparatus like a power supply unit.
Page 359 Debugging of PC programs is described in the reference manual AMPL Configuration Advant Controller 400 Series. 5.5.2 Diagnostics and Fault Announcement Both hardware and software in an Advant Controller 450 are provided with supervision against system fault. For a survey of the diagnostics, see Section 1.7.10.1, Diagnostics.
Page 360 ® Advant Controller 450 User’s Guide Chapter 5 Maintenance Central Operator Station If the controller is included in a control network with a central operator station type Advant Station 500 Series Operator Station or MasterView 800/1, the following facilities apply. •...
Page 361 Free pgm module 7 EXCom. 1 EXCom. 2 I/O Power Supply 24 V supply A PCF1 24 V supply B PCF2 Reg. Redundancy PCF3 PCF4 Figure 5-2. System Status Display Advant Controller 400 applied to Advant Controller 450 3BSE 002 415R701 Rev A...
Page 362 ® Advant Controller 450 User’s Guide Chapter 5 Maintenance Reference in Advant Controller 400 Display: Normal green 24 V supply A (or B) Presentation: Fault - Lost redundancy red cr Supervision of the 24 V power supply for the subrack containing the processor module. Function: (only relevant when two redundant branches A and B are installed).
Page 363 ® Advant Controller 450 User’s Guide Section 5.5.2 Diagnostics and Fault Announcement Reference in Advant Controller 400 Display: Normal green Regulator 1 (2..4) Presentation: Fault - Regulator 1 (2..4) missing or err. red cr Supervision of particular 5 V regulator in the subrack containing the processor module. Function: (only relevant when redundant 5 V regulators are installed).
Page 364 ® Advant Controller 450 User’s Guide Chapter 5 Maintenance Reference in Advant Controller 400 Display: Normal green Backup Pow. Supp. (1) 2 Presentation: Fault red cr Supervision of the backup power supply of RAM Function: Plain System Message POW SUPP ST Battery Charger faulty Net xx Nod yy...
Page 365 ® Advant Controller 450 User’s Guide Section 5.5.2 Diagnostics and Fault Announcement Reference in Advant Controller 400 Display: Normal green Program card 1.1 Presentation: yellow cr Warning - Initial check in progress Fault - wrong check sum or missing card red cr Supervision of program card including system software (check sum) Function:...
Page 366 ® Advant Controller 450 User’s Guide Chapter 5 Maintenance Reference in Advant Controller 400 Display: Normal green Free pgm module 1 Presentation: Fault - Hardware or application program red cr Supervision of free-programmable module PU535 Function: Plain System Message FPB board out of order Net xx Nod yy MISC ST...
Page 367 ® Advant Controller 450 User’s Guide Section 5.5.2 Diagnostics and Fault Announcement Reference in Advant Controller 400 Display: Normal green (I/O) 24 V supply A/B Presentation: Fault - Lost voltage or lost redundancy red cr Supervision of the 24 V power supply for one or several I/O subracks (collecting alarm). Function: Each branch A/B is supervised if redundant branches are installed.
Page 368 ® Advant Controller 450 User’s Guide Chapter 5 Maintenance Reference in Advant Controller 400 Display: Normal - all regulators present and OK green (I/O) Reg. redundancy Presentation: Fault - any regulator missing or erroneous red cr Supervision of redundant 5V regulators in one or several I/O subrack (collecting alarm) Function: Plain System Message I/O voltage regulator faulty...
Page 369 ® Advant Controller 450 User’s Guide Section 5.5.2 Diagnostics and Fault Announcement Reference in Advant Controller 400 Display: Normal green I/O fan Presentation: Fault - any of the fans erroneous red cr Supervision of fans in all I/O subracks (collecting signal) Function: Plain System Message Fan for I/O faulty...
Page 370 ® Advant Controller 450 User’s Guide Chapter 5 Maintenance Reference in Advant Controller 400 Display: Normal - all left (right) bus extenders green S100 I/O Bus Extension L (R) Presentation: are present and OK Left (right) bus extenders are Fault - any bus extender missing or red cr connected to left (right) processor erroneous...
Page 371 ® Advant Controller 450 User’s Guide Section 5.5.2 Diagnostics and Fault Announcement Reference in Advant Controller 400 Display: Normal green F1 (F2..F4) or user defined text Presentation: Fault red cr Supervision of application defined function. Function: Plain System Message User defined error 1 Net xx Nod yy at fault:...
Page 372 ® Advant Controller 450 User’s Guide Chapter 5 Maintenance Reference in Advant Controller 400 Display: Normal green User defined name Presentation: For example Terminal 1 (2..4) Fault - Hardware or software red cr Supervision of terminal MasterView 320 and its communication Function: Plain System Message RS 232...
Page 373 ® Advant Controller 450 User’s Guide Section 5.5.2 Diagnostics and Fault Announcement Reference in Advant Controller 400 Display: Normal green User defined name Presentation: For example EXCom. 1 Fault - Hardware or software red cr Supervision of the communication with an external computer Function: using V.24/RS-232-C and EXCOM protocol Plain System Message...
Page 374 ® Advant Controller 450 User’s Guide Chapter 5 Maintenance S100 I/O 1 Stat Name Stat Name Stat Name Stat Name Figure 5-3. System Status Display, S100 I/O 1 Stat (Status) Reference in S100 I/O 1 Display: Normal green User defined name Presentation: (default: DB item designation for Fault - the board is erroneous...
Page 375 ® Advant Controller 450 User’s Guide Section 5.5.2 Diagnostics and Fault Announcement S100 I/O 2 Name Name Name Name Board 1 Board 2 Board 3 Figure 5-4. System Status Display, S100 I/O 2 Reference in S100 I/O 2 Display: Normal green User defined name Presentation:...
Page 376 ® Advant Controller 450 User’s Guide Chapter 5 Maintenance S100 I/O Redundant Board 1 Board 2 Stat Name Stat AXR1 AXR2 AXR3 Figure 5-5. System Status Display, S100 I/O Redundant Board Stat (Status) Reference in S100 I/O Redundant Board Display: Normal, the board is OK green filled User defined name...
Page 377 ® Advant Controller 450 User’s Guide Section 5.5.2 Diagnostics and Fault Announcement Advant Fieldbus 100 Stat Name Type CI522A AF100_1 AC110 AC110_1 AC110_2 AC110 Figure 5-6. System Status Display, Fieldbus (Status) Reference in Fieldbus Display: Normal green DB item designation for the bus/unit Presentation: Warning or a user defined unique name...
Page 378 ® Advant Controller 450 User’s Guide Chapter 5 Maintenance Fieldbus PROFIBUS Stat Name Type CI541 PBS1 PBS2 Figure 5-7. System Status Display, Fieldbus (Status) Reference in Fieldbus Display: Normal green DB item designation for the bus/unit Presentation: or a user defined unique name Warning red cr Fault - the bus/unit is erroneous...
Page 379 ® Advant Controller 450 User’s Guide Section 5.5.2 Diagnostics and Fault Announcement LONWORKS Stat Name Type CI572 LON1 LONDEV LONDEV1 LONDEV2 LONDEV Figure 5-8. System Status Display, Fieldbus (Status) Reference in Fieldbus Display: Normal green DB item designation for the LONWORKS Presentation : Network Device or a user unique name Warning...
Page 380 ® Advant Controller 450 User’s Guide Chapter 5 Maintenance Advant Fieldbus 100 Bus Unit Display Bus 1 Stn 2 Advant Fieldbus 100 Stat Subpos Name Type AF100_2 CI522A AF100_2 CI522A Figure 5-9. System Status Display, Advant Fieldbus 100 Bus Unit 5-28 3BSE 002 415R701 Rev A...
Page 381 ® Advant Controller 450 User’s Guide Section 5.5.2 Diagnostics and Fault Announcement MasterFieldbus Bus 1 Bus 2 Bus 3 Bus 4 Bus 5 Name AX100 AX101 Figure 5-10. System Status Display, MasterFieldbus Reference in MasterFieldbus Display: (Status) Normal green DB item designation for the bus/unit Presentation: Fault - the bus/unit is erroneous red cr...
