Advant Controller 410

Advant® OCS Advant® Controller 410
with Master software
User’s Guide
3BSE 002 414R601 Rev B
Use of DANGER, WARNING, CAUTION, and NOTE
This publication includes, DANGER, WARNING, CAUTION, and NOTE information where appropriate to point out safety
related or other important information.
DANGER Hazards which could result in severe personal injury or death
WARNING Hazards which could result in personal injury
CAUTION Hazards which could result in equipment or property damage
NOTE Alerts user to pertinent facts and conditions.
Although DANGER and WARNING hazards are related to personal injury, and CAUTION hazards are associated with
equipment or property damage, it should be understood that operation of damaged equipment could, under certain operational
conditions, result in degraded process performance leading to personal injury or death. Therefore, comply fully with all
DANGER, WARNING, and CAUTION notices.
TRADEMARKS
Advant, AdvaBuild, Advant Controller, Advant Fieldbus, Advant Station, MasterBatch, MasterGate, MasterBus, MasterField-
bus, ABB Master, ABB MasterNet, ABB MasterPiece and ABB MasterView registered trademarks of ABB Asea Brown Boveri
Ltd. Switzerland.
Allan-Bradley is a trademark of Allan-Bradley Inc.
CardTalk is a trademark of Microsoft Corporation.
Epson is a registered trademark of Epson Corporation.
HART is a trademark of Rosemount Inc.
ABB Master, ABB MasterNet, ABB MasterPiece and ABB MasterView are registered trademarks of ABB Asea Brown Boveri
Ltd. Switzerland.
Master Safeguard is a trademark of ABB Industri AS, Norway.
Mannesmann Tally is a trademark of Mannesmann Tally Limited.
MC 68040 is a registered trademark of MOTOROLA Inc.
MODBUS is a registered trademark of Gould Electronics.
Profibus-DP is a trademark of the international organization PROFIBUS INTERNATIONAL (PI).
Echelon, LON, LonTalk, LONWORKS, and Neuron are registered trademarks of Echelon Corporation.
Siemens and all Siemens-products mentioned in this publication are trademarks of Siemens AG.
UDPCE is a trademark of ABB Industri AS, Norway.
VT100 is a trademark of Digital Equipment Corporation.
NOTICE
The information in this document is subject to change without notice and should not be construed as a commitment by ABB
Automation Products AB. ABB Automation Products AB assumes no responsibility for any errors that may appear in this
document.
In no event shall ABB Automation Products AB be liable for direct, indirect, special, incidental or consequential damages of
any nature or kind arising from the use of this document, nor shall ABB Automation Products AB be liable for incidental or
consequential damages arising from use of any software or hardware described in this document.
This document and parts thereof must not be reproduced or copied without ABB Automation Products AB’s written permission,
and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose.
The software described in this document is furnished under a license and may be used, copied, or disclosed only in accordance
with the terms of such license.
CE MARKING
This product meets the requirements specified in EMC Directive 89/336/EEC and in Low Voltage Directive 73/23/EEC.
Copyright © ABB Automation Products AB 2001.
3BSE001264/E
Template: 3BSE001286/E
3BSE 002 414R601 Rev B

Advant® Controller 410 User’s Guide
Table of Contents
TABLE OF CONTENTS
Chapter 1 - Introduction
1.1 General Information................................................................................................. 1-1
1.2 Manual Organization ............................................................................................... 1-2
1.3 Conventions ............................................................................................................. 1-5
1.4 Related Documentation............................................................................................ 1-5
1.5 Release History ........................................................................................................ 1-9
1.6 Terminology............................................................................................................1-11
1.7 Product Overview .................................................................................................. 1-15
1.7.1 Product Versions ................................................................................... 1-18
1.7.1.1 Version Designation ....................................................... 1-18
1.7.2 Product Structure .................................................................................. 1-19
1.7.3 General System Utilities ....................................................................... 1-24
1.7.3.1 CPU ................................................................................ 1-24
1.7.3.2 Memory .......................................................................... 1-24
1.7.3.3 Program Module Contents ............................................. 1-26
1.7.3.4 System Clock, External Clock Synchronization ............ 1-33
1.7.3.5 Configuration ................................................................. 1-33
1.7.3.6 Execution ....................................................................... 1-34
1.7.3.7 Start-up........................................................................... 1-34
1.7.4 Free-Programmable Module ................................................................. 1-34
1.7.5 Power Supply........................................................................................ 1-36
1.7.6 Process Interface ................................................................................... 1-42
1.7.6.1 S100 I/O ......................................................................... 1-52
1.7.6.2 S400 I/O ......................................................................... 1-65
1.7.6.3 S800 I/O ......................................................................... 1-67
1.7.7 Communication..................................................................................... 1-78
1.7.7.1 Provided Link Types ...................................................... 1-78
1.7.7.2 Applied Communication ................................................ 1-86
1.7.8 Process Control ..................................................................................... 1-89
1.7.8.1 Application Language .................................................... 1-89
1.7.8.2 Principles of Application Building ................................ 1-92
1.7.8.3 Control Functions........................................................... 1-94
1.7.9 Operator’s Interface ............................................................................ 1-101
1.7.9.1 Maintenance Personnel ................................................ 1-101
1.7.9.2 Local Operator ............................................................. 1-101
1.7.9.3 Central Operator........................................................... 1-103
1.7.9.4 Printer........................................................................... 1-104
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CONTENTS (continued)
1.7.10 Availability and Security..................................................................... 1-105
1.7.10.1 Diagnostics ................................................................... 1-106
1.7.10.2 Redundancy .................................................................. 1-110
1.7.11 Mechanics ........................................................................................... 1-113
1.7.11.1 Cabinets ........................................................................ 1-113
1.7.11.2 Subrack ......................................................................... 1-116
1.7.11.3 Processor Module and Submodules ............................. 1-117
1.8 User Interface ....................................................................................................... 1-118
Chapter 2 - Installation
2.1 Site Planning Environment ...................................................................................... 2-1
2.1.1 Site Selection and Building Requirements.............................................. 2-1
2.1.2 Environmental Considerations ................................................................ 2-2
2.1.3 Electromagnetic Compatibility ............................................................... 2-3
2.1.3.1 Summary of CE-marking Aspects.................................... 2-4
2.1.4 Standard Layout and Disposition of Cabinets......................................... 2-5
2.1.5 Grounding ............................................................................................... 2-5
2.1.6 Cables ...................................................................................................... 2-7
2.1.7 Power Supply and Fusing........................................................................ 2-7
2.1.8 Process Connection ................................................................................. 2-9
2.1.8.1 Connection Principles, Fusing and Voltage Distribution . 2-9
2.1.9 Hazardous Applications ........................................................................ 2-11
2.1.10 High Voltage Switch-gear Applications................................................ 2-11
2.1.11 Lightning Stroke Protection .................................................................. 2-11
2.1.12 Weight and Mounting Dimensions........................................................ 2-11
2.1.13 Transportation and Storing.................................................................... 2-13
2.2 Setup....................................................................................................................... 2-13
2.2.1 Safety Regulations ................................................................................ 2-14
2.2.1.1 Personnel and Process Safety ......................................... 2-14
2.2.1.2 Machine Safety............................................................... 2-15
2.2.2 Unpacking and Storing.......................................................................... 2-16
2.2.3 Location................................................................................................. 2-16
2.2.4 Arrange the Cabinets............................................................................. 2-16
2.2.5 Grounding ............................................................................................. 2-17
2.2.5.1 General ........................................................................... 2-17
2.2.5.2 Protective Earth .............................................................. 2-17
2.2.5.3 Earth Line ....................................................................... 2-17
2.2.5.4 Grounding of Process Cable Shields .............................. 2-17
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2.2.5.5 Grounding of Communication Cable Shields ................ 2-19
2.2.5.6 Grounding of “Internal” System Cable Shields,
Connection Unit -- I/O Board ........................................ 2-22
2.2.5.7 Grounding of Process Signals ........................................ 2-23
2.2.5.8 Grounding of Additional Equipment ............................. 2-24
2.2.5.9 Spare Conductors ........................................................... 2-24
2.2.6 Cable Routing in Cabinets .................................................................... 2-24
2.2.7 Power Supply Connection .................................................................... 2-26
2.2.7.1 General ........................................................................... 2-26
2.2.7.2 Installation...................................................................... 2-26
2.2.7.3 Heating Element............................................................. 2-27
2.2.7.4 Preparation for Start-up.................................................. 2-27
2.2.8 Controller .............................................................................................. 2-28
2.2.9 S100 I/O................................................................................................ 2-30
2.2.10 S800 I/O and S400 I/O.......................................................................... 2-33
2.2.11 Peripheral Units .................................................................................... 2-33
2.2.11.1 Printer............................................................................. 2-35
2.2.12 Communication..................................................................................... 2-37
2.2.13 Engineering Station............................................................................... 2-38
2.2.14 Checklists.............................................................................................. 2-38
2.2.14.1 Grounding Philosophy, Earthing Line System............... 2-38
2.2.14.2 Process Cabling, Shielding, Grounding,
Maximum Length........................................................... 2-39
2.2.14.3 Supply ............................................................................ 2-40
2.2.14.4 Lightning Protection ...................................................... 2-40
2.2.14.5 Subrack, Connection Unit, Circuit Board ...................... 2-41
2.2.14.6 Cabinets, Internal Cables ............................................... 2-42
2.2.14.7 External Cables .............................................................. 2-42
2.2.14.8 Communication, Communication Cables ...................... 2-43
2.2.14.9 Miscellaneous................................................................. 2-44
2.2.15 Final Procedures Before Start-up.......................................................... 2-44
2.3 Shut-down Procedures ........................................................................................... 2-44
2.3.2 Controller and I/O................................................................................. 2-45
2.3.3 Peripheral Equipment ........................................................................... 2-47
2.4 Start-up Procedures................................................................................................ 2-47
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2.4.2 Controller and I/O ................................................................................. 2-48
2.4.2.1 Power-up......................................................................... 2-48
2.4.2.2 Initialization.................................................................... 2-50
2.4.2.3 Connection of Engineering Station ................................ 2-50
2.4.2.4 Controller System Configuration ................................... 2-51
2.4.2.5 Configuration/Application Building............................... 2-57
2.4.2.6 Dumping and Loading.................................................... 2-57
2.4.2.7 Summary of the Controller Start-up and
Verification of the Start .................................................. 2-58
2.4.2.8 Installation of Battery for Backup of Memory ............... 2-60
2.4.3 Peripheral Equipment............................................................................ 2-60
2.4.3.1 Printer ............................................................................. 2-60
2.5 Product Verification ............................................................................................... 2-62
2.5.2 Servicing Tool ....................................................................................... 2-62
2.5.3 Commissioning ..................................................................................... 2-63
2.5.3.1 General ........................................................................... 2-63
2.5.3.2 Procedure........................................................................ 2-63
2.5.3.3 Modify Permission ......................................................... 2-63
2.5.3.4 Blocking and Deblocking of the PC Program ................ 2-64
2.5.3.5 List of some Test Facilities provided by the
Engineering Station ........................................................ 2-64
2.5.3.6 Tuning of Feedback Control Loops................................ 2-66
2.5.3.7 Use of PC Programming During Operation when
Commissioning............................................................... 2-66
2.5.3.8 Listing of Executing Unit Status .................................... 2-66
2.5.3.9 Check of Process Input/Output System.......................... 2-66
2.5.3.10 Listing of PC Program and Data Base............................ 2-70
2.5.4 Final Control ......................................................................................... 2-72
2.6 Implementation of Functions in Systems Already Operating ................................ 2-72
2.6.1 Servicing Tool ....................................................................................... 2-73
2.6.3 General Guidelines................................................................................ 2-73
2.6.4 Additional I/O Boards ........................................................................... 2-75
2.6.5 Enlargement of the System Software .................................................... 2-79
2.6.6 Power-up Ahead of Program Loading .................................................. 2-81
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Chapter 3 - Configuration/Application Building
3.1 Design Considerations ............................................................................................. 3-1
3.1.1 Product Structure .................................................................................... 3-1
3.1.2 General System Utilities ......................................................................... 3-1
3.1.2.1 System Clock ................................................................... 3-2
3.1.2.2 Run/Alarm Relay ............................................................. 3-2
3.1.2.3 Additional Supervisory Inputs ......................................... 3-3
3.1.2.4 Backup of Application Program ...................................... 3-3
3.1.3 Free-Programmable Module ................................................................... 3-4
3.1.4 Power Supply.......................................................................................... 3-4
3.1.5 Process Interface ..................................................................................... 3-8
3.1.5.1 S100 I/O System .............................................................3-11
3.1.5.2 S400 I/O System ............................................................ 3-17
3.1.5.3 S800 I/O System ............................................................ 3-18
3.1.6 Communication..................................................................................... 3-18
3.1.6.1 Provided Link Types ...................................................... 3-18
3.1.7 Process Control ..................................................................................... 3-23
3.1.7.1 Application Building with AMPL.................................. 3-24
3.1.8 Operator’s Interface .............................................................................. 3-25
3.1.8.1 Local Operator ............................................................... 3-25
3.1.8.2 Central Operator............................................................. 3-25
3.1.9 Availability and Security ...................................................................... 3-26
3.1.9.1 Redundancy.................................................................... 3-27
3.1.10 Mechanics ............................................................................................. 3-27
3.1.11 Heat Dissipation.................................................................................... 3-28
3.1.11.1 Cabinet Ventilation......................................................... 3-28
3.1.11.2 Heat Dissipation Permitted in Cabinets ......................... 3-28
3.1.11.3 Cabinets in Groups......................................................... 3-29
3.1.11.4 Calculation of Heat Generated in a Cabinet................... 3-29
3.1.12 Maintenance and Repair ....................................................................... 3-30
3.1.13 Expansion Possibilities and Spare Considerations ............................... 3-30
3.1.14 Memory Calculation ............................................................................. 3-31
3.1.15 CPU-optimization, Load Calculation ................................................... 3-34
3.2 Technical Data Including Capacity & Performance .............................................. 3-39
3.2.1 General System Utilities ....................................................................... 3-39
3.2.1.1 CPU ................................................................................ 3-39
3.2.1.2 Memory .......................................................................... 3-53
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3.2.1.3 System Clock.................................................................. 3-53
3.2.1.4 Free-Programmable Module........................................... 3-54
3.2.2 Power Supply ........................................................................................ 3-54
3.2.3 Process Interface ................................................................................... 3-55
3.2.3.1 S100 I/O ......................................................................... 3-57
3.2.3.2 S400 I/O ......................................................................... 3-58
3.2.3.3 S800 I/O ......................................................................... 3-58
3.2.4 Communication ..................................................................................... 3-59
3.2.4.1 Provided Link Types....................................................... 3-59
3.2.5 Process Control ..................................................................................... 3-60
3.2.5.1 Logging .......................................................................... 3-62
3.2.6 Operator’s Interface .............................................................................. 3-62
3.2.6.1 Local Operator Station ................................................... 3-62
3.2.6.2 Central Operator Station................................................. 3-62
3.2.6.3 Printer ............................................................................. 3-62
3.2.7 Availability ............................................................................................ 3-64
3.2.8 Mechanics ............................................................................................. 3-64
3.3 Application Start-up ............................................................................................... 3-65
3.4 Tutorial ................................................................................................................... 3-65
3.4.1 Introduction to the Design..................................................................... 3-65
3.4.2 Design Procedures................................................................................. 3-66
3.4.2.1 System Definition........................................................... 3-67
3.4.2.2 Configuration/Application Building............................... 3-67
3.5 Application Procedures .......................................................................................... 3-70
3.6 Configuration/Application Building Menus .......................................................... 3-70
Chapter 4 - Runtime Operation

4.1 Product Operation .................................................................................................... 4-1
4.1.1 Working Modes ....................................................................................... 4-1
4.1.2 Ordering Working Modes........................................................................ 4-1
4.1.3 Start Modes ............................................................................................. 4-2
4.1.4 Primary and Backup Processor Module.................................................. 4-2
4.1.5 Relations between Start Modes and Working Modes ............................. 4-3
4.1.5.1 First Power-up .................................................................. 4-3
4.1.5.2 Power-up and Initialization of Controller which Contains
Application ....................................................................... 4-4
4.1.6 Relations between Engineering Station Commands and Working
Modes ...................................................................................................... 4-5
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4.1.6.1 DICONFIG....................................................................... 4-6
4.1.6.2 ECONFIG ........................................................................ 4-7
4.1.6.3 RECONFIG...................................................................... 4-8
4.1.7 Programmed Start ................................................................................... 4-9
4.1.8 System Program.................................................................................... 4-13
4.1.8.1 Operating System ........................................................... 4-15
4.1.8.2 Process Communication................................................. 4-15
4.1.8.3 Diagnostics for the System Program.............................. 4-16
4.1.9 Application Program............................................................................. 4-16
4.1.9.1 Data Base ....................................................................... 4-17
4.1.9.2 Data Area for PC Programs ........................................... 4-17
4.1.9.3 PC Program .................................................................... 4-17
4.1.10 Execution .............................................................................................. 4-19
4.1.10.1 Interpreter....................................................................... 4-19
4.1.10.2 Execution Sequence within an Execution Unit.............. 4-20
4.1.10.3 Sequence of Execution of Execution Units.................... 4-20
4.1.10.4 Execution Sequence for an Individual PC Element ....... 4-21
4.1.10.5 Execution Sequence of PC Elements ............................. 4-22
4.1.10.6 Resetting Execution ....................................................... 4-22
4.1.10.7 Scanning of Process Inputs ............................................ 4-23
4.1.11 Data Transport ...................................................................................... 4-23
4.1.11.1 Reading-in Phase............................................................ 4-23
4.1.11.2 Reading-out Phase.......................................................... 4-24
4.1.11.3 Data Transport between Execution Units....................... 4-25
4.1.12 Initialization of Process Communication.............................................. 4-26
4.1.13 Diagnostics............................................................................................ 4-27
4.2 Operating Overview............................................................................................... 4-27
4.3 Runtime Tutorial.................................................................................................... 4-27
4.4 Operating Instructions............................................................................................ 4-27
4.5 Runtime Operation Menus..................................................................................... 4-27
Chapter 5 - Maintenance
5.1 Preventive Maintenance........................................................................................... 5-1
5.1.1 Safety Regulations .................................................................................. 5-1
5.1.1.1 Personnel and Process Safety........................................... 5-1
5.1.1.2 Machine Safety ................................................................ 5-2
5.1.2 Visual Inspection..................................................................................... 5-3
5.1.3 Safety ...................................................................................................... 5-3
5.1.4 Cleanliness .............................................................................................. 5-3
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5.1.5 Air Filter.................................................................................................. 5-3
5.1.6 Backup Batteries ..................................................................................... 5-3
5.1.7 Forced Cooling........................................................................................ 5-3
5.2 Hardware Indicators ................................................................................................. 5-3
5.3 Error Messages......................................................................................................... 5-4
5.3.1 Halt Codes............................................................................................... 5-4
5.3.1.1 Reading of Halt Codes ..................................................... 5-4
5.3.2 System Messages .................................................................................... 5-4
5.3.2.1 Reading of System Messages ........................................... 5-5
5.4 Fault Finding and User Repair ................................................................................. 5-5
5.4.1 Introduction ............................................................................................. 5-6
5.4.2 Diagnostics and Fault Announcement .................................................... 5-6
5.4.2.1 System Status and Plain Language System Messages ..... 5-8
5.4.3 Fault Finding Principles ........................................................................ 5-27
5.4.4 Fault Classification................................................................................ 5-30
5.4.5 Test Equipment...................................................................................... 5-30
5.4.7 On-line/Off-line Aspects ....................................................................... 5-31
5.4.8 Connection of Engineering Station ....................................................... 5-32
5.4.9 List of General Fault Finding Procedures and Hints............................. 5-32
5.4.9.1 Location of Malfunction................................................. 5-32
5.4.9.2 External Factors.............................................................. 5-32
5.4.9.3 Safety at Start/Stop ......................................................... 5-33
5.4.9.4 Manual Changeover between Redundant
Processor Modules ......................................................... 5-33
5.4.9.5 Check of Power Supply .................................................. 5-33
5.4.9.6 Check of Backup Power Supply..................................... 5-38
5.4.9.7 Check of Processor Module............................................ 5-39
5.4.9.8 Check of Process I/O ...................................................... 5-40
5.4.9.9 Fault Finding by Reducing the System .......................... 5-41
5.4.10 User Repair............................................................................................ 5-42
5.4.10.1 Board and Subrack Mounted Unit Exchange ................. 5-42
5.4.10.2 Replacement of Redundant Processor Module............... 5-54
5.4.10.3 Replacement of Power Supply Unit ............................... 5-54
5.4.10.4 Replacement of 5 V Regulator ....................................... 5-55
5.4.10.5 Replacement of Backup Power Supply .......................... 5-56
5.4.10.6 Battery Exchange............................................................ 5-57
5.4.10.7 Replacement of Connection Unit ................................... 5-57
5.4.10.8 Replacement of Modem ................................................. 5-58
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5.4.11 Adjustment of Analog Input and Output Boards .................................. 5-58
5.4.11.1 Channel Adjustment on DSAI 130 ................................ 5-60
5.4.11.2 Adjustment of A/D Converter........................................ 5-61
5.4.12 Channel Adjustment on AO Board....................................................... 5-63
5.4.12.1 Adjustment of Zero Point, Channel by Channel ............ 5-65
5.4.12.2 Adjustment of the Gain, Channel by Channel ............... 5-65
5.4.12.3 Adjustment of Variable Gain, Channel by Channel ....... 5-66
5.4.12.4 Adjustment of “Limit Low” L1 and “Limit High” L2,
Channel by Channel ....................................................... 5-66
5.4.13 Isolation Amplifier................................................................................ 5-66
5.4.14 Adjustment of Reference Voltage. ........................................................ 5-66
5.4.15 System Restart following Maintenance Activities................................ 5-66
5.4.16 System Restart, INIT ............................................................................ 5-67
5.4.17 Loading of Application Program .......................................................... 5-68
5.5 CPU Load Measurement........................................................................................ 5-69
5.6 Backup ................................................................................................................... 5-70
5.6.1 Backup of System ................................................................................. 5-70
5.6.2 Backup of Application .......................................................................... 5-70
5.7 System Upgrade..................................................................................................... 5-71
Appendix A - Hardware Modules