Page 382 ® Advant Controller 450 User’s Guide Chapter 5 Maintenance S800 I/O Station (non redundant FCI) Advant Fieldbus 100 Bus 1 Stn 2 Stat Name Type Power Supply Text 1 Text 2 CI810 AF100 OS_2 Redundant Stat Stat Name Type DI810_1 DI810 DI810_2 DI810...
Page 383 ® Advant Controller 450 User’s Guide Section 5.5.2 Diagnostics and Fault Announcement Block Diagram: Hardware Software CI810 DB; C I810 System status N AME Status ´Name´ Station DIAGN. DB item design. WARNING or Name DIAG SERVICE EX_STAT1 Pow er Supply EX_T EXT1 EX_STAT2 EX_T EXT2...
Page 384 ® Advant Controller 450 User’s Guide Chapter 5 Maintenance S800 I/O Station (redundant FCI’s) Bus 1 Stn 2 Advant Fieldbus 100 Status Name Type Power Supply AF100 OS_2 CI820 Text 1 Text 2 AF100 OS_2 CI820 Redundant Status Status Name Type DI810_1 DI810...
Page 385 ® Advant Controller 450 User’s Guide Section 5.5.2 Diagnostics and Fault Announcement S100 I/O Bus Extender Name Status Description Type “Description” DSBC 174 “Description” DSBC 174 “Description” DSBC 174 Figure 5-13. System Status Display, S100 I/O Bus Extender Status (L, R) Reference in S100 I/O Bus Extender Display: The board is primary green filled...
Page 386 ® Advant Controller 450 User’s Guide Chapter 5 Maintenance 5.5.3 Fault Finding Principles Introduction Perform fault finding in a systematic and logical manner. You must make a distinction between a system which has been in operation and a system which has not been operated previously.
Page 387 Practical Classification Fault Finding Reference information Advanced 2) Covered by Product fault finding Automation University Sweden ABB Industrial Systems AB methods 2) documentation Training courses Source of Failure Replacement Instructions Figure 5-14. Fault Finding Principles 3BSE 002 415R701 Rev A...
Page 388 ® Advant Controller 450 User’s Guide Chapter 5 Maintenance Typical Simple Scenario A typical simple scenario for a network connected controller follows. A system message appears on the operator station display screen. The message is: fatal error in I/O board, data base item designation XX. You can find cross-references to board type and physical location in the data base documentation and the equipment delivery documentation.
Page 389 Advanced fault finding is not the object of this User’s Guide. However some trial might be successful. Hints are referred. A classification is valuable too when ordering support from ABB. Faults are classified in the following four groups A..D: Faults in the power supply system.
Page 390 ® Advant Controller 450 User’s Guide Chapter 5 Maintenance Advanced Fault Finding In addition: • Advant Station 100 Series Engineering Station or Advant Station 500 Series Engineering Station (with option On-line Builder). 5.5.6 Safety Regulations The instructions given in Section 5.1.1, Safety Regulations are always to be followed when installing, fault finding and operating an Advant Controller system to minimize the risks of injury to personnel and damage to the equipment.
Page 391 AMPL Configuration Advant Controller 400 Series. If the actual Advant Controller 450 is a node in a LAN, the engineering station can be connected to any of the nodes included in the network. Remote configuration/maintenance can be performed in that way.
Page 392 5.5.9.3 Safety at Start/Stop The Advant Controller 450 can perform the control functions while operating normally. Voltage failure, component fault or manual restart usually affect the control system function. Control system failure affects the process in different ways, more or less serious: •...
Page 393 ® Advant Controller 450 User’s Guide Section 5.5.9 List of General Fault Finding Procedures and Hints • Backup processor module in working mode b1 (b1 = STANDBY) Execution • Stop the primary module by setting the start mode selector in position 2 (STOP). Then depress the ENTER button.
Page 394 ® Advant Controller 450 User’s Guide Chapter 5 Maintenance Appendix A, Hardware Modules gives module/unit information including description of the function, block diagram, technical data, maintenance parts and so on. Two variants of power supply system are dealt with: • a.c.
Page 395 ® Advant Controller 450 User’s Guide Section 5.5.9 List of General Fault Finding Procedures and Hints General Fault finding in the controller cabinet is carried out as follows. Before replacing a power supply unit or a fuse or resetting a MCB try to check for a reason of the fault.
Page 396 ® Advant Controller 450 User’s Guide Chapter 5 Maintenance Scenario B - Fault Finding Shut down of an I/O subrack is verified. The controller is operating otherwise. Green LED on processor module is ON. I/O subrack 24VF (rear side) < 18 V I/O Subrack 1 24 V Check for a disconnection...
Page 397 ® Advant Controller 450 User’s Guide Section 5.5.9 List of General Fault Finding Procedures and Hints Redundant a.c. Mains Supply and Redundant Power Supply Regulators (Total redundancy) In an Advant Controller which includes total power supply redundancy, the probability for a shut down caused by a single power supply failure is extremely small.
Page 398 ® Advant Controller 450 User’s Guide Chapter 5 Maintenance Scenario C - Fault Finding Disturbance in the controller power supply is verified. First guidance and measures to be taken, see Figure 5-15. SR511 LEDs Diagnostic Replace or continue with Normal operation ----- Overvoltage Replace SR511...
Page 399 ® Advant Controller 450 User’s Guide Section 5.5.9 List of General Fault Finding Procedures and Hints Scenario D - Fault Finding Disturbance in the I/O subrack power supply is verified. First guidance and measures to be taken, see Figure 5-18. I/O Subrack 1 LEDs Diagnostic Replace or continue with...
Page 400 ® Advant Controller 450 User’s Guide Chapter 5 Maintenance Mains Supply and 24 V Power Supply - General Fault Finding Test 24V distribution (SX554) > 19 V LIVE Replace 5 V Regulator Section 5.5.10.5, Replacement of 5 V Regulator Mains supply A/B U <...
Page 401 ® Advant Controller 450 User’s Guide Section 5.5.9 List of General Fault Finding Procedures and Hints 5.5.9.6 Check of Backup Power Supply The backup power supply and battery diagnostics are indicated in the system status display (see Section 5.5.2.1, System Status and Plain Language System Messages) and by LEDs on the Backup Power Supply SB510/511 front.
Page 402 ® Advant Controller 450 User’s Guide Chapter 5 Maintenance • Red LED HLT (HaLTed) means a serious fault. The controller has stopped. The system halt information is probably missing or incomplete. The recommended actions are: Restart the controller. See Section 5.5.15, System Restart following Maintenance Activities.
Page 403 ® Advant Controller 450 User’s Guide Section 5.5.9 List of General Fault Finding Procedures and Hints • If all the boards with fault indications are in the same subrack, the fault is probably in the bus extension to S100 I/O –...
Page 404 ® Advant Controller 450 User’s Guide Chapter 5 Maintenance NOTE ALSO! If the supply to a subrack is switched on before the DSBC 174 or DSBC 176 is in place, the process outputs in the subrack can set themselves in optional states! You should carefully follow general instructions and the information attached each board/unit type in Section 5.5.10.1, Board and Subrack Mounted Unit...
Page 405 In some applications, this is an absolute requirement for safety reasons. The system software in Advant Controller 450 checks automatically that all I/O boards function correctly. In the event of board fault, and board exchange, the board and associated signals are marked as faulty in the data base.
Page 406 ® Advant Controller 450 User’s Guide Chapter 5 Maintenance Grip the board firmly and extract the board quickly and decisively (I/O subrack). Use both handles (controller subrack). Check that the new board can replace the old: – Ensure that the eventual jumpering is the same as the old board. Table 5-1 Table 5-2.
Page 407 ® Advant Controller 450 User’s Guide Section 5.5.10 User Repair Table 5-1. Replacement Aspects of Individual Board Types (Controller Hardware) Board type - Jumpering Comments CI522A No jumpering - On-line replacement possible - Described in: Advant Fieldbus 100 CI531 No jumpering - On-line replacement possible - Described in: Appendix A, Hardware Modules...
Page 408 ® Advant Controller 450 User’s Guide Chapter 5 Maintenance Table 5-1. Replacement Aspects of Individual Board Types (Controller Hardware) (Continued) Board type - Jumpering Comments CI541V1 No jumpering - On-line replacement possible only together with the hole Carrier-card - Described in: PROFIBUS-DP Advant Controller 400 Series CI543...
Page 409 ® Advant Controller 450 User’s Guide Section 5.5.10 User Repair Table 5-1. Replacement Aspects of Individual Board Types (Controller Hardware) (Continued) Board type - Jumpering Comments PM511V08 No jumpering - This is the processor module of the controller. On line replacement of a single PM511V16 module is from a functional standpoint of (PM511V on...
Page 410 ® Advant Controller 450 User’s Guide Chapter 5 Maintenance Table 5-1. Replacement Aspects of Individual Board Types (Controller Hardware) (Continued) Board type - Jumpering Comments TC560V1 No jumpering - On-line replacement possible however not practical. Reflect the consequences to all S100 I/O boards.
Page 411 ® Advant Controller 450 User’s Guide Section 5.5.10 User Repair Table 5-2. Replacement Aspects of Individual Board Types, S100 I/O Board type - Jumpering Comments DSAI 130 On-line replacement possible DSAI 130A On-line replacement possible DSAI 133 On-line replacement possible DSAI 133A On-line replacement possible 3BSE 002 415R701 Rev A...
Page 412 ® Advant Controller 450 User’s Guide Chapter 5 Maintenance Table 5-2. Replacement Aspects of Individual Board Types, S100 I/O (Continued) Board type - Jumpering Comments DSAI 146 On-line replacement possible DSAI 155A On-line replacement possible DSAO 110 On-line replacement possible Note! In general, the electrical connections between output boards and the process is to be broken before the board is extracted.
Page 413 ® Advant Controller 450 User’s Guide Section 5.5.10 User Repair Table 5-2. Replacement Aspects of Individual Board Types, S100 I/O (Continued) Board type - Jumpering Comments DSAO 120A On-line replacement possible Note! In general, the electrical connections between output boards and the process is to be broken before the board is extracted.
Page 414 ® Advant Controller 450 User’s Guide Chapter 5 Maintenance Table 5-2. Replacement Aspects of Individual Board Types, S100 I/O (Continued) Board type - Jumpering Comments DSAX 110A On-line replacement possible Note! In general, the electrical connections between output boards and the process is to be broken before the board is extracted.
Page 415 ® Advant Controller 450 User’s Guide Section 5.5.10 User Repair Table 5-2. Replacement Aspects of Individual Board Types, S100 I/O (Continued) Board type - Jumpering Comments DSDI 110A On-line replacement possible DSDI 110AV1 On-line replacement possible DSDI 120A On-line replacement possible DSDI 120AV1 On-line replacement possible 3BSE 002 415R701 Rev A...
Page 416 ® Advant Controller 450 User’s Guide Chapter 5 Maintenance Table 5-2. Replacement Aspects of Individual Board Types, S100 I/O (Continued) Board type - Jumpering Comments DSDO 115 On-line replacement possible Note! In general, the electrical connections between output boards and the process is to be broken before the board is extracted.
Page 417 ® Advant Controller 450 User’s Guide Section 5.5.10 User Repair Table 5-2. Replacement Aspects of Individual Board Types, S100 I/O (Continued) Board type - Jumpering Comments DSDP 150 On-line replacement possible S104 S110 S109 S112 DSDP 170 On-line replacement possible S9 S10 3BSE 002 415R701 Rev A 5-65...
Page 418 ® Advant Controller 450 User’s Guide Chapter 5 Maintenance 5.5.10.2 Replacement of Redundant Processor Module When a redundant processor module becomes faulty, the system loses its DUAL status and becomes single. DUAL LED’s on both processor modules will be off. In order to regain redundancy, replace the faulty unit as soon as possible in the following manner: Do not forget to read...
Page 419 ® Advant Controller 450 User’s Guide Section 5.5.10 User Repair Replace a primary DSBC 174 Set the front switch, on the primary DSBC 174 that will be replaced, in position STOP. A processor changeover is executed and the processor, connected to the stopped DSBC 174 will stop with the code 80 presented in the front display.
Page 420 ® Advant Controller 450 User’s Guide Chapter 5 Maintenance Replace a backup DSBC 174 Set the front switch, on the backup DSBC 174 that will be replaced, in position STOP. The RUN and DCOK LEDs are turned off, on the stopped DSBC 174. Pull out the stopped bus extender.
Page 421 ® Advant Controller 450 User’s Guide Section 5.5.10 User Repair Off Line Replacement Switch off the mains supply to the cabinet and wait until the capacitors have discharged. When the power supply system is loaded, the discharge takes 10 secs and when unloaded, 60 secs.
Page 422 ® Advant Controller 450 User’s Guide Chapter 5 Maintenance Single SR511 Switch off the mains supply. Use the power switch S1 on the power switch unit. Provide access to the unit by loosening the screws in the handles. Grip the SR511 firmly and extract it decisively. Use both handles.
Page 423 ® Advant Controller 450 User’s Guide Section 5.5.10 User Repair DSSR 122 Switch off the mains supply. Use the power switch S1 on the power switch unit. Open the hinged frame to gain access to the unit and the connection terminals on the rear side of the I/O subrack.
Page 424 ® Advant Controller 450 User’s Guide Chapter 5 Maintenance 5.5.10.6 Replacement of Backup Power Supply You can replace Backup Power Supply SB510 and SB511 on-line, but not during a mains supply interruption while the battery is used. Some system functionality provided by the backup power supply is essential to a safe controller operation.
Page 425 ® Advant Controller 450 User’s Guide Section 5.5.10 User Repair During the time of replacement the backup power supply will indicate F (Fail) and BF (Battery Fail). This is observed in the system status display in the operator station too. Possibly will, at low battery temperature, the red F LED on the backup power supply still be ON under a few minutes after replacement.
Page 426 ® Advant Controller 450 User’s Guide Chapter 5 Maintenance 5.5.10.9 Replacement of Modem Replacing a modem of course will affect the actual communication link. If no physical redundancy, the communication will be shut down. However a replacement can be made while the controller is operating otherwise.
Page 427 ® Advant Controller 450 User’s Guide Section 5.5.11 Adjustment of Analog Input and Output Boards Adjustment Possibilities on Circuit Boards Table 5-3 shows the adjustments possible on the various analog input and output boards. Table 5-3. Adjustment Possibilities on Analog Circuit Boards Type Channel adjustment Common adjustment...
Page 428 ® Advant Controller 450 User’s Guide Chapter 5 Maintenance Perform the adjustments in the order in which they are described (Z, B, G). If a certain adjustment function is not available, the procedure is continued by setting the next parameter. Potentiometers for adjusting the common section (A/D) are located on the lower part of the front.
Page 429 ® Advant Controller 450 User’s Guide Section 5.5.11 Adjustment of Analog Input and Output Boards 5.5.11.2 Adjustment of A/D Converter Adjustment for Boards DSAI 130, DSAI 133 and DSAX 110 The A/D converter is adjusted in three operations: • Adjustment of zero point Z (automatically adjusted on DSAI 133) •...
Page 430 ® Advant Controller 450 User’s Guide Chapter 5 Maintenance Adjustment of the Full-scale Value on the A/D Converter Perform the adjustment with negative voltage. If negative signals are not used, use a positive reference voltage. Adjust the reference voltage connected to the negative (or positive) input to the full-scale value 10 000 mV.
Page 431 ® Advant Controller 450 User’s Guide Section 5.5.12 Channel Adjustment on AO Board Resetting Stop the GETAB command as described in the preceding chapter. Reset the values for CONV_PAR, FILTER_P and DEADB. Connect the process input or the jumper in the same way as the reference resistor is connected. 5.5.12 Channel Adjustment on AO Board All analog output boards are adjusted during manufacture for current output, which means that units in which the voltage output is used may be readjusted to obtain the full accuracy.
Page 432 ® Advant Controller 450 User’s Guide Chapter 5 Maintenance AC 450 SW Circuit board Connection unit Current output Data base AO ch Register DVM U VALUE D/A conv. 500 ohm 0.01% Figure 5-23. Adjustment of Current Output 5.5.12.1 Adjustment of Zero Point, Channel by Channel Enter the value zero in VALUE (property 10) in the AO channel data base element to be adjusted.