A.1 List of Hardware Modules .......................................................................................A-1
A.2 CI531 - RS-232-C Communication Interface..........................................................A-6
A.3 DSSB 170 - Energy Reservoir .................................................................................A-8
A.4 MB510 - Program Card Interface ..........................................................................A-10
A.5 PM150V - Processor Module ................................................................................A-12
A.6 RB520 - Dummy Module ......................................................................................A-14
A.7 RF540, RF541 - Modem Subrack..........................................................................A-15
A.8 SA1xx - Power Supply Units.................................................................................A-17
A.9 SB171 - Backup Power Supply .............................................................................A-20
A.10 SB522 - Battery Unit .............................................................................................A-24
A.11 SD150 - d.c./d.c. Converter ...................................................................................A-26
A.12 Power Switch and Distribution Units ....................................................................A-28
A.13 SX554 - Distribution Unit 60 V d.c.......................................................................A-34
Appendix B - RM500 Cabinet - Data Sheet

B.1 RM500 Cabinets - General ......................................................................................B-1
B.2 Dimensions and Weight ...........................................................................................B-2
B.3 Mounting Cabinets together.....................................................................................B-4
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B.4 Mounting Cabinets to the Floor .............................................................................. B-4
B.5 Protection Rating..................................................................................................... B-5
B.6 Permitted Power Dissipation................................................................................... B-6
Appendix C - Delivery Documentation

C.1 Delivery Binder Content ......................................................................................... C-1
Appendix D - Item Designations

D.1 General .................................................................................................................... D-1
D.2 Cabinet .................................................................................................................... D-1
D.3 Controller Subracks................................................................................................. D-3
D.4 I/O Subracks............................................................................................................ D-5
D.5 Modem Subracks..................................................................................................... D-6
D.6 Circuit Boards and Units......................................................................................... D-7
D.7 Mains Units ............................................................................................................. D-9
D.8 Examples of Item Designation in Cabinets........................................................... D-10
Appendix E - Current Consumption and Heat Dissipation

E.1 General .....................................................................................................................E-1
E.2 Calculation Algorithms and Forms with Technical Data .........................................E-1
Appendix F - Load Calculation

F.1 Load Calculation Forms...........................................................................................F-1
Appendix G - Memory Calculation

G.1 Form for Memory Calculation ................................................................................ G-1
Appendix H - Product Variants

H.1 Compact Version of Advant Controller 410............................................................ H-1
Appendix I - Halt Codes

I.1 Example of Halt Code Printout .................................................................................I-1
I.2 List of Halt Codes and Corrective Actions ...............................................................I-2
Appendix J - System Messages

J.1 Message Coding ....................................................................................................... J-1
J.2 Message Types ......................................................................................................... J-2
J.3 List of System Messages and Corrective Actions.................................................... J-3
Appendix K - Hexadecimal to Decimal Representation

K.1 Conversion Guide.................................................................................................... K-1
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ILLUSTRATIONS
Figure 1-1. Example of Advanced Control System with Advant Controller 410 ........... 1-1
Figure 1-2. Basic Documentation Structure.................................................................... 1-2
Figure 1-3. Front View of Cabinet RM500 for Advant Controller 410 ........................ 1-15
Figure 1-4. Advant Controller 410, Example of Physical Appearance......................... 1-16
Figure 1-5. Example of PC Element (AND, TON, SHIFT) .......................................... 1-17
Figure 1-6. Example of Version Designation with Compatibility Codes for
Basic Software............................................................................................ 1-18
Figure 1-7. Example of Advant Controller 410 Hardware Configuration incl.
S100 Process I/O ........................................................................................ 1-20
Figure 1-8. Advant Controller 410 Block Diagram ...................................................... 1-21
Figure 1-9. Advant Controller 410 Functional Interfaces ............................................. 1-22
Figure 1-10. Location of System Program Backup......................................................... 1-25
Figure 1-11. Implementation of a Free-Programmed Function ...................................... 1-35
Figure 1-12. Principle of Power Supply of an Advant Controller 410
(a.c. mains supply)...................................................................................... 1-37
Figure 1-13. Principle of Redundant Power Supply of an Advant Controller 410
(a.c. mains supply)...................................................................................... 1-38
Figure 1-14. Voltage Regulation in I/O Subrack with Advant Controller 410 ............... 1-41
Figure 1-15. Redundant Voltage Regulation in I/O Subrack with Advant Controller 4101-41
Figure 1-16. Input and Output Signal Paths (in principle).............................................. 1-45
Figure 1-17. Input and Output Signal Paths (in principle).............................................. 1-46
Figure 1-18. Example of Connection Unit for S100 I/O in RM500 Cabinet .................. 1-47
Figure 1-19. Application of Object Oriented Connection of S100 I/O........................... 1-48
Figure 1-20. Principle of HART Implementation ........................................................... 1-50
Figure 1-21. Principle of HART implementation using S800 I/O .................................. 1-51
Figure 1-22. Digital Input Signal, Block Diagram.......................................................... 1-53
Figure 1-23. Digital Output Signal, Block Diagram ....................................................... 1-54
Figure 1-24. Analog Input Signal, Block Diagram ......................................................... 1-58
Figure 1-25. Analog Input/Output Signal with Redundancy, Block Diagram ................ 1-59
Figure 1-26. Analog Output Signal, Block Diagram ...................................................... 1-62
Figure 1-27. Pulse Counter Input Signal DSDP 110, Block Diagram ............................ 1-63
Figure 1-28. Pulse Counter Input Signal DSDP 150, Block Diagram ............................ 1-63
Figure 1-29. Example of basic I/O Unit, DSDX 452 - 20 Inputs and 12 Outputs .......... 1-65
Figure 1-30. S800 I/O Fieldbus Communication Interface with an I/O-Module on
Compact and Extended MTUs and an S800L Module............................... 1-68
Figure 1-31. Example of Physical Configuration of Non-redundant MasterFieldbus
and S400 I/O Units ..................................................................................... 1-80
Figure 1-32. A non-redundant Advant Fieldbus 100 Configuration using
Coaxial Media ............................................................................................ 1-81
3BSE 002 414R601 Rev B xi

Table of Contents
ILLUSTRATIONS (continued)
Figure 1-33. A redundant Advant Fieldbus 100 Configuration using
Twisted pair Media ..................................................................................... 1-82
Figure 1-34. Media Conversion in Advant Fieldbus 100 ................................................ 1-82
Figure 1-35. PROFIBUS-DP configuration example...................................................... 1-83
Figure 1-36. LONWORKS network configuration example........................................... 1-84
Figure 1-37. Alternative Connections of an External Computer to Advant Controllers. 1-85
Figure 1-38. Example of Automatic AMPL Document Printout .................................... 1-90
Figure 1-39. Process Objects Implemented as User Defined PC Elements .................... 1-91
Figure 1-40. Simple Control Function Realized in AMPL ............................................. 1-92
Figure 1-41. Principle of a Functional Unit Application................................................. 1-93
Figure 1-42. Example of Simple Report.......................................................................... 1-96
Figure 1-43. AC 400 configuration with drives .............................................................. 1-99
Figure 1-44. VT100 Terminal and Keyboard for MasterView 320 ............................... 1-102
Figure 1-45. Communication, Operator Station-Controller-Process............................. 1-104
Figure 1-46. Arrangement of Redundant I/O Modules ................................................. 1-112
Figure 1-47. Cabinet, type RM500................................................................................ 1-113
Figure 1-48. Typical Cabinet Configuration, Redundant Power Supply....................... 1-115
Figure 1-49. Front of I/O Subrack with a Processor Module PM150
at the Position 1-6 ..................................................................................... 1-116
Figure 1-50. I/O Subrack Configuration........................................................................ 1-117
Figure 1-51. Processor Module and Submodule Mechanics ......................................... 1-118
Figure 2-1. Standard Cabinet Configuration (maximum) ............................................... 2-5
Figure 2-2. Grounding of Electronic Equipment............................................................. 2-6
Figure 2-3. Connections with Multi-Core Cable and Coupling Boxes ......................... 2-10
Figure 2-4. Minimum Distance to the Walls and the Ceiling ........................................ 2-12
Figure 2-5. Warning Label regarding ESD.................................................................... 2-15
Figure 2-6. Handling of Process I/O Cable Shields in a CE-marked Cabinet............... 2-18
Figure 2-7. Handling of Cable Shields in a not CE-marked Cabinet ............................ 2-19
Figure 2-8. Principles of Grounding of Communication Cable Shields
in a CE-marked Design............................................................................... 2-20
Figure 2-9. Communication Cable Shield Grounded by Capacitor and Ferrite Coil .... 2-21
Figure 2-10. Grounding of Cable Shield, Connection Unit - I/O Board ......................... 2-22
Figure 2-11. Individual Grounding of Process Signal..................................................... 2-24
Figure 2-12. Assigned Space for Cables in a Cabinet ..................................................... 2-25
Figure 2-13. Main Principle of Power Supply Connection and Distribution .................. 2-26
Figure 2-14. Connection of Run/Alarm Relay ................................................................ 2-28
Figure 2-15. Connection of External Clock Synchronization ......................................... 2-29
Figure 2-16. Connection of Additional Supervisory Inputs ............................................ 2-29
Figure 2-17. Supply of Peripheral Unit without Modem................................................. 2-34
xii 3BSE 002 414R601 Rev B

Table of Contents
Figure 2-18. Short-Distance Connection of Printer ........................................................ 2-35
Figure 2-19. Long-Distance Connection of Printer......................................................... 2-36
Figure 2-20. Connections and Grounding of Communication Cable Shields................. 2-36
Figure 2-21. Power-up, Circuit Breakers and Positive Indications................................. 2-50
Figure 2-22. Controller System Configuration in a Broad Outline................................. 2-51
Figure 2-23. “Modify Permission” in a Control Module ................................................ 2-63
Figure 2-24. Principal Block Diagram of S100 I/O Input Channel, Test Points............. 2-67
Figure 2-25. Principal Block Diagram of S100 I/O Output Channel, Test Points .......... 2-69
Figure 2-26. Graphic Diagram ........................................................................................ 2-71
Figure 2-27. Program List ............................................................................................... 2-71
Figure 2-28. Grounding of Connection Units ................................................................. 2-77
Figure 2-29. I/O Subrack................................................................................................. 2-77
Figure 3-1. External Synchronization of System Clock.................................................. 3-2
Figure 3-2. Run/Alarm Relay Connection ...................................................................... 3-2
Figure 3-3. Connection of Additional Supervisory Inputs.............................................. 3-3
Figure 3-4. Examples of Distribution Board Fusing, d.c. ............................................... 3-7
Figure 3-5. Reduction Factors for Cabinets Installed in Groups................................... 3-29
Figure 3-6. Advant Controller 410 Priority System...................................................... 3-35
Figure 3-7. CPU Load Calculation Methods................................................................. 3-37
Figure 3-8. Load from Cyclic Functions, Overview ..................................................... 3-40
Figure 3-9. Load Caused by Subscription..................................................................... 3-45
Figure 3-10. Load Caused by Sending Data Set ............................................................. 3-46
Figure 3-11. Load Caused by Receiving Data Set .......................................................... 3-47
Figure 3-12. Load Caused by a MasterView 320............................................................ 3-47
Figure 3-13. Load Caused by a Log (Short Intervals)..................................................... 3-48
Figure 3-14. Load Caused by a Log (Medium Intervals)................................................ 3-49
Figure 3-15. Load caused by DSP with Advant Fieldbus 100, basic cycle time 32 ms.. 3-50
Figure 3-16. Load caused by DSP with Advant Fieldbus 100, basic cycle time 512 ms 3-50
Figure 3-17. Load Caused by EXCOM, 1200 bit per seconds........................................ 3-51
Figure 3-18. Load Caused by EXCOM, 9600 bit per seconds........................................ 3-52
Figure 3-19. Load Caused by EXCOM, 19200 bit per seconds...................................... 3-52
Figure 3-20. Structuring Limits....................................................................................... 3-61
Figure 3-21. S100 I/O Subrack, Slot Disposition............................................................ 3-65
Figure 3-22. Example of Designations in a Feedback Control Loop.............................. 3-69
Figure 4-1. Start Mode Selector ...................................................................................... 4-2
Figure 4-2. First Power-up .............................................................................................. 4-3
Figure 4-3. Power-up of Controller which Contains Application ................................... 4-4
Figure 4-4. Working Mode Caused by DICONFIG ........................................................ 4-6
3BSE 002 414R601 Rev B xiii

Table of Contents
Figure 4-5. Working Mode Caused by ECONFIG .......................................................... 4-7
Figure 4-6. Working Mode Caused by RECONFIG ....................................................... 4-8
Figure 4-7. Programmed Start at Power-fail - Power-up............................................... 4-10
Figure 4-8. Programmed Start at AUTO - ENTER ....................................................... 4-11
Figure 4-9. Programmed Start at DICONFIG ............................................................... 4-12
Figure 4-10. Advant Controller 410 - Survey of Software System ................................. 4-14
Figure 4-11. Survey of Processor Module and Operating System .................................. 4-15
Figure 4-12. Example of PC Element: FUNG-1V .......................................................... 4-18
Figure 4-13. Example of Function Performed by FUNG-1V.......................................... 4-18
Figure 4-14. Interpreters .................................................................................................. 4-19
Figure 4-15. Function consisting of Two Execution Units.............................................. 4-20
Figure 4-16. Order of Execution for PC Elements, AND Gate with two Inputs............. 4-21
Figure 4-17. Printout from the Command LTREE .......................................................... 4-22
Figure 4-18. Example of Reading-in Phase..................................................................... 4-23
Figure 4-19. Example, Reading-out Phase ...................................................................... 4-24
Figure 4-20. Data Transport ............................................................................................ 4-25
Figure 5-1. Warning Label regarding ESD...................................................................... 5-2
Figure 5-2. System Status Display, Advant Controller 400 applied to
Advant Controller 410 .................................................................................. 5-8
Figure 5-3. System Status Display, S100 I/O 1 ............................................................. 5-16
Figure 5-4. System Status Display, S100 I/O 2 ............................................................. 5-17
Figure 5-5. System Status Display, S100 I/O Redundant board.................................... 5-18
Figure 5-6. System Status Display, Fieldbus................................................................. 5-19
Figure 5-9. System Status Display, Advant Fieldbus 100 Bus Unit.............................. 5-22
Figure 5-10. System Status Display, MasterFieldbus...................................................... 5-23
Figure 5-11. System Status Display, S800 I/O Station.................................................... 5-24
Figure 5-12. System Status Display, S800 I/O Station.................................................... 5-26
Figure 5-13. Fault Finding Principles.............................................................................. 5-28
Figure 5-14. Fault Finding, Single a.c. Mains Supply..................................................... 5-35
Figure 5-15. Fault Finding, Redundant a.c. Mains Supply.............................................. 5-36
Figure 5-16. Fault Finding, Mains Supply and 24 V Power Supply ............................... 5-37
Figure 5-17. Check of Backup Power Supply ................................................................. 5-38
Figure 5-18. Connections for Channel by Channel Adjustment of DSAI 130................ 5-60
Figure 5-19. Adjustment of Voltage Output .................................................................... 5-64
Figure 5-20. Adjustment of Current Output .................................................................... 5-64
Figure B-1. RM500 Cabinet - Front View ...................................................................... B-1
xiv 3BSE 002 414R601 Rev B

Table of Contents
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. Position of the Holes for fixing the Cabinet(s) to the Floor .........................B-4
Figure D-1. Item Designation of Mounting Planes..........................................................D-1
Figure D-2. Cabinet with Door Removed ........................................................................D-2
Figure D-3. Item Designation in Controller Subrack 12 SU............................................D-3
Figure D-4. Item Designation in Controller Subrack 18SU.............................................D-4
Figure D-5. Addresses in Controller Subrack 12 SU.......................................................D-4
Figure D-6. Item Designation in I/O Subrack..................................................................D-5
Figure D-7. Item Designation in Modem Subrack, 19 inches..........................................D-6
Figure D-8. Item Designation in Modem Subrack, 24 inches..........................................D-6
Figure D-9. Modem Mounted on a Bracket .....................................................................D-6
Figure D-10. Numbering of Submodules and Connectors on the Front ............................D-7
Figure D-11. Numbering of Connectors on the Rear Side.................................................D-7
Figure D-12. Connection Units, Connection and Terminal Numbering ............................D-8
Figure D-13. Location of Connection Units on a Mounting Bar .......................................D-8
Figure D-14. Typical Internal Connection .........................................................................D-9
Figure D-15. Terminal Block Numbering ..........................................................................D-9
Figure D-16. Location of Mains Units...............................................................................D-9
Figure D-17. Example of general Disposition of a Double Cabinet ................................D-10
Figure I-1. Example of LSYSHI Printout........................................................................ I-1
TABLES
Table 1-1. Related Documentation - Configuration/Application Building ................... 1-6
Table 1-2. Related Documentation - Installation........................................................... 1-7
Table 1-3. Related Documentation - Optional Functions .............................................. 1-7
Table 1-4. Related Documentation - Tools .................................................................... 1-9
Table 1-5. PC Elements in the Basic System Program Module QC01-BAS11 ........... 1-27
Table 1-6. Functional Units in Program Module QC01-BAS11 ................................. 1-29
Table 1-7. Additional PC Elements in Program Module QC01-LIB11....................... 1-30
Table 1-8. Additional PC Elements in Program Module QC01-LIB12....................... 1-31
Table 1-9. Functional Units in Program Module QC01-LIB12................................... 1-31
Table 1-10. Modules Used in different Power Supply alternatives ............................... 1-39
Table 1-11. Selection Guide of Power Supply Modules................................................ 1-40
Table 1-12. Digital Input Boards ................................................................................... 1-52
Table 1-13. Digital Output Boards................................................................................. 1-54
Table 1-14. Analog Input Boards................................................................................... 1-56
3BSE 002 414R601 Rev B xv

Table of Contents
TABLES (continued)
Table 1-15. Analog Output Boards ................................................................................ 1-60
Table 1-16. Pulse Counting/Frequency Measurement Boards....................................... 1-62
Table 1-17. Positioning Board ....................................................................................... 1-64
Table 1-18. Converter Connection Board ...................................................................... 1-64
Table 1-19. S400 I/O Units ............................................................................................ 1-66
Table 1-20. Communication Interface Module .............................................................. 1-70
Table 1-21. S800 Digital Modules ................................................................................. 1-71
Table 1-22. S800 Analog Modules ................................................................................ 1-73
Table 1-23. Puls Counting / Freqency Measurement Modules...................................... 1-74
Table 1-24. S800 Module Termination Units................................................................. 1-75
Table 1-25. Power Supplies ........................................................................................... 1-77
Table 1-26. Modulebus Items......................................................................................... 1-78
Table 1-27. Communication Survey .............................................................................. 1-86
Table 2-1. Methods of Handling Communication Cable Shields ................................ 2-21
Table 2-2. Cable Categories in a Cabinet..................................................................... 2-25
Table 2-3. Functional Jumpering ................................................................................. 2-32
Table 2-4. Printer Settings............................................................................................ 2-37
Table 2-5. Grounding Philosophy, Earthing Line System ........................................... 2-38
Table 2-6. Process Cabling, Shielding, Grounding, max. Length................................ 2-39
Table 2-7. Supply ......................................................................................................... 2-40
Table 2-8. Lightning Protection ................................................................................... 2-40
Table 2-9. Subrack, Connection Unit, Circuit Board................................................... 2-41
Table 2-10. Cabinets, Internal Cables ............................................................................ 2-42
Table 2-11. Communication, Communication Cables ................................................... 2-43
Table 2-12. Miscellaneous ............................................................................................. 2-44
Table 2-13. Function List with an Outline of Controller System
Configuration Information.......................................................................... 2-52
Table 2-14. Dump and Load Facilities........................................................................... 2-57
Table 2-15. Situations which Cause Clearing of the RAM............................................ 2-58
Table 2-16. Printer Programmable Parameters .............................................................. 2-60
Table 2-17. Cycle Times for Advant Controller 410 ..................................................... 2-65
Table 2-18. Implementation of Functions in Systems Already Operating..................... 2-75
Table 3-1. Backup of Application Program, Hardware and Software ........................... 3-3
Table 3-2. Free-Programmable Module, Hardware and Software ................................. 3-4
Table 3-3. Distribution Board Fusing, a.c...................................................................... 3-6
Table 3-4. Distribution Board Fusing, d.c...................................................................... 3-6
Table 3-5. Requirement on UPS from Voltage Supply Unit SA162 .............................. 3-8
Table 3-6. Requirement on UPS from Voltage Supply Unit SA168 .............................. 3-8
xvi 3BSE 002 414R601 Rev B