Page 433 ® Advant Controller 450 User’s Guide Section 5.5.12 Channel Adjustment on AO Board 5.5.12.2 Adjustment of the Gain, Channel by Channel Enter a value with RANGEMAX (property 45) in VALUE (property 10). Use an engineering station. Use the command MDB, read RANGEMAX and modify VALUE to RANGEMAX, for example: MDB AO1.X <CR>...
Page 434 ® Advant Controller 450 User’s Guide Chapter 5 Maintenance 5.5.13 Adjustment of Isolation Amplifier The isolation amplifier DSTY 101 is adjusted in the same way as analog input boards, that is, for zero point (Z) and full scale (G). If a live zero (4 mA) is used, a basic value is jumpered in accordance with the unit description. The output signal is then adjusted to 2.000 V with the input signal 0.000 mV (4 mA, 500 ohm ±0,01%).
Page 435 Use the commands LSYSHI (List SYStem HIstory), LSYSM ALL (List SYStem Messages ALL), LTSL (List Task Switch Log) and list all messages. The information from the listing is used in the continued contact with ABB. Set the mode selector back to position 1 (AUTO).
Page 436 ® Advant Controller 450 User’s Guide Chapter 5 Maintenance Additional Information for Redundant Processor Modules A controller with redundant processor modules should be treated as a single system. Make the following additional steps. The one processor module which is primary/backup is denoted primary/backup all through.
Page 437 ® Advant Controller 450 User’s Guide Section 5.5.17 Loading of Application Program Example of Procedure Action Response Set the start mode selector on the Processor Module PM511 front in 3 (CLEAR) Check that the program card is in position. The system software will be reloaded at the cold start.
Page 438 Depress the ENTER button on the backup module 5.6 CPU Load Measurement When the Advant Controller 450 is executing the PC programs, the CPU load depends mainly on the size and nature of the PC programs and, above all, on the cycle times chosen for the various execution units.
Page 439 ® Advant Controller 450 User’s Guide Section 5.7.2 Backup of Application AdvaBuild On-line Builder supports the preparation of flash cards with application dumps, DUAP. The AdvaBuild On-line Builder User’s Guide describes the different working procedures in detail. Following is an overview. Considerations •...
Page 440 ® Advant Controller 450 User’s Guide Chapter 5 Maintenance A red F LED on the MB510 module front indicates hardware error, checksum error or missing program card. If the red F LED is turned on and if the application program card is removed and after that reinstalled again and the red F LED turns off, then you must arrange for a functional test of the backup.
Page 441 By way of introduction, see below a complete list of all types of hardware modules related to the Advant Controller 450. The list includes modules like circuit boards, power supply units and connection units. They are listed in alphabetical order.
Page 442 Š CI570 MasterFieldbus Controller CI572/CI573 Communication Interface Module CI810A Advant Fieldbus 100 Communication Interface CI820 Redundant Advant Fieldbus 100 Communication Interface CI830 PROFIBUS Fieldbus Communication Interface CS513 MB 300, MB 300E Communication Interface DI8xx Digital Input Modules DO8xx Digital Output Modules DP8xx Pulse/Frequency measuring modules DSAI 1xx...
Page 443 Š DSTA xxx Connection Units, for analog signals DSTC X008 Modem for RS-232-C, 230 V a.c. Ref. KM1, Westermo Teleindustri AB DSTC 176 Termination Unit, for S100 I/O bus extension DSTC 404 Terminator DSTC 406 Terminator DSTC 451 Over-voltage Protection Unit DSTC 452 Coaxial Modem, for MasterFieldbus DSTC 454...
Page 444 Š SR511 Regulator 24 V/5 V Section A.16, SR511 - Regulator 24 V/5 V SS110 Voting Unit SV540, SV541 Power Distribution Unit Section A.17, Power Switch and Distribution (with isolation transformer) Units SV542, SV543 Power Distribution Unit Section A.17, Power Switch and Distribution (with isolation transformer) Units SX540...
Page 445 Š TC516 Advant Fieldbus 100 Twisted Pair Modem for bus redundancy TC520 System Status Collector Section A.19, TC520 - System Status Collector TC560Vx Optical Modem, for S100 I/O bus extension (Near side) TC561Vx Optical Modem, for S100 I/O bus extension (Far side) TC562 Modem for RS-232-C, 24 V...
Page 446 Modem support. CI531 is a submodule destined to the Submodule Carrier SC510 and SC520 in Advant Controller 450 and Processor Module PM150 in Advant Controller 410. The two RS-232-C communication interfaces are generally used in the following applications: Printer, EXCOM, MasterView 320. See the controller documentation.
Page 447 Š Data Carrier Detect Receive Data Transmit Data Data Terminal Ready Ground Data Set Ready Request To Send Clear To Send Ring Indicator typical 400 mA max. 670 mA 24 V max. 40 mA Power loss (heat) typical Module size: Occupying one submodule slot (H = 95 mm, L = 140 mm, connector not included) Weight: 0.13 kg (0.29 lbs.) 3BSE 002 415R701 Rev A...
Page 448 Š For use with 24 V direct d.c. supply • Provides a backup time of about 5 ms at full load. • The Energy Reservoir DSSB 170 is a capacitor unit intended for use with 24 V direct supply (without d.c./d.c. converter). In the event of mains power failure, the unit provides the system with energy necessary for storage of important data.
Page 449 Š Voltage rating input 24 V d.c. Output voltage 24 V d.c. Backup time 5 ms (in the range) 18.5 - 16 V with 25 A load Voltage derivative with power failure 0.3 V/ms with 25 A load Width 482 mm (19”) Height 177 mm (7”), 4 U Depth...
Page 450 Š • Holds flash PROM of the type PCMCIA Submodule which fits into Submodule Carrier SC5xx or Processor Module PM150. • Utilizing an MB510 is one method of program card installation in an Advant Controller 400 Series. A program card is equipped with flash PROM for different use. For example to store and backup the system program of the controller.
Page 451 Š LEDs on module front: F (red) Module error RUN (green) Module running normally 5 V d.c. typical 10 mA 170 mA (when reading) Power loss (heat) typical 0.05 W Module size occupying one submodule slot Module weight 0.12 kg (0.26 lbs.) Interface logic Fault Control...
Page 452 • DUAL Description PM511V is a processor module for Advant Controller 450. It is designed to fit into RF533 series controller subracks. The Motorola 68040 processor is a 32-bit virtual memory microprocessor with an integrated floating point unit and with dual independent instruction and data demand paged memory management units (MMUs).
Page 453 Š 8 or 16 Mbyte dynamic RAM for system software and application program. LEDs on module front: F (red) Module error RUN (green) Module running normally HLT (red) CPU halted TO (yellow) Bus time-out BC (green) Backup voltage for RAM connected DUAL (green) Redundant processor ready 5 V d.c.
Page 454 Š Empty slots within a controller subrack should be equipped with dummy modules. The reason is: • Keeping air vented in a settled way Exterior appearance. • Available module types are: RB510 Dummy Module, full height.12 SU, 6 mp (300 mm, 30 mm) Substituting, for example, Carrier Module, Processor Module RB520 Dummy Module, for submodule slot.
Page 455 Š High performance, three fans • Uses redundant power supplies +24 VA and +24 VB • • Each fan separately fused Fan rotating speed supervision • Cassette model including three fans powered by 24 V d.c. Redundant power supply is possible. For proper system function, all three fans must work.
Page 456 482 mm x 425 mm x 100 mm (19” x 16.7” x 4”) incl. cable duct Weight: 3 kg (6.6 lbs.) Miniature Fuse Link, 5 x 20mm, 0.8AF fast, ABB part no. 3BSC 770 001 R43 Filter Carpet (dust filter) ABB part no. 3BSC 930 057 R0001 Fan (spare part) ABB part no.
Page 457 Š 19-inch standard width • Height 300 mm (12 SU) • • Futurebus+ back plane. Subrack for electronic modules with front connection of cables. Mount the subrack close to the back wall in a cabinet. Admittance to the rear side of the subrack is not necessary after the installation. A number of slots for modules of different sizes are included.
Page 458 Š (Panel layout, see below) 2.1 V and 3.3 V Test of termination voltages Test of 5 V power supply of the controller subrack 5VBACK Test of the RAM backup voltage 5 V 24 V/A resp. 24 V/B Connection of system power supply 24 V (B used at redundancy) VBAT/B resp.