Table of Contents
TABLES (continued)
Table 3-7. Link Types, Hardware and Software .......................................................... 3-18
Table 3-8. Applied Communication, Used Links and Interface to
Application Program .................................................................................. 3-21
Table 3-9. Calculation of RAM Requirement.............................................................. 3-32
Table 3-10. Technical Data of CPU and Memory ......................................................... 3-39
Table 3-11. Load from Process I/O Handling................................................................ 3-41
Table 3-12. Estimated Execution Times of Digital Signals........................................... 3-43
Table 3-13. Clock Synchronization, Electrical Data for Minute Pulse.......................... 3-54
Table 3-14. Estimated System Power Consumption...................................................... 3-54
Table 3-15. Size of Buffer for Event Burst.................................................................... 3-55
Table 3-16. Relative Time Errors between Events (DI Signals).................................... 3-56
Table 3-17. Capacity S100 I/O ...................................................................................... 3-57
Table 3-20. Provided Link Types, Capacity .................................................................. 3-59
Table 3-21. Key Data, Process Control ......................................................................... 3-60
Table 3-22. Data Logging Capabilities.......................................................................... 3-62
Table 3-23. Printer Data which must be fulfilled .......................................................... 3-63
Table 3-24. Printer Signals, RS-232-C .......................................................................... 3-63
Table 3-25. S100 I/O Subrack Dimensions ................................................................... 3-64
Table 5-1. Replacement Aspects of Individual Board Types (Controller Hardware).. 5-44
Table 5-2. Replacement Aspects of Individual Board Types (S100 I/O) .................... 5-48
Table 5-3. Adjustment Interval for Analog Input and Output Boards......................... 5-58
Table 5-4. Adjustment Possibilities on Analog Circuit Boards................................... 5-59
Table 5-5. Full Scale Voltages ..................................................................................... 5-65
Table A-1. List of Hardware Modules............................................................................A-1
Table A-2. Pin Designation for Channels 1 and 2. Connector X4 and X5.....................A-7
Table A-3. DSSB 170, Operating Data...........................................................................A-9
Table A-4. Pin Designation for Connector X6 and X17...............................................A-13
Table A-5. SA1xx, Individual Technical Data .............................................................A-18
Table A-6. Fuses in SA1xx...........................................................................................A-19
Table A-7. Electrical Data, Input/Output Signals Connector X2 .................................A-22
Table A-8. SD150, Operating Data ..............................................................................A-27
Table A-9. Individual Technical Data...........................................................................A-29
Table B-1. RM500 Cabinet Measurements ....................................................................B-2
Table B-2. Distances in Figure B-4 ................................................................................B-4
Table B-3. RM500 cabinet protection classes ................................................................B-5
Table B-4. Available Degree of Protection Ratings for RM500 ....................................B-5
3BSE 002 414R601 Rev B xvii

Table of Contents
TABLES (continued)
Table B-5. Permitted Power Dissipation for RM500..................................................... B-6
Table D-1. Designation of Items in Figure D-17 ......................................................... D-11
Table E-1. Current Consumption and Power Dissipation, Controller Modules .............E-2
Table E-2. Current Consumption and Power Dissipation, S100 I/O Boards..................E-3
Table E-3. Current Consumption and Power Dissipation, Power Supply and Sundry...E-4
Table F-1. Calculation of CPU-load from S100 and S800 Inputs..................................F-1
Table F-2. Calculation of CPU-load from S100 and S800 Outputs ...............................F-2
Table F-3. Calculation of CPU-load from User Defined Type Circuits.........................F-3
Table G-1. Calculation of RAM Requirement............................................................... G-1
Table I-1. List of Halt Codes ..........................................................................................I-2
Table J-1. System Message Coding............................................................................... J-1
Table J-2. System Message Types ................................................................................. J-2
Table J-3. Type 2, Code 46 ............................................................................................ J-3
Table J-4. Type 5, Code 21 ............................................................................................ J-3
Table J-5. Type 10, Code 19 .......................................................................................... J-4
Table J-6. Type 17, Code 1, 2, 3, 7, 8, 9 and 11 ............................................................ J-5
Table J-7. Type 18, Code 8 and 11 ................................................................................ J-9
Table J-8. Type 20, Code 1 .......................................................................................... J-10
Table J-9. Type 22, Code 9, 12, 13 and 20 ...................................................................J-11
Table J-10. Type 26, Code 12 ........................................................................................ J-13
Table J-11. List of Common Concept Numbers in System Messages........................... J-14
Table J-12. Type 28 ....................................................................................................... J-15
Table J-13. Type 29, Code 1,2, 3 and 4 ......................................................................... J-23
Table J-14. Type 30, Code 21, 23 .................................................................................. J-24
Table J-15. Type 39 ....................................................................................................... J-26
Table J-16. Type 134, Code ........................................................................................... J-28
Table K-1. Conversion of up to Four Figure Hexadecimal Numbers............................ K-2
xviii 3BSE 002 414R601 Rev B

Section 1.1 General Information
Chapter 1 Introduction
1.1 General Information

Advant OCS is a system for industrial automation. It consists of a family of computer-based
units and a local area network for communication.
A controller is a computer-based unit in which control applications are running.
Advant Station 500 Advant Station 500 Advant Station 500 Master Batch 200/1
IMS Station Operator Station Eng.Station Batch Station
Control Network
(MasterBus 300/300E)
Advant Station 100
Advant Controller 410 Advant Controller 450
Series
Controller Controller Eng. Station
Field Communication
S100 Process I/O
RCOM
Advant Controller 110
Remote Process I/O
S400 I/O Controller
S800 I/O
Remote Terminal Process I/O
Process I/O
Figure 1-1. Example of Advanced Control System with Advant Controller 410
Advant Controller 410 is a medium-sized controller for mixed binary, regulatory and
supervisory control. It can be used standing alone, or as an integrated controller in a distributed
control system, communicating with other Advant OCS equipment (see Figure 1-1).
This manual is intended primarily for plant designers and commissioning and maintenance
personnel, providing them with information about the Advant Controller 410 system,
its capabilities and its limitations.
References are made to other manuals when necessary. Section 1.2, Manual Organization
provides further details about both this manual and other related manuals.
3BSE 002 414R601 Rev B 1-1

1.2 Manual Organization
Basic Structure
Figure 1-2 shows the basic structure of the Advant System’s various documentation.
Each document, whether it is describing and referencing hardware or software, is built around
this one structure to make it easy for you to locate related information in any of the documents.
Since this one structure is not completely applicable to both hardware and software, certain
sections contain only very brief statements in some documents. Small divergences from the
standard structure are given in italics in Figure 1-2.
Chapter
Configuration/ Runtime
Introduction Installation Application Maintenance Appendices Index
Building Operation
General Site Planning Design Product Preventive

Information Environment Considerations Operation Maintenance
Manual Setup Technical Data Operating Hardware
Organization including Overview Indicators
Shut-down Capacity &
Conventions Procedures Performance
Start-up Application Runtime Error
Related Procedures Start-up Tutorial Messages
Documentation
Product Tutorial Operating Fault Finding
Release Verification Instructions & User Repair
History Section
Implementation Application Runtime System Backup
Terminology of Functions Procedures Operation
in Systems Menus
Product Already Configuration/ System Upgrade
Overview Operating Application
Building Menus
User Interface
Figure 1-2. Basic Documentation Structure
The substructure followed in the product description in Section 1.7, Product Overview is also
followed in other sections describing, for example, Design Considerations and Capacity &
Performance. This is done to make it easy for you to find the information you need about
different activities.
Because of the activity-oriented structure of the document, you may find information regarding
an actual function distributed to, for example Overview, Configuration, Operation, and so on.
Sometimes you can find device information gathered in the hardware descriptions in the
appendices.
1-2 3BSE 002 414R601 Rev B

Section 1.2 Manual Organization
Chapter 1, Introduction
(this chapter) provides introductory and background information, including:
• Guidelines on how you can find information in this manual.
• This manual’s relationship to other Advant Controller 410 documents.
• A glossary defining terms frequently used in this manual.
• A product and functional overview. Read this to get an idea of what
the Advant Controller 410 can do and how it works.
Chapter 2, Installation
guides you through various installation activities:
• Section 2.1, Site Planning Environment. This section contains guidelines for planning
installation of the product, outlining what you need to think about when you plan an
installation. It does not, however, provide the complete list of measures to take. You can
find descriptions of alternative solutions, design considerations elsewhere in this manual.
• Section 2.2, Setup. This section gives you concrete information on how to set up the
product. It includes safety regulations, handling and unpacking instructions, inspection
and assembly procedures, cable routing and connections, switch settings and jumper
positions, setup procedures, and so on. You can find common instructions as well as
instructions for specific subsystems in this section. Activities prior to power-up are also
described.
• Section 2.3, Shut-down Procedures. This section provides, in addition to some safety
regulations, basic shut-down procedures. You should know how to shut down the product
if there is a problem with initial power-up.
• Section 2.4, Start-up Procedures. In Section 2.2, Setup, the conditions and the preparation
necessary to begin are discussed. In Section 2.4, Start-up Procedures, you can find basic
power-up procedures, that is how to apply power to and initialize the system. Information
is also given on how you can verify a correct start. You can find information on activities
up to “ready for application program loading” in this section.
• Section 2.5, Product Verification. This section tells you how to make an initial
determination that the product is functional. This includes application program loading as
well as commissioning information.
• Section 2.6, Implementation of Functions in Systems Already Operating. This section
gives you the information you need to determine when, for example, to add an I/O board to
a running system. Important on-line, off-line aspects are discussed.
3BSE 002 414R601 Rev B 1-3

Chapter 3, Configuration/Application Building

gives you detailed information about how to obtain a desired function. The main information is
structured as follows:
• Section 3.1, Design Considerations. You can find design guidelines, including design
rules, in this section. Keywords include the following.
– Limitations
– Combinations of options
– Module assortment supported by the system product
– Location
– Necessary extra HW and SW needed with respect to desired functionality
– CPU load calculation
– Memory calculation.
• Section 3.2, Technical Data Including Capacity & Performance.
In this section, technical data of the following types, for example, are discussed:
– Maximum number of instances
– Dimensions
– CPU-load data
– Memory capacity.
• Section 3.4, Tutorial. This section provides you with a guide through the different phases
of a controller design project.
• Section 3.5, Application Procedures. Not applicable. For information from a configuration
viewpoint, how to achieve an application function, see the appropriate individual manuals.
In this manual, Chapter 2, Installation treats the subject of concrete setup work on site.
Chapter 4, Runtime Operation

addresses the controller’s different start modes and operating modes. The operator interface on
the processor module front is described.
In this chapter, you can also find a survey of the system software. Some important facilities that
you need to know during application work are described in greater detail.
Chapter 5, Maintenance
The preventive maintenance required for electronic equipment is not significant. This chapter
focuses on fault finding supported by built-in diagnostics. Various methods of fault
announcement are presented, including the use of system status in the central operator station
and LEDs on controller hardware units.
1-4 3BSE 002 414R601 Rev B

Section 1.3 Conventions
Appendices
A variety of information which does not fall into other categories within this manual’s structure
are included in the appendices. Examples are:
• Controller hardware descriptions
• Item designations in cabinets
• Description of delivery documentation
• Blanks for use during design work, for example calculation of heat dissipation.
Index
The Index offers you an easy and quick way to find answers to specific questions.
1.3 Conventions
Different versions of the processor module exist. In this User’s Guide the generic name PM150
is used all through the manual.
Advant OCS is used for Advant Open Control System, with Master software, throughout this
manual.
1.4 Related Documentation

This manual is the main document of the system product Advant Controller 410. Many of the
available options are briefly described in this manual. For additional detailed information about
options, see the appropriate individual manuals. Special subjects are also thoroughly treated in
separate documentation.
NOTE
The delivery binder, described in Appendix C, Delivery Documentation, includes
a document, Release Notes, which comprise the latest product information not
covered by the standard user documentation listed below. You may find, for
example, additionals, changes, limitations, alerts and so on.
The extensive list of related documentation is structured into four subject areas:
• Configuration/Application Building
• Installation
• Optional functions
• Tools.
3BSE 002 414R601 Rev B 1-5

Table 1-1. Related Documentation - Configuration/Application Building
Document Description
PC Elements AC 400 Series Data for all PC elements in AC 410/450.
Reference Manual
Data Base Elements Data for all data base elements in AC 410/450.
AC 400 Series
Reference Manual
AMPL Application Building Basic manual covering the use of the application pro-
gram language AMPL.
AMPL Configuration Instructions for the configuration and application pro-
AC 400 Series gramming of AC 410/450 systems using
Reference Manual Advant Station 100 Series ES. Commands for dis-
kette handling are described in the User’s Manual on
the tool concerned.
User Defined PC Elements Describes how to define your own library of PC ele-
ments.
Functional Units Part 1 An introduction to the concept of Functional Units in
Summary and Common Advant OCS with Master software.
Properties
Functional Units Part 2 Describes the functional units AI, AO, DI and DO.
AI, AO, DI, DO
Functional Units Part 3 Describes the functional units SEQ and GROUP.
SEQ, GROUP
Functional Units Part 4 Describes the functional units PIDCON, RATIOSTN
PIDCON, RATIOSTN, and MANSTN.
MANSTN
Functional Units Part 5 Describes the functional units GENCON, GENBIN,
GENCON GENBIN GENUSD and GENUSD.
Functional Units Part 6 Describes the functional units MOTCON
MOTCON, VALVECON and VALVECON.
Functional Units Part 8 Describes the functional unit DRICONS
DRICONS
Functional Units Part 9 Describes the functional unit DRICONE
DRICONE
Functional Units Part 10 Describes the functional unit MOTCONI
MOTCONI
Application Notes Application notes on measurement and control.
1-6 3BSE 002 414R601 Rev B

Section 1.4 Related Documentation
Table 1-2. Related Documentation - Installation
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, elec-
Design and applications tronic devices and systems with high immunity to
interference. It also deals with process adaptation,
communication and power supply with immunity to
interference.
Terminal Diagram Forms Complete set of diagrams on AC 410 covering all the
different I/O sets (boards, cables and terminals) as
well as the central unit and the power supply.
Table 1-3. Related Documentation - Optional Functions
S100 I/O Hardware Reference manual describing the S100 I/O hardware.
S800 I/O User’s Guide This is a complete manual on the S800 I/O system.
Contains technical descriptions, instructions for
installation, commissioning, fault tracing and techni-
cal data.
HART Protocol Interface User’s Guide describing how to include and use the
HART protocol with S100 I/O.
Intrinsic Safety Support User’s Guide describing how to include and use the
S100 I/O Intrinsic Safety System with S100 I/O.
EXCOM Contains a description of EXCOM, necessary hard-
ware and installation instruction.
EXCOM This manual describes how to install and use the
Programmer’s Reference EXCOM communication package in an external com-
Manual puter. It describes all available services and their
parameters. It also covers the subject of declaration
of necessary variables, data types, and so on.
MasterView 320 Complete manual for MV 320 containing descrip-
User’s Guide tions, operating instructions, linkages to PC pro-
grams, descriptions of error messages and a table of
ASCII codes.
3BSE 002 414R601 Rev B 1-7

Table 1-3. Related Documentation - Optional Functions (Continued)
MasterFieldbus and S400 I/O This is a complete manual on the S400 I/O system
and MasterFieldbus. Contains technical descrip-
tions, instructions for installation, commissioning,
fault tracing and technical data. This manual also
describes MasterPiece 51 as a distributed unit, that is
the engineering required in AC 410/450 and the pro-
gramming.
MasterNet Manual describes how to configure, install and main-
tain MasterNet communication networks,
MasterBus 300, MasterBus 300E and GCOM.
For information about ABB MasterGate communica-
tion stations, see the manuals concerned.
RCOM Contains technical descriptions, instructions for con-
AC 400 Series figuration, installation, start-up and fault tracing of
User’s Guide AC 410/450.
MultiVendor Interface Contains technical descriptions, instructions for con-
MODBUS with CI532V02 figuration, installation, start-up and fault tracing of
AC 400 Series User’s Guide Modbus in AC 410/450.
MODBUS with MVB + figuration, installation, start-up and fault tracing of
CI534V02 Modbus in AC 410/450.
AC 400 Series User’s Guide
Siemens 3964R figuration, installation, start-up and fault tracing of
AC 400 Series User’s Guide Siemens 3964(R) in AC 410/450.
Advant Fieldbus 100 Describes how to configure, install and maintain
communication using Advant Fieldbus 100.
Positioning System Complete manual on positioning in MasterPiece 200
User’s Manual (applicable to AC 410/450) containing technical
descriptions, instructions for engineering, installation,
programming, commissioning and maintenance.
The manual also takes up basic positioning theory,
information about pulse transmitters and technical
data on the function.
PROFIBUS-DP Advant Con- Describes the equipment and contains information
troller 400 Series User’s Guide required to install and commission the system.
1-8 3BSE 002 414R601 Rev B

Section 1.5 Release History
Table 1-4. Related Documentation - Tools
Advant Interface to Describes the equipment and contains information
LONWORKS User’s Guide. required to install and commission the system.
Advant Station 100 Series Contains a description of the basic functions, connec-
Engineering Station tion and start-up and how to work with the main func-
tions.
AdvaBuild On-Line Builder This reference manual describes all common com-
mands used in AS 100ES, AS 500ES and
AS 500OS.
AdvaBuild Function Chart Describes how to program an Advant Controller via
Builder Function Chart Builder.
Source Code Handling This manual contains descriptions of and instructions
for source code handling of PC programs and data
bases. It contains instructions for designing source
code, editing, loading and dumping and correcting
defective programs.
1.5 Release History

Advant Controller 400 Series is an evolutionary development of the process station
MasterPiece 200/1. New features have been added.
Two controller models are available:
• Advant Controller 410
• Advant Controller 450.
From a system viewpoint, the new controllers are fully compatible to their forerunners.
This means that you can include new controllers in an available control network, as well as
operate them from MasterView 800/1 and Advant Station 500 Series Operator Stations.
An Advant Controller can run old application programs (if the functional libraries coincide).
The version history from the very first version ∗1.0 is given below:
New highlights in the Advant Controller 410 ∗ 1.0, include:
• New controller hardware
• New type of cabinet, RE500
• Increased use of data base element for definition of the computer configuration
• One flash PROM module for standard system
• SW load modules:
– Basic system
– Options.
3BSE 002 414R601 Rev B 1-9

• Communication including event handling with Advant Controller 110 on:

– Advant Fieldbus 100
– RCOM.
• Routing of Advant Station 100 Series Engineering Station via Advant Controller 400
Series and Advant Fieldbus 100 to Advant Controller 110
• MultiVendor Interface for user-defined protocols
• Versions of MasterBus 300 and MasterBus 300E
• Free-programmable module with C (new series of PC elements)
• Maximum of four MasterFieldbus
• Shortest log interval is 1 sec.
Some limitations apply and some changes were made with reference to MasterPiece 200/1:
• MasterView 100 is not included (it is, however, supported by the software)
• Communication board DSCA 160A is not included (PC elements removed)
• MasterFieldbus only supported via new hardware (not DSCS 131)
• Backup in PROM of application program is removed
• PC element STATUS replaced by COM-STAT
• MasterBus 200 is removed
• MasterBus 100 is removed.
New highlights in the Advant Controller 410 ∗1.1, 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
(Advant Controller 450 only).
• Ex-barriers adapted to the S100 I/O System by certain manufacturer
• HART Interface adapted to the S100 I/O System
• A compact product variant of Advant Controller 410.
• 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
• User defined PC elements
• 4 or 8 Mbyte memory in Advant Controller 410
1-10 3BSE 002 414R601 Rev B

Section 1.6 Terminology
• New appearance of RE500 cabinets

• RE500 cabinet with double doors as an alternative.
• Extended range of the S800 I/O modules
• Modulebus Expansion in S800 I/O station
• New hardware for GCOM (CI543)
• PC element communication between two AC 410/450 on Advant Fieldbus 100
• New configuration of MVI protocol MODBUS (CI534V02).
• Redundant Advant Fieldbus 100
• Redundant Fieldbus Communication Interface for S800 I/O station
• Extended bus length Advant Fieldbus 100
• New Advant Fieldbus 100 interface module CI522A
• PROFIBUS-DP
• Extended range of S800 I/O modules
• MVI - a new protocol (on CI534V04) Allen-Bradley DF1
• New Cabinet RM500 (introduced during version *1.3).
• LONWORKS Network Interface (supported in AC410*1.5/2)
• INSUM Switchgear integration (supported in AC410*1.5/2)
• PROFIBUS-DP, enhanced functionality
• HART data routing support
• Extended range of S800 I/O modules.
• Support for CI547 added in AC410*1.5/1
• RM500 assortment reduced in standard offering (AC410*1.5/2)
Also valid when ordering older versions.
Regarding version designations, see Section 1.7.1, Product Versions.
1.6 Terminology
AMPL
The ABB Master Programming Language is used for application programming.
Application Program
An application program is a general concept of an assembly of program functions aimed at
realizing and automating an addressed process control function.
3BSE 002 414R601 Rev B 1-11

Application (user-built)
An application is a user-implemented configuration of standard hardware and software units.
It is the solution to the user’s problem.
Backplane
A backplane is part of a subrack which interconnects inserted electronics modules with the help
of a communication bus.
Basic System
Basic system is the abstract name of a minimal composition of functional units forming a
system.
Basic Unit
Basic unit is used for ordering purposes (for example in the Price Book) as a name for the
smallest unit to be ordered or a platform for further enlargement with alternatives and options.
Board
A board is usually a hardware component of a module.
Boot
Boot refers to the (re)start of nodes. Phases of the boot process include, for example power-up
diagnostics, software download, data base download and node initialization.
During the initialization phase of booting, control applications directly interfacing to process
outputs perform a cold start or warm start.
Cabinet
The cabinet is the outer case of a piece of equipment (a packaging option), for example
Controller cabinet, I/O cabinet.
CPU, Central Processing Unit
A CPU is a functional unit consisting primarily of a microprocessor and memory.
Circuit Breaker
In the context of a process control system, a circuit breaker is a device designed to open and
close a circuit by nonautomatic means and to open the circuit automatically on a predetermined
overload of current, without injury to itself.
Cold Start
Cold start is a kind of booting of a controller (or process station). This means:
• Erasing the user-built application program
• Transition to working mode CONFIGURATION.
Controller
Controller is a descriptive name for Advant Controller products.
A controller is an entity in which control applications are running.
From the product viewpoint, a controller consists of CPU, communication and certain auxiliary
equipment such as power supply. It also includes the functionality of process I/O (the process
data communication software). It does not include process I/O hardware (and firmware as
applicable).
Control Network
The structure of nodes (for example controllers and operator stations) linked together via
MasterNet is called a control network (DCN). It provides real time communication.
ESD
ESD stands for ElectroStatic Discharge.
1-12 3BSE 002 414R601 Rev B