Page 459 Š Back plane 445 (17.5”) 330 (13”) 482 (19”) y - min100 mm space for cables and All measurements in mm (in.) cable duct Connections 24V/A 24V/B AUX1/A AUX1/B Test AUX2/A AUX2/B PFAIL/A PFAIL/A VBAT/A VBAT/B 0V 2.1V 3.3V 5V 5VBACK 3BSE 002 415R701 Rev A A-19...
Page 460 Š Destined for auxiliary equipment • Screw or top hat rail assembly of units • • 24-inch standard (RF540) and 19-inch standard (RF541) Includes cable duct. • RF540 and RF541 are subracks for assembly of auxiliary equipment like modems and certain connection units for communication links.
Page 461 Š Dimension: Width measurement for the two variants are given below. Otherwise see dimension drawing on previous page. RF541 RF540 Total width 482 mm (19”) 609 mm (24”) Hole pattern 465 mm (18”) 592 mm (23”) Weight: RF541 3 kg (6.6 lbs.) RF540 3.5 kg (7.7lbs.) (13, RF540)
Page 462 Š • Power supply units for a.c. to d.c. conversion • Variants for different mains supply • Unstabilized d.c. output • Variants for different output voltage and load • Provides galvanic isolation • Rack or wall installation. SA1xx is a series of power supply units converting single phase a.c. to smooth but unstabilized 24 V or 48 V d.c.
Page 463 Š Mains voltage a.c., nominal 120 V 230 V 120 V 230 V 120 V 230 V Mains voltage variation 85 - 110% Mains voltage a.c., max. (f=47-65Hz) 142 V 285 V 142 V 285 V 142 V 285 V Mains load VA 450 VA 900 VA...
Page 464 Weight: SA161/162 15 kg (33 lbs.) SA167/168 24 kg (53 lbs.) SA171/172 15 kg (33 lbs.) Midget Fuse, 10 * 38 mm 6 AF (fast), ABB part no.5672 827- 6 10AF 5672 827- 10 15AF 5672 827-15 SA167/168 only d.c.
Page 465 Š Module included in backup power supply system for RAM Connectable to mains supply 100 - 230 V a.c. or d.c. Three modes of operation: battery recharging and trickle charging from mains supply and battery discharging Fits NiCd battery unit SB522. SB510 is a battery charger which works together with one single battery package, for example, SB522.
Page 466 FC, Fast Charging (ylw) Indicates recharging after power-up or battery replacement (10 hours). Miniature Fuse Link, 5 x 20 mm, 2AF (fast) ABB part no. 5672 2011-17 Module size: 6 SU, 12 mp (“half height, double width”) Weight: 0.95 kg (2.1 lbs.)
Page 467 Š Block Diagram Normal Operation Backup Operation Charging of Battery Discharging of Battery Mains Mains Supply Supply a.c. or a.c. or d.c. SB522 d.c. SB522 Processor Module Processor Module Normal Normal 5V supply 5V supply 3BSE 002 415R701 Rev A A-27...
Page 468 Š Module included in backup power supply system for RAM Connectable to mains supply 24 - 48 V a.c. or d.c. Three modes of operation: battery recharging and trickle charging from mains supply and battery discharging Fits NiCd battery unit SB522. SB511 is a battery charger which works together with one single battery package, for example, SB522.
Page 469 FC, Fast Charging (ylw) Indicates recharging after power-up or battery replacement (10 hours) Miniature Fuse Link, 5 x 20 mm, 4AF (fast) ABB part no. 5672 2011-20 Module size: 6 SU, 12 mp (“half height, double width”) Weight: 0.95 kg (2.1 lbs.)
Page 470 Š Rechargeable 12 V, 4 Ah NiCd battery • Charging and discharging via the battery charger • • Fits Battery Charger SB510, SB511 Used for backup current supply of RAM. • SB522 includes 10 NiCd cells size D organized in two lines. The battery package as well as the connecting device are semi-protected.
Page 471 Š Technical Data Nominal battery voltage 12 V Capacity 4 Ah (one-hour discharge) Internal, non-replaceable fuse 20 A (quick action) Dimension: width max. 71 mm (2.8”) height max. 350 mm (13.8”) depth max. 40 mm (1.6”) Weight: 1.4 kg (3.1 lbs.) >...
Page 472 Š Permit flexible functional disposition • • Variants with/without CPU resources. Three variants of submodule carriers are available to fit into RF533 Series controller subrack. A submodule carrier has no complete function but two slots for submodules of different kinds to define the desired function. Communication interfaces are the most common category of submodules.
Page 473 Š Technical Data LED RUN (green) on module front. Indicates module running normally. LED F, Fault (red) on module front. 5 V d.c. typical 1.3 A1.5 A (excl. submodules) max. 2.0 A2.0 A (excl. submodules) 24 V d.c. typical 6 mA6 mA (excl.
Page 474 Š • Power supply unit for d.c. to d.c. conversion Applicable to 24 V and 48 V d.c. networks • Stabilized d.c. output • • Provides galvanic isolation • Rack or wall installation. SD150 is a d.c. voltage converter for 24 V and 48 V d.c. networks. It is intended to supply the voltage regulator units in a controller with 24 V d.c.
Page 475 Š Technical Data Input voltage 24 -48 V d.c. Input voltage variation 80 - 120% of nominal value Output voltage 24 V d.c. Maximum load 20 A Maximum input power 600 W Overcurrent protection, output 25 A Class I according to IEC 536 (earth protected) Width 480 mm (18.8”) Depth...
Page 476 (n+1) -redundant power supply system is derived. In an Advant Controller 450, use two SR511s to achieve redundancy. You can exchange one regulator at a time in a redundant regulator live system without generating malfunction.
Page 477 Š Dual 24 V d.c. inputs Rated input power 310 W at full load; 5 V, 2.1 V Maximum input power 350 W at current limit 46 A Efficiency 70% typ. Rated input voltage 24 V d.c. ±8 V Voltage variation External fuse 30 AF maxfor each 24 V terminal Rated output voltage...
Page 478 Š Power Switch and Distribution units (PSD units) are modular designs fitting 19-inch rails. A rail houses up to three units. Use PSD units to switch on/off the mains supply to an Advant Controller installation and for internal power distribution. Normally the modular box has three socket outlets.
Page 479 Category Supply main/aux main main main main main Distributor expands..SX540 SX550 Expandable Y/N Mains input Single Single Dual Dual Single Single Single Single Single Single Mains Type of network Install. category Frequency , Hz 50/60 50/60 50/60 Rated insulation voltage, V Dielectr.
Page 480 Š Class I according to IEC 536 (earth protected) IP20 according to IEC 529 (IEC 144) SX-types SV-types (including isolation transformer) Width 202 mm (8”) 202 mm (8”) Height 177 mm (7”) 177 mm (7”) (corresponds to 4 U height modules in a cabinet) Depth 95 mm (3.7”) 95 mm (3.7”) + 130 mm (5”) at the rear side of the apparatus plate...
Page 481 Š X1PE X1PE X1PE 120 V, 300 VA Isol. transf. 230 V, 300 VA F1, F2 K 10A K 10A K 1.6A K 3A 10 mm2 10 mm Screw term. Screw term. F1, F2 35 mm 35 mm X3 - X5 Outlet socket 10A K 10A X1 - X2...
Page 482 Š Power switch F1, F2 K 16A K 25A 35 mm2 X1, X2 Screw term. 16 mm X3 - X5 Outlet socket L+, L- L1, L2 Design. as is F1, F2 K 16A K 25A 35 mm2 X1, X2 Screw term. 16 mm X3 - X5 Outlet socket...
Page 483 Š X1PE Power switch F1, F2 K 50A X1PE Screw term. 35 mm Screw rerm. S1, F1, F2 35 mm 3BSE 002 415R701 Rev A A-43...
Page 484 Š Use the power distribution panel SX554 unit for distribution of 24 V or 48 V d.c. tension within an Advant Controller 410/450. It mounts right below an SA1xx power supply unit and may be utilized as a support during replacement of a heavy-weight power supply unit. SX554 is a connector printed circuit board mounted in a steel frame.