Section 1.6 Terminology
Functional Unit
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.
HART
A protocol for connection of intelligent transducers (Highway Addressable Remote
Transducer). For example, measuring range, calibration and other maintenance data can be
transferred.
Hot stand-by Redundancy
Hot stand-by redundancy is redundancy where a system component is backed up by identical
hardware and software in the event of any failure. The backup components do not load-share
with primary components.
I/O
I/O is process Input or Output. From the functional and geographical distribution viewpoint,
process I/O is distinguished into two main categories:
• Central (located close to the controller)
• Distributed (in the process environment).
IMS, Information Management Station
An IMS is a station executing information management applications such as statistical control,
production control, and so on.
Initialization
Initialization sets a starting position.
INSUM
Integrated System for User optimized Motor control. An ABB proprietary, LONWORK based
system for switchgear and motor control systems.
Intrinsically Safe Equipment
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.
LED, Light Emitting Diode
Local Control, local operator
Local control is a mode of operation where responsibility is assigned to an operator/equipment
located in the process environment close to the process object.
LONWORK
Local Operating Network. A fieldbus developed and owned by Echelon Corporation, and with a
public protocol.
Module
A module is a hardware unit, with or without accommodated software, or a software unit.
There are modules of various sizes and functionality. Examples of hardware modules:
Subrack, submodule carrier, communication module, I/O module.
Examples of software modules:
Basic system program module in a controller, a PC element.
Multi-drop Connection
A multi-drop connection is a means of establishing a multi-drop network, that is a network with
two endpoint nodes, any number of intermediate nodes and only a single path between any two
nodes.
3BSE 002 414R601 Rev B 1-13

Node
A node in general - a point in a data network.
A node in an application:
• Any logically addressable unit directly connected to the plant or control network.
Examples are controller, process station, operator station.
• Any logically addressable unit connected via RCOM.
Object Oriented Connection
Object oriented connection means a way of organizing the connection of field intermediate
cables from process objects which utilize different categories of signals, for example, DI and
DO. The purpose is to eliminate the need of marshalling and cable split-up.
Off-line
With off-line configuration, configuration data is created outside the application for later
installation, or the internal configuration data is directly affected, but the application is inactive.
On-line
With on-line configuration, the internal configuration data of a system application is directly
affected, while the application is active.
Process Object
A process object is process concept/equipment, for example, valve, motor, conveyor, tank.
Process Station
Process station is a descriptive name for MasterPiece products.
A process station is an entity in which control applications are running. It includes the process
I/O.
RAM, Random Access Memory
Redundancy
Redundancy in general means the existence of more than one capability of an item (system,
apparatus, component) to perform its intended function.
Slot
A slot means:
• The place in the subrack where you put a module.
• The place in a submodule carrier where you put a submodule.
Formally, for example, in data base elements, the terms POSITION and SUBMODULE
POSITION are used instead.
Submodule Carrier
A submodule carrier is a module (circuit board) which houses smaller modules (submodules).
Subrack
According to IEC 916, subracks are the mechanics which house rows of boards. Different types
of subracks are available, for example controller subrack, I/O subrack.
Type Circuit
Type circuit is an application-specific standard solution in connection to controller
configuration. The scope of a type circuit is the controller data base and the PC program.
Warm Start
Warm start is a type of booting on controllers, which means resetting of dynamic information in
PC programs and the data base.
1-14 3BSE 002 414R601 Rev B

Section 1.7 Product Overview
1.7 Product Overview

Advant Controller 410 is a programmable system for control and supervision of processes and
equipment in industrial environments.
Figure 1-3. Front View of Cabinet RM500 for Advant Controller 410
3BSE 002 414R601 Rev B 1-15

Figure 1-4. Advant Controller 410, Example of Physical Appearance
The system can handle several hundred inputs and outputs, connected directly or remotely to the
controller. Distributed I/O units, PLC-type controllers (Programmable Logic Controller) and
converters for d.c. motor drives can be connected via a field bus. Interface is available to other
vendors’ systems.
Measured values can be logged and/or tied to alarm and event registration.
An Advant Controller 410 is accommodated in a single equipment frame, a special variant of a
process I/O subrack. Besides the limited number of I/O boards (15) located in the I/O subrack,
additional I/O can be connected via a fieldbus.
The controller and I/O boards and necessary connection units are installed in one or two
cabinets.
You can include an Advant Controller 410 in a network with other ABB Master products, for
example other Advant Controllers, products from the Advant Station 100 Series, the Advant
Station 500 Series and the Advant Station 800 Series. These series include operator stations,
information management systems (IMS) and engineering stations. From the compatibility
viewpoint, you can also include MasterPiece 200/1 products, MasterView 800/1 products,
SuperView 900 products and external computers in the network (see Figure 1-1).
1-16 3BSE 002 414R601 Rev B

Section 1.7 Product Overview
You can connect a local operator station and a printer to an Advant Controller 410 via standard
serial channels.
The programmability of Advant Controller 410 covers a wide range of functions, such as logic
and sequence control, data and text handling, arithmetic, reporting, positioning and regulatory
control, including PID control.
A function-block language with graphic representation, you can use AMPL (ABB Master
Programming Language), for configuration and application building. It is especially oriented
toward process control.
The smallest units in the language are standardized functions, represented by graphic symbols
(PC elements). Each PC element represents a complete function such as an AND-gate, a time
delay, a shift register, a PID controller, and so on. (See Figure 1-5). The language offers a simple
method to link PC elements and describe the data exchange between the functions selected to
control the process.
1 & 20 SHIFT
(C1,C2)
2
2 F/B-N
C1 3 >C
4 R
T
1 1 O 5 11 IF OB 12
2 TD TE 6 13 IB OF 14
Figure 1-5. Example of PC Element (AND, TON, SHIFT)
You can assemble a number of PC elements to form a PC module, which in turn can be
incorporated in further modules. Several modules form a PC program, which is the solution to
automate an addressed process control function.
Such a PC program executes the PC modules, element by element, with a periodicity which you
can normally select from 10 ms up to 2 s. You can document the complete program
automatically in graphic form on a printer.
As a complement to the function block language, programmable boards (programmed in C
language) are available for special applications.
A data base, which is a standardized storage place, is used for exchanging data with other parts
of the Master system.
High-performance tools such as the Advant Station 100 Series Engineering Stations are
available for configuration, application programming, documentation, testing and
commissioning.
3BSE 002 414R601 Rev B 1-17

1.7.1 Product Versions

This manual describes the Advant Controller 410 as a product.
The complete standard product including software, hardware and documentation is designated
Advant Controller 410 ∗X.Y/Z.
The software included, which is of modular character, is selected in accordance with the scope
of the function and consists of a basic system program module and applicable function library
program modules. All program modules are designated in principle in the same way, for
example, QC02-BAS11 ∗7.0/0.
1.7.1.1 Version Designation

The designation of a complete standard product or a program module is divided into two parts
by an asterisk.
The first part consists of a product name. The second part consists of a version number, minor
version number and revision number. See Figure 1-6.
A third part, separated by another asterisk, is available for program modules only. It includes
compatibility codes used by the configuration tool/engineering station for checks when loading
and dumping.
The information display on the configuration tool indicates, upon connection into the system,
the current product versions of the program modules.
Compatibility code for data base

Compatibility code for AMPL
Asterisk
Revision
Separation mark
Minor version
Version
Asterisk
Basic software
QC01-BAS11 *7.0/0 *02/01/01
Figure 1-6. Example of Version Designation with Compatibility Codes for Basic Software
1-18 3BSE 002 414R601 Rev B

Section 1.7.2 Product Structure
1.7.2 Product Structure

Headings in this section are:
General Modularization, Hardware, Block Diagram,
Interface, Functional Modularization, Product Variants
General Modularization
ABB Master is a totally modularized system at all levels. The high level consists of a family of
system products. An example of an advanced control system applying system products is
illustrated in Figure 1-1.
The system product is divided into HW modules and SW modules. In this way, the system
shows:
• High reliability
• High maintainability
• High integrity.
Hardware modules are replaceable units of the types power supply units, battery charger, and so
on, and printed circuit boards to be located in subracks.
The assembled program modules defining the product’s overall functionality are examples of
software modules. The different PC elements represent the lowest level of software
modularization exposed to you.
Further modularization exists to simplify different situations, for example sales, design,
application building and so on. Composite units are made by basic modules. Primarily, you can
find such packages in the Product Guide and other tendering and sales documentation.
For example, you will encounter the concept of a basic unit. Basic unit is used when you are
ordering as a name for the smallest unit to be ordered or a platform for further enlargement with
alternatives and options.
Hardware
Controller and process I/O are separate products. This means that, in this manual, you will find
only short presentations of supported I/O systems and I/O boards. For more in-depth
information, see separate I/O documentation.
The Advant Controller 410 includes:
• CPU with memory residing the fixed internal program (the system software) and the
application program
• Communication submodules
• System software backup submodule
• A backup power supply including a battery charger
• 5 V regulators.
3BSE 002 414R601 Rev B 1-19

Physically, the Advant Controller 410 is compactly assembled and consists of a processor
module with a number of slots for optional submodules. Advant Controller 410 is located in an
S100 I/O subrack.
For a physical view of the hardware configuration, see Figure 1-7. The denominations of
communication link types and system functions used are made clear in the subsections
beginning with Section 1.7.2, Product Structure.
The process I/O dedicated to an Advant Controller 410 are multi-channel I/O boards located in
an I/O subrack (for central location close to the controller) or as I/O units (for distributed
location). Also available are different distributed, autonomous units including I/O, for example
PLC-type controllers.
.
Connection of Advant Station 100 ES

Program Card position (system program backup)
Connection of MasterView 320
2 3 4
S100 Process I/O

Processor Module
PM150
1...4 indicates Connection of printer
submodule positions
Figure 1-7. Example of Advant Controller 410 Hardware Configuration incl. S100 Process I/O
1-20 3BSE 002 414R601 Rev B

Block Diagram
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 410.
Communication:
for example MasterBus 300, GCOM, EXCOM, MVI
Advant Fieldbus 100, MasterFieldbus, PROFIBUS-DP
LONWORKS Network
I/O Subrack
Process I/O Devices:

S100 I/O S100 I/O S100 I/O S100 I/O
module module module module
parallel bus communication
Processor Module
Bus
Voltage Backup interface Comm.
System Processor RAM System
regulator power supply superv. module
68020 clock
24 V/5 V
Eng. Printer SW
tool MV 320 backup
“Run” comm. comm.
relay comm. module
Battery
unit
Power
supply
unit
a.c. or d.c. a.c. External Engineering Printer MasterView 320

mains mains indication station
Figure 1-8. Advant Controller 410 Block Diagram
3BSE 002 414R601 Rev B 1-21

Interface
Besides the more “internal” I/O communication, a controller also communicates with a wide
range of peripherals. Figure 1-9 is scheduling the main functional interfaces.
Information
Management
Station
Operator
LAN K Station
LAN Y
Other External
control system computer
MVI
EXCOM GCOM MB 300
AS 100 ES
Terminal for
MasterView 320 LONWORKS LONWORKS
CPU Network Interface
PROFIBUS-DP PROFIBUS
Interface
Printer
Advant Fieldbus 100
AC 110
Advant MasterFieldbus AC 70
Fieldbus 100
Fieldbus
Interface
S100 I/O S800 I/O S400 I/O
I/O signals I/O signals
Process
= Interface = Boundary of Controller
Figure 1-9. Advant Controller 410 Functional Interfaces
1-22 3BSE 002 414R601 Rev B

Functional Modularization
The concepts of basic function and optional function are sometimes used in the documentation
of the Advant Controller 410 system. A system can be provided with a number of optional
functions which enable you to adapt each system for specific control tasks. Certain functions
require extra software while others require both extra software and extra hardware.
The memory system containing the Advant Controller 410 functionality is modular. The fixed
standard system software is stored in one single flash PROM module, a program card.
Additional program cards containing specific function libraries can be developed and used.
When you order an Advant Controller 410, you select the desired function repertoire from a
library of program modules. These modules are factory assembled into a program card.
Available standard program modules with function library follow.
• Basic functions (always included):
– QC01-BAS11 Basic system
– (QC01-BOB11 Boot block).
• Additional functions:
– QC01-LIB11 Additional PC elements 1
– QC01-LIB12 Additional PC elements 2
– QC01-LOS11 MasterView 320
– QC01-OPF11 Operator functions support
– QC01-BAT11 MasterBatch 200/1 support
– QC01-UDP11 User Defined PC Elements.
Examples of other optional functions requiring extra hardware are communication between
controllers, positioning, digital input, and so on.
Product Variants
The Advant Controller 410 is a flexible system offered in several variants with respect to, for
example, redundancy, power supply, cabinetry, marshalling, and so on. You can find general
information regarding principles and capabilities in this manual, but no details of the different
product packages are included. Please refer to relevant tendering and sales documentation for
that information.
An exception from this is a special compact product variant of the Advant Controller 410 which
is briefly presented in Appendix H, Product Variants.
3BSE 002 414R601 Rev B 1-23

1.7.3 General System Utilities
1.7.3.1 CPU
The central processing unit of the Advant Controller 410 comes in two versions with 4 or 8
Mbyte dynamic RAM. The versions are both designated Processor Module PM150V. A label on
module side states the RAM size (PM150V04 or PM150V08). A processor module is built up
around a microprocessor, Motorola 68020, running at 25 MHz.
In this User’s Guide the generic name PM150 is used all through.
On the module front, you can see indicators and a character display for high level system
diagnostics. The main operable equipment is a four-position rotary switch for start and
operating mode selection and a restart push button. See Chapter 4, Runtime Operation for more
information on these functions.
You can connect a configuration and maintenance tool on the module front.
1.7.3.2 Memory
The Processor Module PM150 contains the total amount of RAM (Random Access Memory),
which is a 4 or 8 Mbyte dynamic RAM with error correction code. This memory holds the
system program which is in use as well as the controller system configuration and application
program, that is all memory executed in run time.
The system program is described from the organizational viewpoint in Section 1.7.2, Product
Structure, under the heading Functional Modularization. The functional content is treated in the
next section, Section 1.7.3.3, Program Module Contents.
System Program Backup

The system program is backed up in flash PROM and automatically loaded to the RAM in
connection to system start. Physically, the standard system software is stored in a program card
(PCMCIA). The location of the basic program card in the processor module is illustrated in
Figure 1-10.
Additional program cards, if any, can be located on Program Card Interfaces MB510 which are
inserted in the slots ordinarily for submodules. Normally the program card should be in place
during operation.
1-24 3BSE 002 414R601 Rev B

Section 1.7.3 General System Utilities
Processor module
PM150
Program card
(PCMCIA)
Figure 1-10. Location of System Program Backup
Application Program Backup

The controller system configuration and the application program is normally created in an off-
line or sometimes an on-line configuration session supported by an engineering station. The work
is basically backed up in the engineering station environment (hard disc, flexible disc or likely).
To restore a RAM which has been cleared by an accident or a fatal error some measures have to
be taken, automatically and manually. In addition to the automatic loading of the system
program, described above under the heading System Program Backup, somebody has to
manually load the application program backup (including the controller system configuration)
using an engineering station. In some applications this is a too time consuming procedure and it
needs assistance of qualified maintenance people.
As an alternative the Advant Controller 410 can be equipped with an optional flash card of
similar type as the one used for the system program. However in this case a program card must
be located on a Program Card Interface MB510 which is inserted in a slot ordinarily for
submodules. The flash card is contained with a DUmp of Application Programs (DUAP)
preferably taken while the controller is in the operation mode. At need, the controller system
configuration and the application program is likewise automatically loaded from its flash card
into the controller RAM. No manual intervention is needed to get into operation after the
interruption.
Flash cards are available in different memory-sizes. Select a type that take the actual application
program.
The system program backup and the application program backup can not be mixed in one single
program card.
Power Supply Backup of Memory

The RAM is secured against loss of power for a minimum of four hours (after ≥20 h recharging)
by a backup power supply, located at the rear of the subrack, and a battery. This is important for
the configured application program, which is basically not otherwise backed up. The backup
time is increased by a longer recharging time. See technical data in Chapter 3,
Configuration/Application Building.
3BSE 002 414R601 Rev B 1-25

1.7.3.3 Program Module Contents

The program function library, among others, contains PC elements and functional units.
A functional unit is a package of different program functions such as PC elements and
operator’s functions. This simplifies the realization of combined functions with both the control
function and associated operator’s handling via a display screen and keyboard.
Please find below a survey of the functional contents and the concrete PC elements and
functional units in the different program modules.
Basic System, QC01-BAS11

The basic system program is sufficient when you need digital signal processing, arithmetic,
queue and shift functions. It works with both analog and digital input and output signals.
Functional Serve
• Logic and time delays
• Sequence control
• Data and text handling
• Calendar time functions
• Arithmetic
• Positioning
• Fast pulse counting and frequency measurement
• Reports
• Functional units, binary 1
• Functional units, analog 1
• Functional units, motor and valve control, group start 1
• Table handling
• EXCOM Data Set communication
• Support for MasterBus 300
• Support for GCOM
• Support for RCOM
• Support for MultiVendor Interface
• Support for connection to Advant Fieldbus 100
• Support for PROFIBUS-DP
• Support for LONWORK Network
• Support for connection to ACV 700 and DCV 700 thyristor converters
• Support for connection to TYRAK and SAMI thyristor converters
• Support for connection to strain gauge scales
• Free-programmable module.
1. Only the PC and data base element parts of the functional units are included in the basic program module.
For presentation and dialog support, QC01-OPF11 must be added. Special dedicated interface boards are not
included in the basic unit.
1-26 3BSE 002 414R601 Rev B

Table 1-5. PC Elements in the Basic System Program Module QC01-BAS11
Type Function PC element

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 calculation ABS, ADD, ADD-MR,
elements modes and some special expressions, ADD-MR1, DIV,
including square root, absolute value and DIV-MR, LIM-N, MUL,
limitation. SQRT, SUB
Time delays Timer elements for on- and off-delays and MONO, TON,
pulse functions. TON-RET, TOFF,
TRIGG, OSC-B
Calendar time Time of day and date elements and DATE, TIME, TIMER
elements element for generating output signals at
certain dates and times of day.
Registers Shift and queue registers and register with FIFO, REG, REG-RET,
retentive memory. SHIFT, SHIFT-L,
Group data Register assembling single data into a EXPAND, EXPAND-A
elements group data and elements for expanding REG-G
group data or arrays into single data items.
Queue registers Queue register with various data FIFO-RW
manipulation capabilities.
Multiplexers/ Select single data items from groups of DEMUX-MI,
Demultiplexers data and vice versa. DEMUXA-M, MUX-I,
MUX-MI, MUX-MN,
MUX-N, MUXA-I
Code Convert data from one data type to CONV, CONV-AI, CONV-
converters another, for example binary to integers, BI, CONV-IA, CONV-IB,
arrays (text) to integers and string data to CONV-SA
array data and inversely.
Counters Pulse counters. COUNT, COUNT-L
Comparators Compare single data items and select COMP, COMP-I, COMP-
maximum and minimum values. R, MAX, MIN
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
3BSE 002 414R601 Rev B 1-27

Table 1-5. PC Elements in the Basic System Program Module QC01-BAS11 (Continued)

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, GENUSD-O
valves and other process objects. GENCON-I,
GENCON-O,
MOTCON, VALVECON,
MMC-IND, MMC-ORD
Switches Switch between two sets of data. SW, SW-C
Positioning Positioning and length-measuring POS-A, POS-O, POS-L
elements elements with both analog and on/off out-
puts. Works with hardware module DSDP
140A.
Pulse counting Synchronize the board DSDP 110 for low- COUNT-DP, FREQ-MP,
and frequency speed pulse counting. Pulse counting and FREQ-SP, PULSE-S,
measurement frequency measurement when used with PCU-COM, PCU-I,
elements DSDP 150 and DSDP 170. PCU-O, PCU-SS
Pulse counting Dynamic data (measured values) is read DP820-I, DP820-O
and frequency from one channel, and set points for one
measurement channel of the DP820 pulse counter
elements module on Advant Fieldbus 100.
Data handling Copy data from input to output. MOVE, MOVE-A
Event handling Create event text for MasterView 320. EVENT
elements
Report elements Print reports in Advant Station 500 Series REPORT
Operator Stations.
Elements for Input and output elements for the FPM-COM, FPM-I, FPM-
programmable hardware module PU535. IA, FPM-O,
module FPM-OA
MasterView 100 Elements for control of the panel units. DISP, DISP-SEG, KEYB-
elements FU, KEYB-GR, KEYB-
N1, NUM-IN
Weighing Interface strain-gauge scales with PC pro- SCALE, SCALE_DOS
elements grams 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
Controller 100 Series, element for con-
necting of supervisory signals from Mas-
terNet to AMPL program.
1-28 3BSE 002 414R601 Rev B

Table 1-5. PC Elements in the Basic System Program Module QC01-BAS11 (Continued)

PROFIBUS-DP Provide communication on PROFIBUS- PB-R, PB-S, PB-DIAG
communication DP
elements
LONWORK Provide communication on LON LON-R, LON-S
Network
Communication
elements
MasterFieldbus Provide communication with COM-CVI1,
communication MasterPiece 51, MasterPiece 90, COM-CVO1,
elements Advant Controller 110, TYRAK or SAMI via COM-MP51,
MasterFieldbus. MFB-OUT, MFB-IN
Advant Provide fast communication with DSP-R, DSP-S,
Fieldbus 100 other AC 400 Series nodes and Motor DRI-CNV, DRI-R,
communication Drive Control. DRI-S
elements
Data Set Initiate execution of Data Sets. SENDREQ
elements
Table 1-6. Functional Units in Program Module QC01-BAS11
Functional unit Description