Page 485 Height: 43 mm (1.7”), corresponds to 1 U height module in a cabinet Weight 1 kg (2.2 lbs.) Miniature Fuse Link, 5 x 20 mm 1AF ABB part no. 3BSC 770 001 R44 LIVE 10AT Terminal Description X21, X22 screw term. 10 mm power inlet tab 6.3 x 0.8 mm...
Page 486 Š General status collector System backplane signal inputs RUN, LIVE, BAT, PFail Four general-purpose inputs 24 V One FANFAIL input One external system clock SYNC input Two relay outputs controlled by RUN signal (Processor Modules A and B). TC520 is positioned in a controller subrack to interface with the backplane bus. The module collects status information from around the system.
Page 487 Š > STATUSA1 IO24VA or “F1” -50 to +2 V +12 to Opto 1ms/100ms Positive 100ms +60 V STATUSA2 IO24VB or “F2” COMMONA (ref. to A1, A2) STATUSB1 “F3” STATUSB2 “F4” COMMONB (ref. to B1, B2) RUN A1 Relay contact: Max. 250 V a.c. or d.c. Max.
Page 488 Š A-48 3BSE 002 415R701 Rev A...
Page 489 ® Advant Controller 450 User’s Guide Section B.1 RM500 Cabinets - General Appendix B RM500 Cabinet - Data Sheet B.1 RM500 Cabinets - General The RM500 cabinet (available in three protection classes) is used for installation of Advant Controller 400 Series in control rooms. Two protection classes are ventilated, and complies with IEC 529 protection class IP 21, and IP41.
Page 490 ® Advant Controller 450 User’s Guide Appendix B RM500 Cabinet - Data Sheet B.2 Dimensions and Weight The dimension and weight of the RM500 cabinets are given in Table B-1. Table B-1. RM500 Cabinet Measurements Cabinet Type RM500V1 RM500V1 RM500V2 Characteristics Height = 1925 mm Height = 2125 mm...
Page 491 ® Advant Controller 450 User’s Guide Section B.2 Dimensions and Weight Figure B-2. Mounting Cabinets together - Screw Position Double door Single door Figure B-3. Swing Radius for Door(s) and Hinged Frame 3BSE 002 415R701 Rev A...
Page 492 ® Advant Controller 450 User’s Guide Appendix B RM500 Cabinet - Data Sheet B.3 Mounting Cabinets together If cabinets are to be mounted to each other use the included screw/bolt kit. The four M8 screws, with washers and nuts, in the angle hinges and six M6 screws at about Z1=500, Z2=1.000, Z3=1.500 mm height from the floor, see Figure B-2.
Page 493 IP 54 Sealed with heat exchanger IP 54 (1) Advant Controller 450 with S100 I/O, installed in this cabinet is not verified for CE-marking. (2) Standard cabinet without filter on ventilation grilles. (3) Ventilation grilles are covered with metallic net to prevent insects to enter the cabinet.
Page 494 ® Advant Controller 450 User’s Guide Appendix B RM500 Cabinet - Data Sheet B.6 Permitted Power Dissipation The permitted power dissipation in a single RM500 cabinet is given in Table B-5 If required, due to environmental conditions, use Protection Class IP54. Table B-5.
Page 495 The diagram is mainly used at installation, commissioning and system maintenance (fault finding). Support and Problem Reporting Includes information and instructions on how to get support from ABB and how to report problems with the product and its functions. Forms are available for problem reporting. 3BSE 002 415R701 Rev A...
Page 496 ® Advant Controller 450 User’s Guide Appendix C Delivery Documentation 3BSE 002 415R701 Rev A...
Page 497 ® Advant Controller 450 User’s Guide Section D.1 General Appendix D Item Designations D.1 General To use the documents provided at delivery, you must be familiar with the item designation system used in Advant Controller cabinets. Each component in the system has a unique designation which indicates exactly the location of the component in the cabinet.
Page 498 ® Advant Controller 450 User’s Guide Appendix D Item Designations When there are several cabinets, they are designated 1 and 2 from the left. The mounting planes are for example 1B, 2B and so on. All mounting planes A, B, C, D, E, H, V (hinged frame) and U (hinged frame) are divided vertically into height modules (U), 1U = 44.45 mm (see Figure D-1).
Page 499 ® Advant Controller 450 User’s Guide Section D.3 Controller Subracks D.3 Controller Subracks The controller subracks are 12 and 18 SU modules high (1 SU = 25 mm) and 85 mp modules wide (1 mp = 5 mm). Subracks have 14 slots for modules, center-center spacing 6 mp (general design). Variants of module height and width exist (6 mp and 12 mp).
Page 500 ® Advant Controller 450 User’s Guide Appendix D Item Designations Figure D-4. Item Designation in Controller Subrack 18SU Address Voltage Voltage Reg. Reg. Sub- positions Backup Backup Power Power Supply Supply Address/Position 4 5 6 Figure D-5. Addresses in Controller Subrack 12 SU 3BSE 002 415R701 Rev A...
Page 501 ® Advant Controller 450 User’s Guide Section D.4 I/O Subracks D.4 I/O Subracks The I/O subracks are 8 (U) modules high (1 U = 44.45 mm), including cable duct. Subracks have 21 slots for modules. The first module in a subrack is designated 101, the next 105, the next 109, and so on. Figure D-6.
Page 502 ® Advant Controller 450 User’s Guide Appendix D Item Designations D.5 Modem Subracks The modem subracks are 6 (U) modules high (1 U = 44.45 mm), including cable duct. Two wide variants are available, 19 inches and 24 inches. The places in the subrack for modems have sequential numbers 1 - 9 and 1 - 12. Places 10, 11 and 13, 14 are contacts for power supply distribution (24 V).
Page 503 ® Advant Controller 450 User’s Guide Section D.6 Circuit Boards and Units D.6 Circuit Boards and Units Connectors on the Front Connectors on the front are numbered X1, X2, and so on, from the top downward. With several circuit boards in a unit, the boards are designated 1, 2, 3, and so on, and the connectors on the different boards are designated X21, X22, X31, and so on.
Page 504 ® Advant Controller 450 User’s Guide Appendix D Item Designations Connection Units The item designation code for the contacts of the connection unit are shown in Figure D-12. The connector for internal connections in the cabinet is always designated X80. The terminal block group or connector for external connections is designated X90.
Page 505 ® Advant Controller 450 User’s Guide Section D.7 Mains Units This connection is designated U4.125.X2 - B1.1.X80. (Hinged frame) U4.125 (Rear mounting plane) B1.1 Flat Cable Figure D-14. Typical Internal Connection The poles of the connection terminal block on the connection unit are numbered from left to right, see Figure D-15.
Page 506 ® Advant Controller 450 User’s Guide Appendix D Item Designations D.8 Examples of Item Designation in Cabinets A number of modules, connection points, and so on, located in a double cabinet are illustrated in Figure D-17. Figure D-17. Example of general Disposition of a Double Cabinet An extract from a wiring table, Table D-1, shows the corresponding item designations,...
Page 507 ® Advant Controller 450 User’s Guide Section D.8 Examples of Item Designation in Cabinets Table D-1. Designation of Items in Figure D-17 Connection point A Instar. Item designation Terminal 1B12 1B12 1C32.x 2H15 1H35 F1X3 (1) x stands for 1, 2, 3 and so on. 3BSE 002 415R701 Rev A D-11...
Page 508 ® Advant Controller 450 User’s Guide Appendix D Item Designations D-12 3BSE 002 415R701 Rev A...
Page 509 Appendix E Current Consumption and Heat Dissipation E.1 General The tables below present the current consumption and power dissipation of all relevant hardware modules included in Advant Controller 450 and its I/O. Use this information: • When dimensioning the supply to the system •...
Page 510 ® Advant Controller 450 User’s Guide Appendix E Current Consumption and Heat Dissipation Table E-1. Current Consumption and Power Dissipation, Controller Modules Current Consump. (A) Type Tot. Power No of Total Comments Designation Dissipation (W) Boards 24 V CI522A CI531 0.04 CI532Vxx 0.04...
Page 511 ® Advant Controller 450 User’s Guide Section E.2 Calculation Algorithms and Forms with Technical Data Table E-2. Current Consumption and Power Dissipation, S100 I/O Boards Current Consump. (A) Total Type Tot. Power No of Comments Designation Dissipation (W) Boards +5 V +24 V DSAI 130 0.25...
Page 512 ® Advant Controller 450 User’s Guide Appendix E Current Consumption and Heat Dissipation Table E-2. Current Consumption and Power Dissipation, S100 I/O Boards (Continued) Current Consump. (A) Total Type Tot. Power No of Comments Designation Dissipation (W) Boards +5 V +24 V DSDO 115 0.65...
Page 513 ® Advant Controller 450 User’s Guide Section E.2 Calculation Algorithms and Forms with Technical Data Table E-3. Current Consumption and Power Dissipation, Power Supply and Sundry Current Consump. (A) Total Type Tot. Power No of Comments Designation Dissipation (W) Units +5 V +24 V SA1xx...
Page 514 ® Advant Controller 450 User’s Guide Appendix E Current Consumption and Heat Dissipation 3BSE 002 415R701 Rev A...
Page 515 ® Advant Controller 450 User’s Guide Section F.1 Load Calculation Forms Appendix F Load Calculation F.1 Load Calculation Forms Table F-1. Calculation of CPU-load from S100 and S800 Inputs No of Basic load Scan time Dynamic load Changes/sec. Signal type Total load signals (ms)
Page 516 ® Advant Controller 450 User’s Guide Appendix F Load Calculation Table F-2. Calculation of CPU-load from S100 and S800 Outputs No of Basic load Scan time Dynamic load Changes/sec. Signal type Total load signals (ms) (ms) (ms) per signal _______ _______ ____ 0.02...
Page 517 ® Advant Controller 450 User’s Guide Section F.1 Load Calculation Forms Table F-3. Calculation of CPU-load from User Defined Type Circuits Execution Cycle time Function Load (%) Number Total load time (ms) (ms) C)=A*100/B C*D) C)=A*100/B C*D) C)=A*100/B C*D) C)=A*100/B C*D) C)=A*100/B C*D)
Page 518 ® Advant Controller 450 User’s Guide Appendix F Load Calculation 3BSE 002 415R701 Rev A...
Page 519 ® Advant Controller 450 User’s Guide Section G.1 Form for Memory Calculation Appendix G Memory Calculation G.1 Form for Memory Calculation Table G-1. Calculation of RAM requirement Factor Object type Remark Total RAM req. (kbytes) AI/AO signals S100 I/O x 0.30 S400 I/O (MP 51 not included) x 0.30 S800 I/O...
Page 520 ® Advant Controller 450 User’s Guide Appendix G Memory Calculation Table G-1. Calculation of RAM requirement (Continued) Factor Object type Remark Total RAM req. (kbytes) MasterView 320 Basic requirements for QC07-LOS41 x 240.00 No. of displays x 2.00 No. of MasterView 320 with event lists x 9.00 AS 500 Series Basic requirement for QC07-OPF41...
Page 521 ® Advant Controller 450 User’s Guide Section G.1 Form for Memory Calculation (1) The figures are calculated for 8 steps (MOTCON not included). (2) The figures are calculated for 1 table with 10 rows and 100 values per row. (3) The figures are calculated for 40 text strings with 20 characters and 30 dynamic values. (4) The figures apply to 100 events per list.
Page 522 ® Advant Controller 450 User’s Guide Appendix G Memory Calculation 3BSE 002 415R701 Rev A...
Page 523 You can obtain the result of the command LSYSHI as a printout on the printer with the command HARDCOPY in accordance with Figure H-1. ‘*LSYSHI QC02-BAS21 *7.0/0 *02/01/01 COPYRIGHT 1994 BY ABB INDUSTRIAL SYSTEMS AB CXNLIB7.0/0 CXKLIB *7.0/0 Network, node :11,1 Time, date : 10:10:15, 1994-12-24 Current task :CXKK 340 H’00482360...
Page 524 ® Advant Controller 450 User’s Guide Appendix H Halt Codes NOTE In all situations when the controller has stopped you should carefully read all halt codes and system messages available before you proceed. See Section 5.4.2.1, Reading of System Messages. Table H-1.
Page 525 ® Advant Controller 450 User’s Guide Section H.2 List of Halt Codes and Corrective Actions Table H-1. List of Halt Codes (Continued) Halt Significance Corrective Actions Code Overload, STALL ALARM Note the error code and the red LED indicators which have illuminated.
Page 526 Further detailed information of the possible reason of the halt is stored in the system. This Error in changeover. Unexpected status. information is accessible by ABB experts only. System with redundant processor modules only. This means a serious shut down of a redundant Indication on the “new”...
Page 527 Further detailed information of the possible reason of the halt is stored in the system. Error in changeover. MOVEM instruction to/from This information is accessible by ABB experts only I/O during changeover. System with redundant processor modules only. This means a serious shut down of a redundant Indication on the “new”...
Page 528 ® Advant Controller 450 User’s Guide Appendix H Halt Codes 3BSE 002 415R701 Rev A...
Page 529 ® Advant Controller 450 User’s Guide Section I.1 Message Coding Appendix I System Messages I.1 Message Coding System and error messages are format coded as follows: 13:25:09 28 CXPHSC1 H’81250B06 H’01400001 H’000A0050 Network Node Time Type Code Task Interrupted Address Data 1 Data 2 Interpretation can be found in...
Page 530 MasterBus See also Master Net User’s Guide Data Set Communication EXCOM Clock synchronization GCOM See Master Net User’s Guide Data Set Peripheral, Advant Fieldbus 100 VFI communication Internal errors. Please report to ABB System/Node supervision 3BSE 002 415R701 Rev A...
Page 531 In the following listing those messages which are of particular interest to an end user are included. These can be easily corrected by the user himself. System messages not described here shall be noted and forwarded to ABB to determine if any action is necessary.
Page 532 ® Advant Controller 450 User’s Guide Appendix I System Messages Type 10 Task killed 12:23:44 10 CXAA 000 H’000FF333 61000 Table I-5. Type 10, Code 19 Type Code Significance Data 1 Comments/Actions Task interrupted 61000 Gap in Data Set 61001 Dat referred to missing 61002 No RAM at initialization...
Page 533 ® Advant Controller 450 User’s Guide Section I.3 List of System Messages and Corrective Actions Type 17 MasterNet 12:23:44 17 CXNM540 H’00000000 Table I-6. Type 17, Code 1, 2, 3, 7, 8, 9 and 11 Type Code Significance Data 1 Data 2 Comments/Actions Configuration error...
Page 534 ® Advant Controller 450 User’s Guide Appendix I System Messages Table I-6. Type 17, Code 1, 2, 3, 7, 8, 9 and 11 (Continued) Type Code Significance Data 1 Data 2 Comments/Actions Configuration error H’LRSNCPSP Config. error Logical Record in the data base Slave Number Carrier Position in the subrack Submodule Position on the carrier...
Page 535 ® Advant Controller 450 User’s Guide Section I.3 List of System Messages and Corrective Actions Table I-6. Type 17, Code 1, 2, 3, 7, 8, 9 and 11 (Continued) Type Code Significance Data 1 Data 2 Comments/Actions Hardware error H’CCSSTT00 CS513 error Carrier position in the subrack Submodule position on the carrier...
Page 536 ® Advant Controller 450 User’s Guide Appendix I System Messages Table I-6. Type 17, Code 1, 2, 3, 7, 8, 9 and 11 (Continued) Type Code Significance Data 1 Data 2 Comments/Actions Clock No clock master node available. synchronization Backup node There might be more than one backup nodes message in the net.
Page 537 ® Advant Controller 450 User’s Guide Section I.3 List of System Messages and Corrective Actions Type 20 Error on V24 / RS-232-C Channel 06:03:54 20 CXBH260 H’000000B8 H’00020609 H’00000082 Table I-8. Type 20, Code 1 Type Code Significance Task Comments/Actions No contact with printer, CXBH260 Printer...
Page 538 ® Advant Controller 450 User’s Guide Appendix I System Messages Type 22 PC interpreter 12:23:45 22 DAYIP30 34392 Table I-9. Type 22, Code 9, 12, 13 and 20 Type Code Significance Data 1 Comments/Actions Correct again after overload. Overload. Insufficient memory or memory error. Clock change or overload.