AI Analog input signal, including AI, Temp (Pt100), TC (thermo-
couple), AIC (calculated AI) and pulse counter (DSDP 110)
AO Analog output signal, including AO and AOC (calculated AO)
DI Digital input signal, including DI and DIC (calculated DI)
DO Digital output signal, including DO and DOC (calculated DO)
DAT General data base value
DRICONE Integration to engineered Drive
DRICONS Integration to Drives of ACS600 type.
TEXT Text in data base
GENUSD General user-defined device controller
GENBIN User-defined on-off controller
GENCON User-defined regulatory controller
SEQ Sequence controller
GROUP Device group controller
MOTCON Motor controller
3BSE 002 414R601 Rev B 1-29

Table 1-6. Functional Units in Program Module QC01-BAS11 (Continued)

MOTCONI INSUM Motor controller
VALVECON Valve controller
The program module QC01-BAS11 is in principle composed by QMP240 in earlier releases of

ABB MasterPiece 200/1.
Additional PC Elements 1, QC01-LIB11

QC01-LIB11 extends the PC element library that is included in the basic system program
module with PC elements to support the functions listed below.
The optional program module QC01-LIB11 is selected, for example, for control operations with
few demands for operator intervention from panels or when, for example, a local operator
station like MasterView 320 is adequate.
Functional Survey
• Feedback control
• Connection to analog thyristor converters.
Table 1-7. Additional PC Elements in Program Module QC01-LIB11

Logic ele- A general type of gate function element THRESH-L
ments with selectable number of inputs.
Arithmetic Select the median and majority values from MED-R, MAJ-R, LN,
elements a group of values and calculate exponential EXP
and logarithmic expressions.
Multiplexers Multiplex group data and single data items. MUXGR-MI, MUXGE-MI
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. FILT-1P, FILT-2P
ments
Feedback P, I and D functions and their combinations, P-DEADB, P-1, INT,
control ele- plus pulsed outputs and ramp generator. DER, PI, PIP, PDP,
ments CON-PU1, RAMP
Analog thyris- Interface analog converters with PC CVB-I, CVB-O
tor converter programs in Advant Controller 400 Series.
elements
1-30 3BSE 002 414R601 Rev B

Additional PC Elements 2, QC01-LIB12

QC01-LIB12 extends the PC element library that is included in the basic system program
module with PC elements and functional units for supporting the functions listed below.
The optional program module QC01-LIB12 is selected for advanced controlling which requires
powerful operator’s functions from an Advant Station 500 Series Operator Station or a
MasterView 800/1.
Advanced process control requires, in addition to QC01-LIB12, the program module for
operator functions support, QC01-OPF11.
Functional Survey
• Feedback control
• Self-tuning adaptive control, NOVATUNE
• Functional units, PID loop control, PIDCON, PIDCONA.
Table 1-8. Additional PC Elements in Program Module QC01-LIB12

Elements for Contains a PID-controller, a ratio station PIDCON, RATIOSTN,
functional and a manual station, all with ready-to-run MANSTN
units interfacing with Advant Station 500 Series
and MasterView 800/1 operator stations.
Self-tuning Adaptive, self-tuning, controller with NOVATUNE
adaptive feed-forward and dead-time compensation.
controller
Table 1-9. Functional Units in Program Module QC01-LIB12

PIDCON Regulatory controller
RATIOSTN Ratio station
MANSTN Manual station
MasterView 320, QC01-LOS11

The optional program module QC01-LOS11 extends the functionality given by the basic system
program module with functions listed below.
QC01-LOS11 adapts the Advant Controller 410 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.
3BSE 002 414R601 Rev B 1-31

Functional Survey
• MasterView 320
• Reports for MasterView 320.
Operator Functions Support, QC01-OPF11

The optional program module QC01-OPF11 extends the functionality given by the basic system
QC01-OPF11 adapts the Advant Controller 410 to an Advant Station 500 Series Operator
Station and IMS Station or a MasterView 800/1 operator station.
Functional Survey
• Reports for Adva Command or MasterView 800/1
• Functional units, binary 1
• Functional units, analog 1
• Functional units, PID loop control, PIDCON 1
• Functional units, motor and valve control, group start 1
• Trend data storage
• Status list
• Group alarm
• Adva Command or MasterView 800/1 support.
1. Only the presentation and dialog support are included in QC01-OPF11. The PC elements and corresponding data
base are included in QC01-BAS11 and QC01-LIB12.
1-32 3BSE 002 414R601 Rev B

MasterBatch 200/1 Support, QC01-BAT11

The optional program module QC01-BAT11 extends the functionality given by the basic system
QC01-BAT11 adapts the Advant Controller 410 to the advanced batch functionality offered by a
MasterBatch 200/1.
Functional Survey
• MasterBatch 200/1 support.
User Defined PC Elements, QC01-UDP11

The optional program module QC01-UDP11 extends the functionality given by the basic system
program module with the possibility to define your own library of user defined PC elements.
The user defined PC element is created in the Advant Station 100 Series Engineering Station
and built-up of a combination of normal PC elements found in the standard PC elements
libraries of the Advant Controller 410. After the user defined PC element is installed in the
Advant Controller 410 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.
1.7.3.4 System Clock, External Clock Synchronization

The Processor Module PM150 is provided with a calendar clock which is backed up by the
same battery used for memory backup. You can set the date and time from the programming
unit or from a local operator station, for example MasterView 320. A slow, smaller adjustment
in the interval ±100 s can also be performed with the programming unit.
With Advant Controller 410 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 10 ms.
If extreme synchronization accuracy is required between controllers (in the order of 2 ms) and
synchronization to an external clock, an external minute pulse signal can be connected to all
systems concerned.
The Backup Power Supply SB171 has a special input for external synchronization of the
calendar clock.
1.7.3.5 Configuration
You configure the system in accordance with the hardware and software selected, for example,
the number of I/O boards, communication lines, functional units and PC programs. This is
performed using commands from a configuration tool such as the Advant Station 100 Series
Engineering Station and results in the internal organization and activation of the data base and
program areas.
Configuration/application building is introduced in Section 1.7.8.2, Principles of Application
Building.
3BSE 002 414R601 Rev B 1-33

1.7.3.6 Execution
The execution units in a PC program are normally given cycle times of 10 ms - 2 s (5 ms - 32 s
after reconfiguration). The internal program system (operating system and PC interpreter)
organizes the execution of the units with the periodicity selected, simultaneously performing
other tasks such as communication with a MasterView 320 and programming units.
Ordinarily, you can select the same cycle times for reading in values from digital and
analog boards.
1.7.3.7 Start-up
The CPU front panel has a rotary switch which you use to select start and working mode.
The normal position of the switch is AUTO. This means an automatic start when voltage is
switched on or when voltage is recovered after a power failure. At an interruption of voltage,
the system stores all the information necessary for restarting. Whether the system is to continue
operations from its status at the interruption of the voltage or if it is to be reset to zero before
restart is selected with parameters.
The different ways to start are CLEAR, STOP, AUTO or OFF LINE. The way to start is selected
on the basis of the duration of the voltage failure.
You can connect a control module which is activated when the voltage returns and which
executes one cycle to each start alternative. All start modules must belong to the same PC
program. You can define how the process is to start with these control modules. Alarm can also
be blocked at initialization of the I/O boards. Start-up features and their application are
described in AMPL Configuration Advant Controller 400 Series, Reference Manual.
1.7.4 Free-Programmable Module

The Free-Programmable Module PU535 works as a slave-processor unit in
Advant Controller 410. It is used to execute application programs written in the high-level
language C. With respect to its function, such a program is a part of the main application
program (PC program).
PU535 communicates with the PC program via a number of special PC elements.
These elements are used for control of the application program on PU535 and for data exchange
between the PC program and PU535.
For programming of the PU535, you can use an HP 9000/700 workstation to write and test the
application programs and to download them into the PU535 using the built-in SLIP protocol.
The PU535 also contains a simple User Test Interface for execution control and diagnostics,
available through the service port (V24/RS-232-C).
1-34 3BSE 002 414R601 Rev B

Section 1.7.4 Free-Programmable Module
The application program is stored in flash PROM on PU535.
PM150 PU535
PC program C program
FPM-O
D
/Read from AMPL appl/
o
u block = 1; Service port
section =1;
b element = 1;
l V.24/RS-232-C
if (( readstat = read
+ e
P /Perform calculation/
o apioRVal = (456.77 )
r
FPM-I t /Write to AMPL appl/
block = 2;
M section = 1;
e element = 1;
m if (( writestat
o
r
+ y
D=7.3
Figure 1-11. Implementation of a Free-Programmed Function
For a detailed description of the auxiliary function, see the

Free-Programmable Module, Development Environment, User’s Guide.
3BSE 002 414R601 Rev B 1-35

1.7.5 Power Supply
System Power Supply

An Advant Controller 410 is normally delivered in one or two cabinets. The equipment is
designed, as standard, for connection to a 120/230 V single-phase or two-phase a.c. mains
supply, 50/60 Hz or for connection to a 24-48 V d.c. mains supply. Several alternatives are
available. The main alternatives are:
• Supply from an a.c. mains supply A
• Supply from a d.c. mains supply A
• Direct supply (without d.c./d.c. converter) from d.c. mains supply A
• Supply from one or two a.c. mains supplies, A/B with redundant supply units
and regulators
• Supply from a d.c. mains supply A with redundant d.c./d.c. converters and regulators.
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.
The uppercase A, B and C identify the mains supply in the documentation. They refer to mains
supply with different requirements. Networks A and B are low-quality networks and they are
redundant to each other. Network C is a high-quality network.
You can get more information on the planning viewpoint in Chapter 2, Installation,
Section 2.1.7, Power Supply and Fusing.
The one-line diagram, Figure 1-12, shows the power supply of an Advant Controller 410.
Figure 1-13 shows an alternative with redundancy. Supply from a.c. mains supply, including use
of the optional mains supply C, is illustrated.
A d.c. alternative only differs in the use of alternative power supply units.
Depending on differing needs for circuit breaker capacity, there are different types of power
switch and distribution units (SX5xx) specified to the individual installations. See the delivery
documentation.
CE-marked equipment is provided with net filter at the enclosure port. These are not shown in
the one-line diagram.
Detailed information on, for example, terminal block dispositions, locations, connections
between units, and so on, is also given in a circuit diagram enclosed with the controller’s
delivery documentation.
The main functions in the power supply system are briefly described below. In addition, you can
find more detailed hardware descriptions in Appendix A, Hardware Modules of this manual and
in the S100 I/O Hardware Reference Manual.
1-36 3BSE 002 414R601 Rev B

3BSE 002 414R601 Rev B
Cabinet 1
Power switch
Figure 1-12. Principle of Power Supply of an Advant Controller 410 (a.c. mains supply)
I/O subrack with Controller
and distribution
Power supply 24V distr.
SX540 SA16X SX554 Regulator
Mains A LIVE Test
DSSR 122
24 V
24V
F1
x2 Fail
Live
Power Supply for
A Backup power supply field equipment
Power supply for 24V
Battery
field equipment SB171 Power Supply 24V distr.
SB522
CHARGE SA1XX SX554
LIVE Test
DSTC 452/454 24 V
MFb modem
Power distr. DSTC 24 V
Short distance
452/454 modem A
SX542
Pw DSTC x2
Mains C
Tw X008
Rw PWR
TD
Modem subrack
RD
RTS AF 100 and short distance modems
24V A
DCD
TC516
TC513 TC515
TC512 TC514

TC630 Alt. TC562
P Optical
Bus Ext.
Tx
24V B
24V A Rx
Section 1.7.5 Power Supply

24V B
1-37
1-38
Cabinet 1
Figure 1-13. Principle of Redundant Power Supply of an Advant Controller 410 (a.c. mains supply)
Power switch I/O subrack with Controller
and distribution Power supply Regulators
24V distr.
SX540 SA16X SX554 Voting unit
Mains A LIVE Test DSSS 171 DSSR 170
24 V
24VA Live Fail
A 24V Fail
A
24VB Live
x2 B
PBC
Power Supply for

A 24V field equipment
Power supply for Battery
field equipment Backup Power Supply 24V distr.
power supply SB522
SA1XX SX554
SB171 LIVE Test
DSTC 452/454 24V

CHARGE
MFb modem
Power distr. DSTC Short distance
SX542 452/454 modem A
Pw DSTC x2
Mains C
Tw X008
Rw PWR
Diode Unit
TD
RD DSSS 170 Fail
24V A Diagnostics
RTS Modem subrack
24V B signal to DI
DCD
AF 100 and short distance modems 24V A
24V A 24 V
TC516 24V B
TC513 TC515
TC512 TC514
TC630 P TC562 SA1XX SX554
Power supply 24V distr. 24V B LIVE Test
Power switch Tx Alt.
and distribution SA16X SX554 24V A Optical
PRx Bus Ext. 24V
SX540 LIVE Test 24V B
Tx
24V A
3BSE 002 414R601 Rev B
Mains B
24 V Rx
B 24V B B
x2
x2
B Power supply for

field equipment
Module Utilization
Table 1-10. Modules Used in different Power Supply alternatives
Single supply Redundant supply

Application a.c. d.c. a.c. d.c.
120 V 230 V 24 V 24 V (1) 48 V 120 V 230 V 24 V 48 V
Mains Power Switch and
Distribution:
Mains A and B SX540 SX540 SX555 SX555 SX550 2*SX540 2*SX540 2*SX555 2*SX550
Mains C, category II (2) SX542 SX542 --- --- --- SV543 SV542 --- ---
Mains C, category III (2) SV541 SV540 --- --- --- SV543 SV542 --- ---
Power Supply:
Controller + I/O SA167 SA168 SD150 DSSB SD150 2*SA167 2*SA168 2*SD150 2*SD150
170
Power supply units for field SA161 SA162 “ --- “ 2*SA161 2*SA162 “ “
(3) (3) (3) (3)
equipment 24 V d.c.
Power supply units for field SA171 SA172 --- --- --- --- --- --- ---
equipment 48 V d.c.
Distribution 24-48 V SX554 is generally applied
Voltage Regulation:
Controller + I/O DSSR 122 3*DSSR 170 + Voting unit DSSS 171
(1) 24 V without d.c./d.c. converter.

(2) According to IEC 664.
(3) A diode unit DSSS 170 is used for voting of 24 V A or B.
Mains Net Filter

The CE-marked design provides a mains net filter for each supply A, B and C. The filter is
installed between the enclosure port and the mains power switch. The purpose is to minimize
the risk of interference and the emission of conducted radio frequency field.
The filter is adapted to the estimated load from the installed equipment.
3BSE 002 414R601 Rev B 1-39

Mains Power Switch and Distribution

You use the power switch and distribution unit to connect and disconnect the
Advant Controller 410 system to the mains and for distribution of voltage to different units in
the cabinet. The power switch unit contains terminal blocks, miniature circuit breakers and
power outlets for, for example, power supply units.
Normally, a common circuit breaker disconnects the mains from all cabinets housing the
controller and the I/O installation, that is the “hard” related cabinets. Variants can exist. Please
refer to the actual delivery documentation for further information.
Power Supply
The power supply units provide the regulators in the subracks with 24 V unstabilized d.c.
voltage. They can also be used to supply other circuits which do not require stabilized 24 V
voltage such as sensors, indicators, and so on.
There are certain restrictions on utilizing a common power supply for the system itself and
external equipment. Please refer to Section 3.1, Design Considerations.
Use duplicated voltage supply units to provide redundancy.
Varying requirements on power supply are met by a range of supply modules with different
technical data. You can select according to Table 1-11.
Table 1-11. Selection Guide of Power Supply Modules
Module type a.c./d.c. Net Max. load Remarks

SA161 a.c. 120 V 24 V, 10 A
SA162 a.c. 230 V 24 V, 10 A
SA167 a.c. 120 V 24 V, 25 A
SA168 a.c. 230 V 24 V, 25 A
SD150 d.c. 24-48 V d.c. 24 V, 20 A
SA171 a.c. 120 V 48 V, 5 A For field equipment only
SA172 a.c. 230 V 48 V, 5 A For field equipment only
Voltage Regulation
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.
An I/O subrack housing an Advant Controller 410 can be equipped with a single voltage
regulator DSSR 122 or redundant regulators of the type DSSR 170. The number of DSSR 170 is
always three, two of which are needed with respect to capacity (n+1 redundancy).
1-40 3BSE 002 414R601 Rev B

Figure 1-14 and Figure 1-15 illustrate the two alternatives. These regulator modules are
installed on the rear of the I/O subrack.
.
Regulator
Output Fuse
Terminal blocks DSSR 122
for connection
of 24 V
Rear of subrack
Backup power supply

SB171
Input fuse F1 for

the regulator
Cable +24 V to DSSR 122
Fuse protected +24 V
to the backplane Cable 0 V to DSSR 122 and backplane
Figure 1-14. Voltage Regulation in I/O Subrack with Advant Controller 410
Alternative at Redundancy
Rear of subrack
Regulator 1 - 3 Backplane DSBB 188
DSSR 170
Voting Unit
DSSS 171
Fuses Backup power supply
SB171
X4
X9
Connections X1 Fuse
X6
X2 DSSR
170
DSSR
X7 170 LF
DSSR IA
DSSS 170 LF VI
171F IA EL
L LF VI
IA IA EL
VI VI
EL EL
A
B
PBC
Figure 1-15. Redundant Voltage Regulation in I/O Subrack with Advant Controller 410
3BSE 002 414R601 Rev B 1-41

Backup Power Supply

The power supply system for Advant Controller 410 includes a battery package intended for
current supply for RAM and the system clock in the event of a power failure.
The Ni-Ca battery included in Battery Unit SB522 is kept charged by a Backup Power Supply
SB171 located on the rear side of the I/O subrack.
The backup power supply is supervised. Status is available to the controller diagnostic system.
Status is also indicated by LEDs on the backup power supply.
Battery capacity is four hours (after ≥20 h recharging). A longer recharging time results in a
longer backup time.
For further technical data, see Chapter 3, Configuration/Application Building and the respective
module descriptions in Appendix A, Hardware Modules of this manual.
Fusing
The fusing and electronic overload protection of the Advant Controller 410 and its main parts
are illustrated in Figure 1-12 and Figure 1-13.
Earthing
The signal processing electronics in Advant OCS are normally earthed to chassis and all
interference suppression for external signals refers to chassis. If this rule is broken, the system is
sensitive to high-frequency interference, mainly interference from unsuppressed relays, to
contactors and to discharge of static electricity.
Power Supply for Field Equipment

Auxiliary equipment in the controlled system is normally powered separately. This means
separate power supply units and fusing. However, given a small current requirement, and if you
follow the rules given in Section 3.1, Design Considerations, you can also use the system power
supply unit for field equipment.
The series of power supply units listed in Table 1-11 is, of course, generally applicable.
1.7.6 Process Interface

An Advant Controller 410 communicates with the process through various types of sensors and
actuators connected to process interface units. Three variants of the I/O system are offered,
S100 I/O, S400 I/O and S800 I/O. The I/O systems are optimized for different use.
As the short presentation below illustrates, the S100 I/O is the most complete system with
respect to special functions.
Process events can be time-tagged. The time accuracy is determined by the applied I/O system
and the selected board type.
In Advant Controller 410, a maximum of 15 I/O boards can be located in a common subrack for
the controller and S100 I/O.
1-42 3BSE 002 414R601 Rev B

Section 1.7.6 Process Interface
Cabling represents a large portion of the cost of installing a process control system. In order to
reduce this cost, a range of distributable I/O units (S400 I/O and S800 I/O) are available
covering the most common process signal types. The distributable I/O units communicate with
the controller through MasterFieldbus (S400 I/O) and Advant Fieldbus 100 (S800 I/O).
It is, of course, possible to mix the different I/O systems in the same application, if you wish.
This manual gives an overall presentation of the I/O systems. Since the I/O systems are common
to several Advant Controller products, the detailed information is collected in separate
documents as follows.
• S100 I/O: Hardware descriptions and technical data of I/O boards, connection units
and the S100 I/O bus extension.
- S100 I/O Hardware, Reference Manual
• S400 I/O: System description, hardware description and technical data of I/O units and
MasterFieldbus.
- MasterFieldbus and S400 I/O, User’s Guide.
• S800 I/O: System description, hardware description and technical data of I/O modules and
Advant Fieldbus 100.
- Advant Fieldbus 100, User’s Guide
- S800 I/O User’s Guide.
Function descriptions, including configuration-application building information on I/O boards
and signals, which are applicable to the actual Advant Controller, are found in separate
documents as well. Please refer to either of these two documents:
• Data Base Elements, Advant Controller 400 Series, Reference Manual
• Functional Units part 2, Reference Manual.
3BSE 002 414R601 Rev B 1-43

General Signal Paths

The input and output signals can be in digital or in analog form (current or voltage signals).
Figure 1-16 and Figure 1-17 shows, in principle, the layout of the signal paths for the input and
output signals for the different I/O systems. The signal paths are built up of the following units
which are described in principle below.
S100 I/O:
• External signal cable
• Connection unit
• Internal cable
• I/O board
• Bus extension to S100 I/O
• Internal system bus.
S400 I/O:
• I/O unit
• MasterFieldbus LDB (long-distance bus)
– Bus cable
– Modem.
• MasterFieldbus SDB (short-distance bus)
• Modem/Connection Unit TC570
• Communication module for MasterFieldbus
S800 I/O:
• Module Terminal Unit (MTU)
• I/O module
• Fieldbus Communication Interface (FCI)
• Advant Fieldbus 100
• Communication module for Advant Fieldbus 100
1-44 3BSE 002 414R601 Rev B