Page 539 ® Advant Controller 450 User’s Guide Section I.3 List of System Messages and Corrective Actions Table I-9. Type 22, Code 9, 12, 13 and 20 (Continued) Type Code Significance Data 1 Comments/Actions The address jumpering of the positioning board and the I/O address given on the PC element FREQ-MP are different.
Page 540 ® Advant Controller 450 User’s Guide Appendix I System Messages Type 26 Other Faults (System Messages from Printer and operator station) 16:23:54 26 DCCA910 H’04900010 Table I-10. Type 26, Code 12 Type Code Address Comments/Actions H’04900010 Text too long to be printed H’04900020 PC element PRINT with LAST missing.
Page 541 ® Advant Controller 450 User’s Guide Section I.3 List of System Messages and Corrective Actions Type 28 Process Communication 16:23:54 28 CXPHSC1 H’81250B06 H’014D0001 Data 1 contains concepts and instance numbers which can be used to locate incorrect data base elements with the help of the command MDB.
Page 542 ® Advant Controller 450 User’s Guide Appendix I System Messages Table I-11. List of Common Concept Numbers in System Messages DB Element (Concerning) Event Set S100 I/O bus extension (DSBC 174/DSBC 176) LONNV, LONWORKS Network Variables LONMNVI, LONWORKS Multiple Network Variables LON, LONWORKS Interface Table I-12.
Page 543 ® Advant Controller 450 User’s Guide Section I.3 List of System Messages and Corrective Actions Table I-12. Type 28 (Continued) Type Code Data 1 Data 2 Comments/Actions Concept, The internal diagnostics of the board have reported instance No. a hardware fault. There can also be a value too small or too large on a reference channel.
Page 544 ® Advant Controller 450 User’s Guide Appendix I System Messages Table I-12. Type 28 (Continued) Type Code Data 1 Data 2 Comments/Actions H’014D H’xxxxyyzz AF100 and PROFIBUS (333),x xxxx = Bus number yy = 0 No redundant CI52x yy = 1 CI52x sub module 1 yy = 2 CI52x sub module 2 zz = Station number (of CI52x or CI541) xxxxyyzz = 32-bit device error diagnostics.
Page 545 ® Advant Controller 450 User’s Guide Section I.3 List of System Messages and Corrective Actions Table I-12. Type 28 (Continued) Type Code Data 1 Data 2 Comments/Actions H’xxxxyyyy MasterFieldbus cable A fault xxxx = Bus number yyyy = Node number H’xxxxyyyy MasterFieldbus cable A in operation xxxx = Bus number...
Page 546 ® Advant Controller 450 User’s Guide Appendix I System Messages Table I-12. Type 28 (Continued) Type Code Data 1 Data 2 Comments/Actions Concept, A previous hardware error has vanished. The board instance No. or node is taken into operation again. H’015D H’xxxxyyyy MasterFieldBus...
Page 547 ® Advant Controller 450 User’s Guide Section I.3 List of System Messages and Corrective Actions Table I-12. Type 28 (Continued) Type Code Data 1 Data 2 Comments/Actions Concept, H’0000000x Reference in EVS(R), AIEV or DIEV, cannot be instance No. found. Less number of references than in H’015F corresponding EVS(S) or reference is of wrong (351),x...
Page 548 ® Advant Controller 450 User’s Guide Appendix I System Messages Table I-12. Type 28 (Continued) Type Code Data 1 Data 2 Comments/Actions Concept, System Error. Device has one or more system instance No errors. H’014D AF100, 32-bit system error diagnostic: (333),x H’00200000 Wrong parameter memory...
Page 549 ® Advant Controller 450 User’s Guide Section I.3 List of System Messages and Corrective Actions Table I-12. Type 28 (Continued) Type Code Data 1 Data 2 Comments/Actions Concept, Minor Device/Station Error or I/O S800 Module instance No warning. Nonfatal hardware error. H’wwxxyyzz S800 I/O modules H’0145...
Page 550 ® Advant Controller 450 User’s Guide Appendix I System Messages Type 29 Redundant Processor Modules, Operating System, Kernel 18:33:55 29 CXKK600 H’00000012 Table I-13. Type 29, Code 1, 2, 3 and 4 Type Code Significance Address Comments/Actions Message from redundant Changeover has been performed automatically.
Page 551 ® Advant Controller 450 User’s Guide Section I.3 List of System Messages and Corrective Actions Type 30 MasterBus (Data Set, EXCOM) H’EEAC 13:25:09 30 CXAA000 H’1010002 H118100FF Table I-14. Type 30, Code 21, 23 Type Code Significance Address Data 1 Data 2 Comments/Actions Overload in receiving end.
Page 552 ® Advant Controller 450 User’s Guide Appendix I System Messages Table I-14. Type 30, Code 21, 23 (Continued) Type Code Significance Address Data 1 Data 2 Comments/Actions The data reference of the H’EE49 H’XXXXYYYY Routine: data base element (DS, MS (=61001) CXAA000 DS (MV 300)
Page 553 ® Advant Controller 450 User’s Guide Section I.3 List of System Messages and Corrective Actions Type 39 Data Set Peripheral, Advant Fieldbus 100 H’00230011 13:25:10 39 CXAP000 H’014F0001 Table I-15. Type 39 Type Code Significance Data 1 Data 2 Comments/Actions Configuration of DSPs on Concept, Result from...
Page 554 ® Advant Controller 450 User’s Guide Appendix I System Messages Table I-15. Type 39 (Continued) Type Code Significance Data 1 Data 2 Comments/Actions Illegal bus or bad See Comments The DSP is defined for a non definition of Advant Comments existing bus or the bus is badly Fieldbus 100 defined.
Page 555 ® Advant Controller 450 User’s Guide Section I.3 List of System Messages and Corrective Actions Type 134 System/Node Supervision H’ 13:25:10 134 H’ H’ Table I-16. Type 134, Code Type Code Significance Data 1 Data 2 Comments/Actions H’EEEE ⇒ Error coming AC 410/AC450, 24 V error Concept, MSW: Direction...
Page 556 ® Advant Controller 450 User’s Guide Appendix I System Messages Table I-16. Type 134, Code (Continued) Type Code Significance Data 1 Data 2 Comments/Actions H’EEEE ⇒ Error coming AC450, Concept, MSW: Direction H’2222 ⇒ Equip. in working order I/O regulator error instance No.
Page 557 ® Advant Controller 450 User’s Guide Section J.1 Conversion Guide Appendix J Hexadecimal to Decimal Representation J.1 Conversion Guide An explanation of the difference between notation systems is necessary to avoid confusion. The decimal system is that commonly used but binary and hexadecimal notation systems are often used in computers.
Page 558 ® Advant Controller 450 User’s Guide Appendix J Hexadecimal to Decimal Representation Table J-1. Conversion of up to Four Figure Hexadecimal Numbers 4096 8192 12288 16384 1024 20480 1280 24576 1536 28672 1792 32768 2048 36864 2304 40960 2560 45056 2816 49152 3072...
Page 559 ® Advant Controller 450 User’s Guide Index INDEX Address D-4 Data and text handling 1-97 Advant Station 500 Series 1-105 Data entry 2-57 AI810 1-75 Data Set 1-92 AI820 1-75 Delivered Version Specification C-1 AI830 1-75 to 1-76 Delivery Specification C-1 AI835 1-75 DI810 1-73 AO810 1-75...
Page 560 ® Advant Controller 450 User’s Guide Index Jumpering - Overview 5-54 Release Notes C-1 Reports 1-99 Run/Alarm relay Description 1-108 License Certificate C-1 Electrical data A-46 Lifting instructions 2-18 Installation 2-31 Location of components D-1 Location-Oriented Item Designations D-3 Logic and Time Delays 1-97 Safety switch 2-10 Safety system aspects 1-108 SD811 1-78 to 1-79...
Page 561 ® Advant Controller 450 User’s Guide Index Valve control 1-102 VT100 terminal 1-105 3BSE 002 415R701 Rev A...
Page 562 ® Advant Controller 450 User’s Guide Index 3BSE 002 415R701 Rev A...
Page 564 3BSE 002 415R701 Rev A March, 2000...

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