S100 I/O
I/O subrack with processor module
Processor Module PM150
Parallel CPU Internal

bus system
Built-in bus
bus converter
Connection I/O
unit board
S400 I/O I/O subrack with processor module
Processor Module PM150
SDB CPU
Short-distance bus Internal
system
I/O bus
unit
Modem Comm.
Modem Modem module
I/O TC570 CI570
unit LDB
Long-distance bus SDB
(max 750 m (2460 ft.) el.
max 3000 m (9842 ft.) opto)
I/O
unit
Figure 1-16. Input and Output Signal Paths (in principle)
3BSE 002 414R601 Rev B 1-45

S800 I/O
Controller subrack
I/O interfaces on a DIN rail

Processor
module
Internal
Modulebus system
bus
Advant Fieldbus 100
Modem Comm.
“FCI” module
CI810 TC512V1
CI522A
Twisted pair media
I/O (max bus length of the
module configuration 1700 m (5500 ft.))
Optical
ModuleBus
Expansion
Modulebus
TB820
I/O
module
FCI - Fieldbus Communication Interface
Figure 1-17. Input and Output Signal Paths (in principle)
External Signal Cable

The process cables are connected to screw terminals (terminal blocks) on the connection units
or directly to the I/O units.
Connection Unit
The connection unit consists of a circuit board which is to be located on a mounting bar in the
backplane of the cabinet. See example in Figure 1-18.
You can distribute the connection unit 3 - 15 m if you use shielded cables to join the I/O board.
Mounting bars are available in two models for 19-inch and 24-inch widths.
Connection units have different widths. For dimensions and other technical data, see the S100
I/O Hardware, Reference Manual.
A connection unit is provided with terminal blocks to connect external signal cables.
Normally, a connection unit has additional terminals for power distribution to sensors and
actuators. Generally, you can disconnect the terminals individually or group by group to isolate
the I/O channels from the process for fault tracing and test measurements.
1-46 3BSE 002 414R601 Rev B

Circuits for interference suppression, fuses and, for analog inputs, a shunt resistor, are located
on the connection unit. The shunt resistor is located so that you can replace an analog input
board without breaking any current loops.
Mounting bar for

connection units
Connection to Process
Connection Cable
to I/O board in Subrack
“Internal Cable”
Figure 1-18. Example of Connection Unit for S100 I/O in RM500 Cabinet
A connection unit relates to an I/O board in different ways. The basic arrangement is that one
connection unit corresponds to a specific I/O board. Sometimes two or more connection units
are used to adapt to a single I/O board application. For example, the need of different rated input
voltages to a digital input multi-channel board.
Two I/O boards of different categories (for example, DI and DO) are used to support an object
oriented type of connection unit. An object oriented connection unit facilitates the connection of
field cables without using any marshalling or process cable slit-up. Process objects like motors
and valves utilizing both ordering and indicating signals are joined with the control system in a
rational and uniform way. Figure 1-19 gives an example of application.
3BSE 002 414R601 Rev B 1-47

Motor object
M
DO Contactor
Mounting bar
Process cable
MCB DI Ready
DI Run
Fuses Plug-in Trip
Terminals DI
connector
I/O boards Connection unit
F
DSDI 110A
8 objects per row
DSDI
110
1 9
2 10
3 11
4 12
5 13
6 14
7 15
8 16
17 25
18 26
19
20
21
22
23
27
28
29
30
31
Up to 8 rows in a cabinet
24 32
F
1 9
2 10
3 11
DSDO 110
4 12
5 13
6 14
7 15
8 16
17 25
18 26
19 27
20 28
21 29
Connection
22 30
23 31
24 32
DSDO
110 cable
Figure 1-19. Application of Object Oriented Connection of S100 I/O
Internal Cable in S100 I/O

The connection units and I/O boards are joined by prefabricated cables. Ribbon cable is used to
connect I/O boards intended for currents under 1 A and voltages under 60 V. Shielded cable is
used for signals particularly sensitive to interference.
I/O Board (S100 I/O)

I/O boards convert incoming electrical signals from the process controlled, so that they can be
further processed in the processor module. Outgoing signals are adapted to their functions in the
process. I/O boards are divided into the following groups:
• Digital input boards
• Digital output boards
• Analog input boards
• Analog output boards
1-48 3BSE 002 414R601 Rev B

• Pulse counter/frequency measurement boards

• Positioning boards
• Others.
Connection units and wiring which connects boards and connection units are associated with
each I/O board.
You can exchange I/O boards while the system is running. You can also insert new boards live,
provided they are predefined in the data base. A newly inserted board is taken into operation
within 10 seconds.
I/O Unit (S400 I/O)

An I/O unit in the S400 I/O system correspond to an I/O board in S100 I/O.
I/O units are divided into the following groups:
• Digital basic units
• Digital expansion units
• Analog units.
You can connect process cables directly to the I/O unit’s terminal blocks.
You can exchange an I/O unit while the system is running. You can also install new I/O units
live, provided they are predefined in the data base. A newly inserted I/O unit is taken into
operation within 10 seconds.
I/O Module (S800 I/O)

An I/O module in the S800 I/O system corresponds to an I/O board in S100 I/O.
I/O modules are divided into the following groups:
• Digital modules
• Analog modules.
• Pulse counter / frequency measurement module
• Digital and analog modules with Intrinsically safe interface
• Analog modules with Intrinsically safe interface and HART communication.
You can connect process cables directly to the I/O module’s terminal blocks.
You can exchange an I/O module while the system is running. You can also install new I/O
modules live, provided they are predefined in the data base and there is a free Module
Termination Unit of right type in the station. A newly inserted I/O module is taken into
operation within 10 seconds.
3BSE 002 414R601 Rev B 1-49

Intrinsic Safety Barriers (S100 I/O)

Hazardous applications may use barriers between the standard electronics and the equipment
located in hazardous atmosphere. Certain barrier brands provide rational connection facilities
adapted to the Advant Controller 400 Series thus making these brands especially advisable.
The basic principle is to replace the connection units of the S100 I/O System with termination
boards housing the intrinsically safe isolator modules. The Advant Controller 400 and the
intrinsically safe equipment are always delivered in separate cabinets.
You are referred to the separate documentation Intrinsic Safety Support for S100 I/O System.
HART Interface (S100 I/O)

Intelligent transducer using the Highway Addressable Remote Transducer protocol (HART)
may be applied in an Advant Controller 400 installation utilizing the S100 I/O System. External
products and a PC-compatible complement the Advant Controller, thus making an integrated
solution.
The principles of connection is illustrated in Figure 1-20. Otherwise you are referred to the
separate documentation HART Protocol Interface to the Advant Controller 400 Series
Controllers.
Intelligent Connection
transducer Unit
1
Special I/O board Data base

2 internal
cable
16
Multiplexer
Man-Machine
16 channels Interface
Next 16 channels
RS485 RS-232-C
Next
Multiplexer
Figure 1-20. Principle of HART Implementation
1-50 3BSE 002 414R601 Rev B

HART Interface (S800 I/O)

Intelligent transducer using the HART protocol may be applied in an Advant Controller 400
installation utilizing the S800 I/O System. S800 I/O modules supporting HART together with an
Advant Control Configurator tool version supporting HART and its integrated HART
configuration tools are conditions for this function. HART specific data is not available in
Advant Controller 450 which is acting as a router between the S800 I/O modules and the HART
configuration tool. The principle is illustrated in Figure 1-21.
Advant Engineering Workplace with

HART configuration tool, that is Cornerstone
HART data
Master Bus 300
AI/AO signals AC 410
Advant Fieldbus 100
S800 I/O Station HART data
HART device
Figure 1-21. Principle of HART implementation using S800 I/O
3BSE 002 414R601 Rev B 1-51

1.7.6.1 S100 I/O

S100 I/O is the group of input and output boards located in the I/O subrack.
Information in this section is divided according to the different categories of boards and
subdivided into Main Points, available Board Types and signal Block Diagram.
Regarding connection units and internal cables used in the hazardous and HART applications
you are referred to the separate documentation.
Digital Input, Main Points

• All digital inputs are opto-isolated from the system potential.
Grouping of channels, with respect to isolation, can exist. See information given with the
actual board type and connection unit type.
• You can select the mode of data base updating, either by interrupts or by scanning.
The scan cycle times are normally selected from the range 10 ms to 2 s.
• Some boards offer pulse extension, for example to avoid rapid scanning of push buttons.
• The input signals are filtered on the input board to suppress the effects of electrical
interference or bouncing contacts. The filter time is fixed to 5 ms or configurable
depending on board type selected.
• Board types offering interrupt-controlled scanning are most suitable to get time-tagged
events.
Digital Input, Board Types

Table 1-12 presents available digital input boards.
Table 1-12. Digital Input Boards
Board type Description Connection unit Cable

DSDI 110A 32 (4 x 8) channels, 24 V d.c., controlled by DSTD 150A / DSTD 190 DSTK 221L3
scanning or interrupt
DSDI 110AV1 32 (4 x 8) channels, 24 V d.c., controlled by DSTD 150A / DSTD 190V1 DSTK 221L3
scanning or interrupt
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 (1) DSTK 226L3
(1)
120 V a.c., 4 x DSTD 197 DSTK 226L3
230 V a.c., 4 x DSTD 198 (1) DSTK 226L3
DSDI 110AV1 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 (2) DSTK 226L3
(2)
120 V a.c., 4 x DSTD 197 DSTK 226L3
230 V a.c., 4 x DSTD 198 (2) DSTK 226L3
1-52 3BSE 002 414R601 Rev B

Table 1-12. Digital Input Boards (Continued)

DSDI 110A 32 (4 x 8) channels, 24 V d.c., controlled by 24 V d.c. 4 x DSTD 196 (2) DSTK 226L3
scanning or interrupt This connection unit
provides 48 V d.c. over
open sensor contact.
DSDI 110AV1 32 (4 x 8) channels, 24 V d.c., controlled by 24 V d.c. 4 x DSTD 196P (2) DSTK 226L3
scanning or interrupt This connection unit
provides 48 V d.c. over
open sensor contact.
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.
Digital Input, Block Diagram
Process Signal adaption units Controller

software
Transducer
current
supply
Digital
input Data base Program
board
Digital
connection
Transducer unit
Status indication (yellow)
Figure 1-22. Digital Input Signal, Block Diagram
Digital Output, Main Points

• All digital outputs are galvanically isolated from the system potential by means of relays
or opto-couplers.
Grouping of channels, with respect to isolation, can exist. Please refer to information given
with the actual board type and connection unit type.
• Transistor- and relay-type outputs are available.
• There are low-power relay outputs for currents < 100 mA.
3BSE 002 414R601 Rev B 1-53

Digital Output, Board Types

Table 1-13 presents available digital output boards
Table 1-13. Digital Output Boards

DSDO 115 32 channels, 24 V d.c. 4x DSTK 226L3
DSTD 108 / DSTD 108L(1)
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. 4x DSTK 226L3
DSTD 108P / DSTD 108LP (1)
These connection units pro-
vide 8 relay outputs each, 24 -
250 V a.c./ d.c. max 3 A.
DSDO 115 32 channels, 24 V d.c., short-circuit protected, DSTD 110A / DSTD 190 DSTK 221L3
transistor output, max. 150 mA
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).
Digital Output, Block Diagram
Controller Signal adaption unit Process

software
Digital Unit
output board Connection controlled:
Program Data base unit lamp,
contactor,
and so on.
Status indication (yellow)
Figure 1-23. Digital Output Signal, Block Diagram
1-54 3BSE 002 414R601 Rev B

Analog Input for Standard Signal, Main Points

• Input units are available for standard voltage or current signals, single-ended or
differential, with or without live zero.
• An isolation amplifier is available in the form of a connection unit. The isolation
voltage is 3 kV.
• Some board has reference channels for automatic calibration and testing.
• The data base is updated by scanning, with cycle times normally selected from the
range 100 ms to 600 s.
• Optional software filtering, square-root linearization and deadband limits for updating
can be selected.
• Optional redundancy. Two types of boards can be duplicated to achieve increased
availability.
• A board is offered which combines analog inputs and analog outputs (loop dedicated I/O).
Analog Input for Pt 100, Main Points

• Different temperature ranges for optimization of measurement accuracy.
• A 13-bit resolution unit is available. This very high resolution requires special precautions
when it comes to cabling. The unit can optionally be used with 12-bit resolution.
• Each board has built-in reference channels for automatic calibration and testing.
• The data base is updated by scanning, with cycle times normally selected from the range
100 ms to 600 s.
• The suppression frequency is selectable between 20, 30, 50 and 60 Hz.
• The current generators for sensors deliver 2.5 mA, in accordance with DIN 43760.
• Optional software filtering and deadband limits for updating can be selected.
Analog Input for Thermocouple, Main Points

• Thermocouple inputs are available for different sensor types.
• Each board has built-in reference channels for automatic calibration and testing.
• The data base is updated by scanning, with cycle times normally selected from the range
100 ms to 600 s.
• Optional software filtering and deadband limits for updating can be selected.
3BSE 002 414R601 Rev B 1-55

Analog Input, Board Types

Table 1-14 presents available analog input boards.
Table 1-14. Analog Input Boards

DSAI 130 16 channels, differential inputs, resolution DSTA 131 DSTK 221L3
12 bits + sign,
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 0.1%, CMV 100 V
DSAI 130A 16 channels, differential inputs, resolution DSTA 131 DSTK 221L3
12 bits + sign,
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,
shunt 250 Ω 0.1%, CMV 100 V
DSAI 130 Eight differential and eight directly grounded DSTA 133 DSTK 221L3
inputs (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,
shunt 250 Ω 0.1%, CMV 100 V
DSAI 130A Eight differential and eight directly grounded DSTA 135 DSTK221L3
inputs (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,
shunt 250 Ω 0.1%, CMV 100 V
DSAI 133 32 channels, directly grounded inputs (single 2 x DSTA 002A DSTK 222L3
ended), transducer supply fused channel by
channel, resolution 12 bits unipolar,
0 to + 10 V, 0 to + 5 V, 0 to + 20 mA,
shunt 250 Ω 0.05%
1-56 3BSE 002 414R601 Rev B

Table 1-14. Analog Input Boards (Continued)

DSAI 133A 32 channels, directly grounded inputs (single 2 x DSTA 00B DSTK 222L3
ended), transducer supply fused channel by
channel, resolution 12 bits unipolar,
0 to + 10 V, 0 to + 5 V, 0 to + 20 mA,
shunt 250 Ω 0.05%
2 x DSAI 133 DSAI 133 in redundant coupling. Data other- 2 x DSTA 002A (1) 2 x DSTK 222L3
wise the same as for DSAI 133 above.
2 x DSAI 133A DSAI 133 in redundant coupling. Data other- 2 x DSTA 002B (1) 2 x DSTK 222L3
wise the same as for DSAI 133 above.
DSAI 146 31 channels (+ one ref. channel) for Pt100, DSTA 145 DSTK 229SL3
three-wire, resolution, 12 bits + sign,
-100 to +320°C or -200 to +640°C
DSAI 155A 14 channels (+ two ref. channels + one comp. DSTA 156 DSTK 225SL3
channel) 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. channels + one comp. DSTA 156B DSTK 225SL3
channel) for thermocouples, resolution DSTA 155P
12/13 bits + sign, measurement range:
B, C, E, J, K, R, S and T for insulate
thermocouples
DSAX 110 Analog input: DSTA 001A DSTK 223L3
Eight channels, directly grounded inputs
(single ended) resolution 12 bits unipolar
0 to + 10 V or 0 to + 20 mA,
shunt 250 Ω 0.05%
Analog output:
Eight channels, resolution 12 bits unipolar
0 to + 20 mA,
0 to + 10 V (over shunt 500 Ω 0.1% on
DSTA 001)
3BSE 002 414R601 Rev B 1-57

Table 1-14. Analog Input Boards (Continued)

DSAX 110A Analog input: DSTA 001B DSTK 223L3
0 to + 10 V or 0 to + 20 mA,
shunt 250 Ω 0.05%
Analog output:
0 to + 20 mA,
DSTA 001)
2 x DSAX 110 Redundant coupling. Data otherwise the same DSTA 001A 2 x DSTK 223L3
as for DSAX 110 above.
2 x DSAX 110A Redundant coupling. Data otherwise the same DSTA 001B 2 x DSTK 223L3
as for DSAX 110 above.
(1) Two connection units are used due to space requirement.
Analog Input, Block Diagram
Process Signal adaption unit Controller

software
Analog
input
Connection board
unit Data base Program
Process
transducer
Test
point (X3)
Figure 1-24. Analog Input Signal, Block Diagram
With redundancy, the pair of boards is treated as an individual in the data base.
A common connection unit is used to connects the singular process object (transducer, actuator).
1-58 3BSE 002 414R601 Rev B

Figure 1-25 illustrates an application with redundancy.
Process Signal adaption unit Controller

software
Connection Inputs Board

unit
Trans- 1
ducer
Outputs
Data base Program
Inputs Board
2
Actuator
Outputs
Figure 1-25. Analog Input/Output Signal with Redundancy, Block Diagram
3BSE 002 414R601 Rev B 1-59

Analog Output, Main Points

• Analog outputs are available for standard voltage and current signals.
• There are both isolated and non-isolated outputs.
• Optional redundancy is featured, where one type of board can be duplicated to achieve
increased availability.
• A board is offered which combines analog inputs and analog outputs (loop dedicated I/O).
• An output is read out each time new values are entered into the data base.
• Optional software limitations can be selected.
Analog Output, Board Types

Table 1-15 presents available analog output boards.
Table 1-15. Analog Output Boards

DSAO 110 Four channels, resolution 12 bits incl. sign, DSTA 160 DSTK 223L3
0 to ±10 V or
0 to ±20 mA, 0 to ±10 mA,
galvanic isolation, channel by channel
DSAO 120 Eight channels, resolution 12 bits incl. sign, DSTA 170 DSTK 223L3
0 to ±10 V or
0 to ±20 mA
DSAO 120A Eight channels, resolution 12 bits incl. sign, DSTA 171 DSTK 223L3
0 to ±10 V or
0 to ±20 mA
DSAO 130 16 channels, resolution 8 bits unipolar DSTA 180 DSTK 221L3
0 to + 10 V or
0 to + 20 mA, 0 to + 10 mA
DSAO 130A 16 channels, resolution 8 bits unipolar DSTA 181 DSTK 221L3
0 to + 10 V or
0 to + 20 mA, 0 to + 10 mA
1-60 3BSE 002 414R601 Rev B

Table 1-15. Analog Output Boards (Continued)

DSAX 110 Analog input: DSTA 001A DSTK 223L3
0 to + 10 V,
0 to + 20 mA,
shunt 250 Ω 0.05%
Analog output:
0 to + 20 mA,
DSTA 001)
DSAX 110 Analog input: DSTA 001B DSTK 223L3
0 to + 10 V,
0 to + 20 mA,
shunt 250 Ω 0.05%
Analog output:
0 to + 20 mA,
DSTA 001)
2 x DSAX 110 Redundant coupling. Data otherwise the DSTA 001A 2 x DSTK 223L3
same as for DSAX 110 above.
2 x DSAX 110 Redundant coupling. Data otherwise the DSTA 001B 2 x DSTK 223L3
same as for DSAX 110 above.
3BSE 002 414R601 Rev B 1-61

Analog Output, Block Diagram
Controller Signal adaption unit Process

software
e.g.
Analog
Program Data base output Connection
board unit
Test
terminal (X3)
(not all types of units)
Figure 1-26. Analog Output Signal, Block Diagram
Pulse Counting/Frequency Measurement, Main Points

• Pulse counter units are available for pulse counting and frequency measurement,
for 5, 12 or 24 V d.c. inputs and frequencies up to 2.5 MHz.
• Scaling (conversion to process-related units).
• Optional software limitations can be selected.
Pulse Counting/Frequency Measurement, Board Types

Table 1-16 presents available boards.
Table 1-16. Pulse Counting/Frequency Measurement Boards

DSDP 150 12 channels, 5/12/24 V d.c., max. 10 kHz DSTD 150A / DSTD 190 DSTK 225SL3
DSDP 170 Four measurement systems each DSTX 170 DSTK 228L3
containing inputs for pulse generator:
Two channels and strobe
5/12/24 V or ±13 mA,
max. 2.5 MHz
DI: 24 V d.c.
DO: 24 V max. 250 mA d.c.
1-62 3BSE 002 414R601 Rev B

Pulse Counting/Frequency Measurement, Block Diagram
Connection Circuit board Controller software

unit
Data base
Pulse Filter 8-bit Program
counter Pulse board
Pulse
Direction
Figure 1-27. Pulse Counter Input Signal DSDP 110, Block Diagram
Board DSDP 150 Controller software
Discrimination
level
5, 12 or 24 V
Channel 1 PC element Applic.

progr.
Frequency
Function Function Frequency measurement
selector selector calculation
IN Signal
adaptation
Number of pulses
16-bit Reading
and
counter Calculation Error
Error signal
supervision
Channel 2
Internal data exchange
Figure 1-28. Pulse Counter Input Signal DSDP 150, Block Diagram
3BSE 002 414R601 Rev B 1-63

Positioning, Main Points

For further information on positioning, see Section 1.7.8.3, Control Functions, under the
heading Positioning and see the Positioning System User’s Manual.
Positioning, Board Types

Table 1-17 presents the available board.
Table 1-17. Positioning Board

DSDP 140A One positioning loop input for pulse DSTD 150A / DSTD 190 DSTK 225SL3
generator:
three channels, ±15 mA,
max. 80 kHz
DI/DO: 24 V d.c.,
AO: Resolution 11 bits + sign,
0 to + 10 V or 0 to ±20 mA
Converter Connection, Main Points

For further information on converter connection, see
Section 1.7.8.3, Control Functions, under the heading Converter Connection.
Converter Connection, Board Types

Table 1-18 presents the available board.
Table 1-18. Converter Connection Board

DSDC 111 Eight DI + Sync. 24V d.c. DSTX 110 DSTK 224L3
Eight DO, 24 V d.c.
Two AI
AI one, resolution 9 bits + sign
0 to ±10V
AI two, Ref. input to AO2
Three AO 0 to ±10V resolution:
AO one, 11 bits + sign
AO two, 9 bits + sign
AO three, 9 bits + sign
1-64 3BSE 002 414R601 Rev B

1.7.6.2 S400 I/O

S400 I/O units communicate with Advant Controller 410 using MasterFieldbus.
See the outline presentation of MasterFieldbus in Section 1.7.7, Communication or the separate
documentation mentioned.
Process variables, connected via S400 I/O units and S100 I/O boards, are available in the
process data base in the same way. The high performance of MasterFieldbus makes the delay in
process scanning due to fieldbus communication negligible in most applications.
However, time-tagged events have comparatively reduced accuracy.
If an S400 I/O unit loses its contact with Advant Controller 410 for any reason, it enters “local
mode.” In this mode, it maintains its output signals at their most recent correct values or to a
predetermined value, as selected by the user. These safe values are set in the Advant Controller
410 data base and transferred to the unit at start-up. Normal operation is resumed when the
connection is re-established.
S400 I/O Units, Outline Description

A basic S400 I/O unit for binary signals has 32 channels. You can expand it with another
32 channels by adding an expansion unit. Analog units have 20 channels and cannot be
expanded.
Basic units are ready for direct connection to MasterFieldbus. Expansion units are connected to
the basic units by means of short ribbon cables.
The units are enclosed and equipped with a built-in power supply including a separate, isolated
supply for sensors. The enclosure is in accordance with IEC 529, IP20. All external connections
are made by plug detachable screw terminals. You can mount the units directly on a wall, or,
more commonly, in a protective enclosure on a mounting plate, or on DIN mounting rails.
All units have LED indicators for power supply and communication. Digital units also have
LEDs for indication of the status of each I/O channel.
240 220 120 AB AB AB AB AB AB AB
ABB Master
................... 1 17
............. ......... .........
DSDX 452
5 21
......... .........
9 25 192 mm (7.6”)
......... .........
13 29
......... .........
1 2 3 4 5 6 7 8 9 10
237 mm (9.3”)
Figure 1-29. Example of basic I/O Unit, DSDX 452 - 20 Inputs and 12 Outputs
3BSE 002 414R601 Rev B 1-65

S400 I/O Units
Table 1-19. S400 I/O Units
S400 I/O units Description

Digital basic units
DSDX 452 DI: 20 channels,
DSDX 452L 24 V d.c. for DSDX 452 and DSDX 452L
DSDX 454 48 V d.c. for DSDX 454 and DSDX 454L
DSDX 454L DO: 12 channels, relay output (1), expandable
Supply: 120/220 (230)/240 (230) V a.c., 50/60 Hz
DSDI 452 DI: 32 channels,

DSDI 454 24 V d.c. for DSDI 452, 48 V d.c. for DSDI 454
Supply: 120/220 (230)/240 (230) V a.c., 50/60 Hz
Digital expansion units
DSDX 451 DI: 20 channels,
DSDX 451L 24 V d.c. for DSDX 451 and DSDX 451L
DSDX 453 48 V d.c. for DSDX 453 and DSDX 453L
DSDX 453L DO: 12 channels, relay output, expandable
Supply: 120/220 (230)/240 (230) V a.c., 50/60 Hz
DSDI 451 DI: 32 channels,

DSDI 453 24 V d.c. for DSDI 451
48 V d.c. for DSDI 453
Supply: 120/220 (230)/240 (230) V a.c., 50/60 Hz
Analog units
DSAX 452 AI: 14 channels,
differential 0 to ±10 V or 0 to ±20 mA,
resolution 12 bits + sign
AO: 6 channels,
unipolar 0 to + 10 V or 0 to + 20 mA,
resolution 10 bits
Supply: 120/220 (230)/240 (230) V a.c., 50/60 Hz
(1) Relay data for units without L in the type designation.
Loading: max. 3 A, min. 0.1 A with 24 V or 2.5 VA
Breaking capacity: a.c. max. 720 VA with cosϕ >0.4, d.c. max. 44. 44 W with L/R <40 ms.
Relay data for units with L (outputs for low current)

Loading: min. 1 mA but min. 0.05 VA, max. 200 mA but max. 5 VA
Breaking capacity: a.c. max. 200 mA or 5 VA with cosϕ >0.4, d.c. max. 200 mA or 5 W with L/R <40 ms.
1-66 3BSE 002 414R601 Rev B

1.7.6.3 S800 I/O

The S800 I/O provides distributed I/O to the Advant Controller 410 controller using the Advant
Fieldbus 100 (AF 100). See the outline presentation of Advant Fieldbus 100 in Section 1.7.7,
Communication or the separate documentation mentioned for all details.
Process variables, connected via S800 I/O modules and S100 I/O boards, are available in the
process data base in the same way. The high performance of Advant Fieldbus 100 makes the
delay in process scanning due to fieldbus communication negligible in most applications.
However, time-tagged events have comparatively reduced accuracy for modules without
internal sequence of event handling.
If an S800 I/O module loses its contact with Advant Controller 410 for any reason, it enters
“local mode.” In this mode, it maintains its output signals at their most recent correct values or
to a predetermined value, as selected by the user. These safe values are set in the Advant
Controller 410 data base and transferred to the unit at start-up. Normal operation is resumed
when the connection is re-established.
Mechanics
The mechanics components of the S800 I/O are characterized by the following features:
• Highly modularized mechanics with three or four basic parts:
– Communication Interface modules (or Field Communication Interface module),
– Optical Modulebus modem,
– S800L I/O modules including the field wiring termination, or
– I/O modules and field wiring termination Units (MTUs) (Module Termination Units)
which act as I/O module carriers.
The communication interface modules, Optical Modulebus modem, S800L I/O modules
and MTUs are mounted on standard DIN-mounting rails according to DIN EN50033-
35*15.
• All modules have plastic injection moulded enclosures which provide safety protection
degree IP20 according to IEC 529.
• I/O modules, except for S800L I/O modules where it is not applicable, are protected from
destruction by a mechanical keying arrangement if an attempt is made to insert a module type
in a position with a different key code than the factory set code of the I/O module. MTUs have
keys which are set to key code of its I/O module’s key code.
3BSE 002 414R601 Rev B 1-67

Figure 1-30. S800 I/O Fieldbus Communication Interface with an I/O-Module on

Compact and Extended MTUs and an S800L Module
S800 I/O Station

A S800 I/O Station can consist of a base cluster and up to 7 additional I/O clusters. The base
cluster consists of a Fieldbus Communication Interface and up to 12 I/O modules.
I/O cluster 1 to 7 consist of an Optical Modulebus modem and up to 12 I/O modules.
A S800 I/O Station can have a maximum of 24 I/O modules. I/O cluster 1 to 7 are connected to
the FCI module through an optical expansion of the Modulebus.
Modulebus
The Fieldbus Communication Interface module communicates with its I/O modules over the
Modulebus. The Modulebus can support up to 8 clusters, one base cluster and up to 7 I/O clusters.
The base cluster consists of a communication interface module and I/O modules. An I/O cluster
consist of an Optical Modulebus modem and I/O modules. The Optical Modulebus modems are
connected via optical cables to a optional Modulebus Optical port module on the communication
interface module. The maximum length of the Optical Modulebus expansion is dependent of the
number of Optical Modulebus modems. The maximum length between two clusters is 15 m
(50 ft.) with plastic fibre and 200 m (667 ft.) with glass fibre. Factory made optical cables (plastic
fibre) are available in lengths of 1.5, 5 and 15 m (5, 16 or 49 ft.). The Optical Modulebus
expansion can be build up in two ways, a ring or a duplex communication.
Within a cluster the Modulebus is made up of increments integrated into each Module
Termination Unit (MTU) or S800L I/O module. Each communication interface module and
Optical Modulebus modem has a Modulebus outlet connector to connect to a MTU or S800L I/O
module. A MTU or S800L I/O module has a bus inlet and a bus outlet connector. By adding, on
1-68 3BSE 002 414R601 Rev B

the DIN rail, a MTU or S800L I/O module to a communication interface module or an Optical
Modulebus modem, the bus is automatically expanded, offering optional further expansion of
MTUs or S800L I/O modules to a maximum of 12 modules. Unique position codes are
automatically assigned to each MTU or S800L I/O module as the bus is expanded. Through the
incremental bus design the physical size of an S800 I/O installation is directly proportional to the
number of installed MTUs or S800L I/O modules.
MTUs and their associated I/O modules or S800L I/O modules can within a cluster be set up in
two or three physically separated groups with extension cable adaptors which fit to the bus outlet
and inlet connectors of communication interface modules, Optical Modulebus modem and
MTUs or S800L I/O modules. The factory made extensions cables which plug into the cable
adaptors are available in lengths of 0.3, 0.6 and 1.2 m (1, 2 or 4 ft.), allowing together with up to
12 I/O modules, for a total bus length of 2,5 meters (8.2 ft.).
The S800 I/O modules, except S800L I/O modules, can be inserted and removed from MTUs
without disturbing system operation. The physical lock which locks an I/O module to its MTU
allows I/O module removal only when the lock is in its unlock position. The locking mechanism
also acts as a logic lock so that an I/O module is operable only when the lock is in the locked
position. If the lock is in its unlocked position, output channels are de-energized and I/O modules
can be inserted/removed without need to remove system or field power.
The MTUs are totally passive units and all active circuitry is allocated to the I/O module.
3BSE 002 414R601 Rev B 1-69

Fieldbus Communication Interface Modules

The Fieldbus Communication Interface (FCI) modules have an input for one 24 V d.c. power.
The FCI provides 24V d.c. (from the source) and an isolated 5V d.c. power to the base cluster’s
I/O modules (12 maximum) by way of the ModuleBus connections. There are three types of FCIs
one for single Advant Fieldbus 100 configurations, one for redundant Advant Fieldbus 100
configurations and one for single PROFIBUS configurations. The power source can be the
SD811/812 power supplies, battery, or other IEC664 Installation Category II power sources.
Power status inputs, 2 x 24 V, to monitor 1:1 redundant mains are also provided.
The singleAdvant Fieldbus 100 FCI module have two connectors and built-in modems, for
redundant AF 100 twisted pair cables, a connector for the Modulebus Optical port module and a
galvanically isolated RS-232 service port to allow trouble free tools connection.
The redundant Advant Fieldbus 100 FCI module have one connector and built-in modem, for one
AF 100 twisted pair cable and connectors to a connection unit.Two redundant FCI modules are
connecting to each other via an Interconnection Unit (TB815). Connectors for electrical
Modulebus, Modulebus Optical port module and two galvanically isolated RS-232 service ports
are placed on the Interconnection Unit TB815, one for each FCI.
The AF 100 connector plugs can be inserted/removed without interrupting AF 100
communication between other stations.
The single PROFIBUS FCI module have one connector and built-in modems, for PROFIBUS
twisted pair cables, a connector for the Modulebus Optical port module and galvanically isolated
RS-232 service port to allow trouble free tools connection.
The front plate of the FCI modules provides LEDs for diagnostic and status indications.
Two rotary switches are provided for setting of the station address. No other addresses are
required to be set within the I/O-station. Labels for optional user text and item number are also
provide.
Table 1-20. Communication Interface Module
Module type Description

CI810A AF 100 Fieldbus Communication Interface, 2 x AF 100 Modems for
twisted pair cable. Power supply 24 V,.
Rated isolation voltage 50 V.
CI820 AF 100 Fieldbus Communication Interface for redundant configurations,
1x AF 100 Modems for twisted pair cable. Power supply 24 V,
TB815 Interconnection Unit
CI830 PROFIBUS Fieldbus Communication Interface, one Modems for twisted
pair cable. Power supply 24 V. Rated isolation voltage 50 V.
1-70 3BSE 002 414R601 Rev B

I/O Interfaces
A range of I/O modules is available covering analog, pulse and digital signals of various types.
Interfaces for RTDs and TCs of various types and modules with intrinsically safe interface and
HART communication are available.
The S800 system provides I/O modules with typically 2, 4, 8 or 16 channels depending on type
and ratings of the individual module.
All I/O modules are supervised at system start-up as well as under normal operation. The status
of a module is indicated with front mounted LEDs; RUN (R), green, normal operation, FAULT
(F), red, when a fault is detected, WARNING (W), yellow, when a channel fault is detected and
OUTPUT SET AS PREDETERMINED (OSP), yellow, when the module has lost
communication. Detailed status and diagnostics are available on the System Status Displays of
the Operator Station.
All I/O modules can be replaced with both system power and field power connected.
Digital Modules
The digital I/O modules all have galvanic isolation relative to chassis ground. All modules have
LEDs to indicate channel status (on/off) and the standard set of module status indicators. Some
modules has also a LED per channel indicating fault.
24 V and 48V modules have two isolated groups with 8 channels.each Each group has a field
power status input to indicate presence of field power. Loss of field power is indicated on
Warning LED and channel status set to error. 120/250 V and modules with intrinsically safe
interface modules have individually isolated channels. The input module can be configured to
monitor field power status. Outputs do not need external inductive load suppression components.
Table 1-21. S800 Digital Modules
DI801 Digital Input 24 V d.c., 1*16 channels. Current sink.

DI810 Digital Input 24 V d.c., 2 x 8 channels. Current sink.
DI811 Digital Input 48 V d.c. 2 x 8 channels. Current sink.
DI814 Digital Input 24 V d.c. 2 x 8 channels, current source.
DI820 Digital Input 120 V a.c. 8 x 1 channels. Current sink.
DI821 Digital Input 230 V a.c. 8 x 1 channels. Current sink.
DI830 16 channels (2x8) 24V d.c., current sink, with sequence of event
(SOE) handling.
DI831 16 channels (2x8) 48V d.c., current sink, with sequence of event
(SOE) handling.
3BSE 002 414R601 Rev B 1-71

Table 1-21. S800 Digital Modules (Continued)
DI885 Digital Input 24/48 V d.c. 1 x 8 channels, Current sink with

sequence of event (SOE) handling.
DI890 Digital Input, Intrinsically safe interface 8 x 1 channels
DO801 Digital Output 24 V d.c. 0.5A. Current source, short circuit proof,
1*16 channels. Rated isolation voltage 50 V.
DO810 Digital Output 24 V d.c. 0.5 A Current source short circuit proof,
2 x 8 channels. Rated isolation voltage 50 V.
DO814 Digital Output 24 V d.c. 0.5 A short circuit proof, 2 x 8 channels,
Current sinking.
DO815 Digital Output 24 V d.c. 2 A current source short circuit proof,
2 x 4 channels.
DO820 Digital Output Relay 8 x 1 channels. 24-230 V a.c. 3 A cos ϕ >
0.4 Normal Open
d.c. < 42 W. Varistor protected.
DO821 Digital Output Relay 8 x 1 channels. 24-230 V a.c. 3 A cos ϕ >
0.4 Normal Closed
d.c. < 42 W. Varistor protected.
DO890 Digital Output, Intrinsically safe interface 4 x 1 channels
1-72 3BSE 002 414R601 Rev B

Analog Modules
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.
Table 1-22. S800 Analog Modules
AI801 Analog Input 1*8 channels. 0(4)…20mA, 12 bit., 0.1%

Current shunt resistor 250Ω is protected to 30V.
Rated isolation voltage 50V.
AI810 Analog Input 1 x 8 channels. 0(4)…20 mA, 0(2)…10V, 12 bit.,

0.1% Current shunt resistor is protected to 30 V.
AI820 Analog Input differential 1 x 4 channels. -20…20 mA, -5...5 V,

-10…10 V, 12 bit + sign, 0.1 %, CMV 50 V.
Current shunt resistor is protected to 30 V.
AI830 Analog Input 1 x 8 ch. Pt100 (-80... 80oC, -200... 250oC,
-200 ... 850oC), Ni100 (-60 ... 180oC), Ni120 (-80 ... 260oC),
Cu10 (-100 ... 260oC), Resistor (0 ... 400Ω), 14 bit.
AI835 Analog Input 1 x 8 ch. Termo Couples (TC),

type B (0 ... 1820oC), type C (0 ... 2300oC),
type E (-270 ... 1000oC), type J (-210 ... 1200oC),
type K (-270 ... 1372oC), type N (-270 ... 1300oC),
type R (-50 ... 1768oC), type S (-50 ... 1768oC),
type T (-270 ... 400oC), linear -30 ... 75 mV, 14 bit.
AI890 Analog Input, with Intrinsically safe interface 1 x 8 ch.

0 (4)...20mA, 12 bit, 0.1%
AI895 Analog Input, with Intrinsically safe and HART interface,

0(4)...20mA, 12 bit, 0.1%
AO801 Analog Output 1*8 channels, 0(4)…20mA, 12 bit.

RL maximum 850 Ohms.
AO810 Analog Output 1 x 8 channels, 0(4)…20 mA, 14 bit 0.1%

RL maximum 500/850 Ohms.
3BSE 002 414R601 Rev B 1-73

Table 1-22. S800 Analog Modules (Continued)
AO820 Analog Output 4 x 1 channels, -20…20 mA, -10...10 V,

12 bit + sign, 0.1%, individually galvanical isolated.
Current output RL maximum 550 Ohms.
Voltage output RL minimum 2 kohms.
AO890 Analog Output, with Intrinsically safe interface 1 x 8 ch.

0(4)...20 mA, 12 bit, 0.1%
AO895 Analog Output, with Intrinsically safe and HART interface
0(4)...20mA, 12 bit, 0.1%
Pulse Conting / Frequency Measurement Modules

The Pulse Counting / Frequence Measurement modules DP820 is a two-channel pulse counter
module in the S800 I/O series. Each channel can be used for independent pulse count/length
measurement and frequency/speed measurement. The module is placed in a S800 I/O station
connected to the Controller via Advant Fieldbus 100.
Configuration and signal handling of module DP820 is handled via the data base element
DP820 and PC-element DP820-I and DP820-O.
NOTE
At least one DP820-O PC element must be used for each DP820 module to
achieve proper functionality in all situations for AC 400 Series.
Table 1-23. Puls Counting / Freqency Measurement Modules
DP820 Pulse counter measurement. A 29 bits bidirectional counter with:

- Coincidence detection controlling one digital output signal.
- Freezing of counter value depending on different
conditions.
- Synchronization of counter depending on different
conditions.
Frequency/Speed measurement up to 1.5 MHz with:
- Freezing of value depending on different conditions.
- Selectable measure time within 1 up to 2000 milliseconds.
- Built-in scaling of frequency value to engineering units.
Transducers with quadrature encoded signals or with up/down
pulse signals can be connected to the module.
1-74 3BSE 002 414R601 Rev B

Module Termination Units (MTU)

Termination Units are available as Compact MTUs or Extended MTUs. A compact MTU
normally offers termination of one wire per channel for a 16 channel module. With compact
MTUs power distribution of field circuits must be made with external terminal blocks and current
limiting components if required. Extended MTUs with group-wise isolated interfaces allows for
two or three wire termination of field circuits and provides group-wise or individually fuses,
maximum 6.3A glass tube type, for powering field objects. Extended MTUs which offer two or
three wire terminations allows direct field object cable termination. The need for external
marshalling is therefore drastically reduced or eliminated when extended MTUs are used.
Compact MTUs are 58 mm (2.3”) wide and extended MTUs are 120 mm (4.72”) wide. The two
MTU types can be mixed and matched within an I/O-station to fit a user’s needs. Choice of
compact MTU or extended MTU can be made freely trading space versus termination needs.
Compact and extended MTUs are available with rated isolation voltages 50 V and 250 V.
The 50 V types can be used with all 24 V or 48 V discrete I/O and analog I/O modules.
The MTUs with 250 V rated isolation voltage are used with all 120 V and 250 V rated I/O
modules. There is also one compact MTU for modules with Intrinsically safe interface.
Table 1-24. S800 Module Termination Units
TU810 Compact MTU, 58 mm wide. Two isolated groups each with

2 rows of 4 uncommitted terminals, 2 pcs L+ terminals and one
row of 5 pcs L-.
Conductor area: 0.2-2.5 mm2, AWG 24-12.
TU811 Compact MTU, 58 mm wide. 2 x 8 uncommitted terminals.

TU812 Compact MTU, 58 mm wide. 25 pin D-sub Connector for field

connection
TU814 Compact MTU, 58 mm wide. Crimp Snap-in Connectors for field

connection.
Conductor area: 0.5-1,0 mm2, AWG 16-22 .
TU830 Extended MTU, 120 mm wide. Two isolated groups each with 2
rows of 8 uncommitted terminals, 2 pcs L+ terminals and one row
of 10 pcs L-.
TU831 Extended MTU, 120 mm wide. 2 x 8 uncommitted terminals.

Conductor area 0,2-4 mm2, AWG 24-10.
3BSE 002 414R601 Rev B 1-75

Table 1-24. S800 Module Termination Units (Continued)
TU835 Extended MTU, 120 mm wide. Two isolated groups with 2 rows
each one rows of 4 uncommitted terminals individually fused,
one rows of 4 uncommitted terminals, 2 pcs L+ and 2 pcs
L- terminals.
Conductor area: 0.2-2.5 mm 2, AWG 24-12.
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.
TU837 Extended MTU, 120 mm wide. 16 individually isolated terminals

(8 ch) each channel has one process voltage terminal and one
fused (3 A) load outlet.
Two groups of uncommitted return terminals.
2 + 3 interconnected terminals.
Conductor area (ch): 0.2-4 mm2, AWG 24-10.
Conductor area (return): 0.2-2.5 mm2, AWG 24-12.
TU838 Extended MTU, 120 mm wide. Two isolated groups. Each group
8 I/O channels, 4 fused transducer power outlets, 4 return tecon-
nections and process power connection.
Conductor area: 0.2-2.5 mm2, (Stranded) AWG 24-12.
TU890 Compact MTU, 58 mm wide for modules with Intrinsically safe

interface. 27 uncommitted terminals and 4 terminals for power
supply.
Conductor area (return): 0.2-2.5 mm2, (Stranded) AWG 24-12.
1-76 3BSE 002 414R601 Rev B

Power Supplies
The power supplies SD811 and SD812 (24 V output) can be used to power processor modules
and S800 I/O modules, through the processor unit and to power 24 V field circuits (optional).
The supplies have a wide input voltage range, nominally 110V-240 V without input voltage range
selection. The primary side can connect to industrial mains installation class III (IEC664).
The outputs are short circuit proof and can operate with resistive, capacitive and constant power
loads, for example, switched mode power converters.
The outputs of the supplies can be connected in parallel to increase power, 2 x SD811 or
2 x SD812, or be configured for redundant mains to increase availability, 2 x SD811 or
2 x SD812. Each supply has a power OK signal which can connect to the SA or SB inputs of the
communication interface modules or Optical Modulebus modem to monitor power status in 1:1
redundant mains configurations.
Table 1-25. Power Supplies
Module Type Description
SD811 SD811 Power Supply 100-240 V a.c./185-250 V d.c.

24 V d.c. 2.5 A.
SD812 SD812 Power Supply 100-240 V a.c./185-250 V d.c

24 V d.c. 5 A.
Optical Modulebus Expansion

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.
Optical Modulebus Modem
The Optical Modulebus modems have an input for one 24 V d.c. power. The FCI provides 24V
d.c. (from the source) and an isolated 5V d.c. power to the base cluster’s I/O modules (12
maximum) by way of the ModuleBus connections. The power source can be the SD811/812
power supplies, battery, or other IEC664 Installation Category II power sources. Power status
inputs, 2 x 24 V, to monitor 1:1 redundant mains are also provided
The front plate of the Optical Modulebus modem provides LEDs for diagnostic and status
indications. One rotary switches is used for setting of the cluster address. Labels for optional user
text and item number are also provided.
3BSE 002 414R601 Rev B 1-77

Modulebus Optical Port

The Modulebus Optical port have connectors for optical cables and connector for connection to
the communication interface module.
Table 1-26. Modulebus Items
TB810 Modulebus Optical port 10 Mbit/s for Modulebus optical

expansion used together with S800 I/O and Drive equipment.
Option to the Fieldbus Communication Interface.
TB811 Modulebus Optical port 5 Mbit/s for Modulebus optical expansion

used together with Drive equipments.
Option to the Fieldbus Communication Interface.
TB815 Module Bus Interconnection Unit to redundant FCIs (CI820)

TB820 Optical Modulebus modem. Optical and electrical Modulebus
interface.
Power supply 24 V
1.7.7 Communication
System communication resources are primarily treated in Section 1.7.7.1, Provided Link Types.
You will find an enumeration of the main applications of these communication links in Advant
Controller 410 in this section.
1.7.7.1 Provided Link Types

Information in this section is divided according to the different link types. An outline
description follows. All link types, besides the widely spread standard V.24/RS-232-C,
are described in separate users’ guides. For referral to specific documents, see Section 1.4,
Related Documentation.
Provided link types in Advant Controller 410 are:
MasterBus 300/MasterBus 300E, GCOM, Bus Extension to S100 I/O, MasterFieldbus,
Advant Fieldbus 100, PROFIBUS-DP, LONWORK Network, RCOM, EXCOM,
MultiVendor Interface and V.24/RS-232-C
MasterBus 300/MasterBus 300E, Outline Description

Use MasterBus 300 to interconnect Advant Controller 400 Series, Advant Station 500 Series,
MasterPiece 200/1, MasterView 800/1 Series and MasterBatch 200/1 stations in a control
network (network communication). It provides high-speed, high-performance communication
over medium distances.
1-78 3BSE 002 414R601 Rev B

Section 1.7.7 Communication
MasterBus 300 is based on the IEEE 802.2 class 1 connection-less unconfirmed data link
service protocol and IEEE 802.3 CSMA/CD (Carrier Sense Multiple Access/Collision
Detection) medium access control. In short, this means that there is no specific master station,
but all stations/controllers have equal access to the bus. A connection-oriented transport
protocol according to ISO class 4 ensures flow control and reliability.
Use MasterBus 300E (Extended) when communicating via bridges (and radio links, satellites,
and so on) to interconnect MasterBus 300 networks. The communication bridges must conform
to the IEEE 802,3 standard. The characteristics of MasterBus 300E are the same as for
MasterBus 300 except that the communication parameters can be tuned to allow communication
over links, which introduces delays and limits the bandwidth.
The MasterBus 300/MasterBus 300E separates the communication function within a
station/controller. You can expand or reconfigure the control network without any changes to
the application in the controllers or operator’s stations. The network is self-configured, that is
no configuration of the data base is required. The configurator sets network and node identity on
hardware.
The transmission rate is 10 Mbits/s.
To also ensure availability of data communication when a cable or a communication unit fails,
you can duplicate MasterBus 300/MasterBus 300E.
GCOM, Outline Description

GCOM is a data link protocol used for data exchange with the help of message passing between
external computers and Advant OCS stations/controllers. The protocol is available for VAX
computers. The following data link protocol alternatives are supported:
• IEEE 802.2 class 1 logical link control and IEEE 802.3 CSMA/CD medium access control
• CCITT recommendation X.25.2 LAPB with transmission rate 19.2 or 50 kbits/sec
• ADLP-10 (ABB Data Link Protocol), an asynchronous protocol based on ECMA 16 and
ECMA 24, with transmission rate of 9.6 kbits/sec.
You can duplicate GCOM to achieve full redundancy.
Bus Extension to S100 I/O

In contrast to the Advant Controller 450, the Advant Controller 410 cannot extend the S100 I/O
bus to further I/O subracks, so the number of S100 I/O boards is limited.
MasterFieldbus, Outline Description

MasterFieldbus is a high-speed communication link that connects S100 I/O. In addition, it also
connects local processing units such as MasterPiece 90, MasterPiece 51 and converters for
motor drives (TYRAK L or SAMI) to Advant Controller 410.
You can connect several buses to one Advant Controller 410, and each bus can take up to 16
remote units.
You can disconnect remote units from the bus and replace them without disturbing other units or
their communication with Advant Controller 410. Communication with a reconnected unit is
resumed automatically.
3BSE 002 414R601 Rev B 1-79

MasterFieldbus operates at 2 Mbits/s.

For distances up to 25 m (82 ft.), use MasterFieldbus with twisted pair cable and without
modems. For longer distances, use modems. Both coaxial and optical types of cable are
available.
MasterFieldbus can also operate at 375 kbits/s. This speed is used, for example,
when communicating with MasterPiece 90.
For increased availability, you can duplicate the cables and modems (physical redundancy).
Figure 1-31 gives an example of a physical configuration.

“Bus controller”
Comm. module
CI570
Conn. unit
TC570
Max. 25 m (82 ft.)
SDB
Modem Distr. Modem Distr. Exp.

DSTC452 unit DSTC454 unit unit
LDB
Optic cable
(typ. 3000 m
(9842 ft.)
Modem
LDB
Coaxial cable
DSTC454
(max. 750 m) Max. 25 m
(2460,6 ft.) (82 ft)
Modem Max. 25 m (82 ft)
DSTC452 SDB
SDB
Distr. Distr. Exp. Distr. Exp.
unit unit unit unit unit
Modem
DSTC452
LDB - Long-Distance Bus
Max. 25 m (82 ft) SDB - Short-Distance Bus
SDB
Distr. Distr.
unit unit Termination unit
Figure 1-31. Example of Physical Configuration of Non-redundant MasterFieldbus and S400 I/O Units
1-80 3BSE 002 414R601 Rev B

Advant Fieldbus 100, Outline Description

Advant Fieldbus 100 is a high-performance bus specially designed for real-time applications.
A number of different products are connectable to Advant Fieldbus 100, that is
Advant Controller 410/450, Advant Controller 110, distributed S800 I/O stations, ACV 700
Converter, and so on. It features reliable, cyclic data transfer as well as event-driven background
transfer of service data.
Advant Fieldbus 100 also features a distributed master scheme. If one or several controllers are
lost, the bus is not affected and operations continue.
Three types of transmission media, coaxial cable, twisted pair cable and optical fibre are
supported. The maximal bus length is depending on which transmission media is used.
For increased availability, you can duplicate the cables and modems (physical redundancy) or
for full redundancy also duplicate the bus interface modules.
An S800 I/O station has a built in modem and communication interface for the twisted pair
media.
AC 410
CI522A AdvaSoft for Windows

CI526
TC625 TC625
Advant Fieldbus 100
CT CT
External
CI626
CI626
Device
AC 110 AC 110
CT Grounded 75 Ohm BNC termination
CT 75 Ohm BNC termination
Figure 1-32. A non-redundant Advant Fieldbus 100 Configuration using Coaxial Media
3BSE 002 414R601 Rev B 1-81

With modem TC515V2 you can extend the bus length up to 1400 m.
AC 410
CI522A
TC516
Advant Fieldbus 100
TT TT
TT TT
External
PM810V1 Device
I/O Modules
AC 70
CI820
TB815
CI820
TC515V2
TT TT
TT TT
S800 I/O Station TT Grounded twisted pair termination

TT Twisted pair termination AC 70
Figure 1-33. A redundant Advant Fieldbus 100 Configuration using Twisted pair Media
Together with the opto-modem TC630 or TC514 and opto-fibre cable, you can extend the bus
length up to 1700 m.
AC 410
Optical media
TC630 TC630
Coaxial media Coaxial media
CT CT CT CT
CI522A
TC512V1 TC513
CI626
CI626
Twisted pair media

TT TT
AC 110 AC 110
TC514V2
PM810 CT Grounded 75 Ohm BNC termination
AC 70 CT 75 Ohm BNC termination
Optical media TT Grounded twisted pair termination
TT Twisted pair termination
TC514V2
Twisted pair media
TT TT
S800 I/O Station
Figure 1-34. Media Conversion in Advant Fieldbus 100
1-82 3BSE 002 414R601 Rev B

PROFIBUS-DP Outline Description

PROFIBUS is a set of international fieldbus standards included in the European standard
EN 50 170. Within the PROFIBUS family of protocols, PROFIBUS-DP is optimized for high
speed and inexpensive hookup. It features reliable, cyclic data transfer.
PROFIBUS-DP is designed especially for communication between automation control systems
and distributed I/O at the device level.
Network Configurations
AC 400 Series
or AC 110
DP to PA PROFIBUS-
segment coupler PA device
PROFIBUS-DP PROFIBUS-DP
device device
Figure 1-35. PROFIBUS-DP configuration example
Up to 125 slave nodes can be connected to one bus. Up to four buses can be configured in an
Advant Controller 410.
3BSE 002 414R601 Rev B 1-83

LONWORK Outline Description

LONWORKS is an open fieldbus which has been designed to be used as a control network. Is
is characterized by multiple communications media, MultiVendor equipment, low maintenance
cost, and very low per node cost. It features event handling and reliable, cyclic data transfer.
Network Configurations
AC 400 Series
Router to other LONWORKS

media or speed device
LONWORKS LONWORKS LONWORKS

device device device
Figure 1-36. LONWORKS network configuration example
Up to 64 devices can be supervised by Advant Controller 410 on one LONWORKS network.

Meaning that more devices can be connected to the network, but can not supervised by the
Advant Controller 410. See Functional Unit 10 MOTCONI User’s Guide for details about the
INSUM integration. Up to four LONWORKS network can be configured in an Advant
Controller 410.
1-84 3BSE 002 414R601 Rev B

EXCOM, Outline Description

EXCOM (EXternal computer COMmunication) permits the external computer to read or write
in the Advant Controller 410 data base with the help of simple commands and an asynchronous
serial communication link V.24/RS-232-C. The communication is controlled by the external
computer. Figure 1-37 shows the possible alternative means of connection with an external
computer. This figure shows how you can connect an external computer directly to one or more
Advant Controller systems. The external computer can reach other nodes in the configuration
through communication via a MasterBus.
EXTERNAL Advant Controller

COMPUTER 400
EXTERNAL
COMPUTER
Advant Controller Advant Controller Advant Controller

400 Series Operator Station
400 Series 400 Series
MasterBus
Advant Controller Advant Controller Advant Controller

400 Series 400 Series 400 Series
Figure 1-37. Alternative Connections of an External Computer to Advant Controllers
RCOM, Outline Description

RCOM (Remote COMmunication) enables Advant Controller 410 to communicate/transmit
data to other units over long distances via a serial V.24/RS-232-C asynchronous communication
bus.
You can connect the following Advant OCS product lines and alien equipment to the Advant
Controller 410:
• Advant Controller 50 series
• MasterPiece 200/1
• Older types of ABB Master process stations or alien computers
• Various equipment, for example, Essentor PC manager.
3BSE 002 414R601 Rev B 1-85

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. Use redundant RCOM only for point-to-point connections.
MultiVendor Interface, Outline Description

MultiVendor Interface (MVI) is communication with other manufacturers’ control systems.
The following MVI protocols are available as standard:
• MODBUS
• Siemens 3964 (R)
• Allen-Bradley DF1.
In addition, there is an MVI free-programmable communication interface which you can use to
support user-defined protocols. This function enables you to connect “intelligent” transducers of
different types to an Advant Controller. The module used has two serial asynchronous channels
and is programmed in C language. The programming is done in a MVI Development
Environment based on a work station.
MVI uses a V.24/RS-232-C asynchronous serial communication link. This link allows
communication at long distances.
1.7.7.2 Applied Communication

Advant Controller 410 communicates with a wide range of products, as indicated in Table 1-27.
The links used are shown. RCOM is, in some cases, an alternative for long-distance or low-
cost/less-performance applications. The main functionality obtained is given. Additionally,
there are diagnostics generally included as a basic link function.
Diagnostics information on the communicating units is also commonly accessible via status
messages.
Table 1-27. Communication Survey
Equipment Used link(s) Functionality (explanations below)

Advant Controller 410/450 MasterBus 300/300E, RCOM R I B EA
Advant Station 500 Series OS MasterBus 300/300E E S C
Advant Station 500 Series IMS MasterBus 300/300E E S C
Advant Station 500 Series ES MasterBus 300/300E 2)
MasterPiece 200/1 MasterBus 300/300E, RCOM R I B EA
MasterView 800/1 MasterBus 300/300E E S C
MasterBatch 200/1 MasterBus 300/300E 1)
MasterGate 230/1 MasterBus 300/300E E S C
1-86 3BSE 002 414R601 Rev B

Table 1-27. Communication Survey (Continued)
Equipment Used link(s) Functionality (explanations below)

Advant Station 100 Series IMS GCOM E S C
SuperView 900 GCOM E S C
AdvaSoft for Windows GCOM R I B
S100 I/O Bus Extension to S100 I/O E 6)
S400 I/O MasterFieldbus EA 6)
S800 I/O Advant Fieldbus 100 R I B EA 6)
MasterPiece 51 MasterFieldbus B
TYRAK L, SAMI, and so on MasterFieldbus R I B 3)
Advant Controller 110 Advant Fieldbus 100, RCOM R I B E
MasterPiece 90 MasterFieldbus R I B
ACV 700, DCV 700 Converter Advant Fieldbus 100 R I B
Advant Station 100 Series ES Internal bus 2)
ABB Prologger, DCS Tuner EXCOM R I B 4)
Printer V.24 / RS-232-C 5)
MasterView 320 V.24 / RS-232-C R I B E
Advant Controller 55 RCOM R I B EA
Advant Controller 70 Advant Fieldbus 100 R I B E
ABB Active Mimic Controller RCOM B
Other manufacturers’ equipment MVI R I B
PROFIBUS-DP R I B
LONWORKS Network R I B E
Explanations
1) Mainly recipe data and report data are sent.
2) Configuration data transfer.
3) The control of d.c. motors in a drive system is integrated in the converter, which involves a
considerable exchange of signals with Advant Controller 410. A special communication
package implemented in the converter makes this adaptation possible.
4) EXCOM also provides reading of object data of the type AI, AO, DI, DO (Analog
Input/Output, Digital Input/Output). This is utilized by the given product.
3BSE 002 414R601 Rev B 1-87

5) The main use of a printer for generating reports is described in Section 1.7.8.3, Control
Functions, under the heading Reports.
6) Read/write process I/O data.
R, I, B indicates Real, Integer and Boolean data, respectively. Bi-directional information flow is
possible.
E indicates handling of time-stamped events. Events are defined and time-stamped in the central
I/O of Advant Controller 410 or in distributed units of the type Advant Controller 110 and
Advant Controller 70. Advant Controller 410 sends the information to operator stations for
presentation in lists. High accuracy in time.
EA also indicates handling of time-stamped events. Events originated in certain distributed
units are time-stamped in the Advant Controller 410. Time delay due to communication must be
reflected. When Data Set is used a supporting application program is needed in Advant
Controller 410. Advant Controller sends the information to operator station for presentation in
lists. Less accuracy in time.
S indicates subscription of data from the Advant Controller 410 data base. It is requested by an
operator station or a similar station. A subscription is normally an object-oriented, complex
package of mixed data used for presentation purposes.
C indicates command signals, for example complex commands including several parameters or
increase/decrease, start/stop, and so on from an operator station or similar device.
Data Set
Information is exchanged between separate controllers (and between a controller and other
equipment indicated in Table 1-27) by means of “Data Sets,” that is messages containing
aggregates of data base information. Data Sets are explicitly specified in the communicating
controllers, as part of the application programming.
With a Data Set, the communication normally transmits cyclically between the nodes.
The cyclic time is configurable.
In addition to Data Set, other variants exist, for example MVI Set, Data Set Peripheral.
A Text Set is a type of Data Set. With a Text Set, you can send text between controllers/process
stations of the type Advant Controller 410/450 and MasterPiece 200/1 using MasterBus 300.
Transmission of a Text Set is commanded from a PC program.
For a detailed description of Data Set and Text Set, see the reference manual AMPL
Configuration Advant Controller 400 Series.
1-88 3BSE 002 414R601 Rev B

Section 1.7.8 Process Control
1.7.8 Process Control

Advant Controller 410 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.
1.7.8.1 Application Language
General
Process control applications are programmed in the ABB Master Programming Language
(AMPL), a function-block language with graphic representation which has been developed
especially for process control applications. The language is characterized in this way: each
function is seen as a building block with inputs and outputs. The function of such a block can be
simple, such as a logic AND function, or complex, such as a complete PID regulator. A program
written in AMPL is referred to as a PC (process control) program, and the building blocks are
called PC elements. The range of ready-to-use function blocks is wide and powerful.
You can program a controller in AMPL fully on-line with the programs running and controlling
the process. If required, you can block part of a PC program, a complete PC program or the
whole controller during programming. You can also develop programs off-line in an
engineering station and load them into the controller at a later stage.
In addition to functional PC elements, AMPL contains a number of structural elements for
division of a PC program into suitable modules which can be managed and executed
individually. You can give the modules different cycle times and priorities so that both fast and
slow control operations can be managed by the same PC program.
The inputs and outputs of an element are connected to the inputs and outputs of other elements
or to process I/O points. Picking these elements and making these connections constitutes the
programming work. The resulting PC program can then be documented graphically, which
Figure 1-38 illustrates.
When a dedicated station is used for programming, it can be connected, either directly to the
controller to be programmed, or indirectly via another controller in the communications
network. For remote access, the public telephone network can be used.
Signals are represented in engineering units throughout the whole application program.
This facilitates the configuration work, especially in connection to arithmetic operations. It also
simplifies reading and understanding of the graphical documentation of the application
program.
Scaling of an I/O signal from an electrical variable, for example, 4 - 20 mA, to a variable
expressed in engineering units is made in the data base for the point.
3BSE 002 414R601 Rev B 1-89

PC7
PCPGM(40,7
=DI1.1/START 1 ) 5 P =DO1.1/RUNNING
D=0 2 ON RUN
1
CONTRM(250,3,
D=1 1 0) 5
D=0 2 6
D=0 3 ON RUN
1
=DI1.6/MOTOR_STOP C 1
& 60 P =DO1.5
2
=DI1.6/MOTOR_START C 11 IND_MOTOR-START
Š1
12
2
=AI1.3/MOTOR_CURRENT C 1 + 20 P =AO1.4/
D=5.000Amp 2 R IND_MOTOR_CURRENT
3
COMP-R(2,1)
1 I
D=0.000 1 HHYS I<H1 20
CURRENT_WARNING D=95.000Am 1 H1 I>=H1 21 P =DO1.6
CURRENT_LIMIT D=100.000Amp 1 H2 I>=H2 22 IND_CURRENT_WARNING
D=0.000 3 LHYS I>L1 40
D=0.000 3 L1 I<=L1 41
4
1 S 5 P =DO1.18
=DI1.7/ALARM_ACKNOWLEDGE C 2 R ALARM_CURRENT LIMIT
5
F=1 F1 PRINT(1,1,72)<
F=1 F1 FIRST BUSY 5
F=1 F1 LAST REPNO 6
1 FF ERR 7
2 NODE
3 BUS
3 PRID
>ACT
D=’HIGH MOTOR CURRENT’ 1 TEXT1
EXECUTION ORDER; 1 2 3 4 5
1
PC7
Figure 1-38. Example of Automatic AMPL Document Printout
Type Circuits
To boost application programming productivity even further, the engineering stations support
the use of type circuits, that is, control solutions that are repeated frequently in an application
area or in a specific application project. For instance, a type circuit may comprise all the
functions required to control motors of a certain type, or pumps, valves, temperature loops, and
so on, including all the necessary controller data base definitions for I/O and operator
communication.
1-90 3BSE 002 414R601 Rev B

User Defined PC Elements

Another way to implement your frequently used control solution and ensure a fully integrated
engineering environment is to make use of the option User Defined PC Elements.
A user defined PC element appears in every sense as a standard PC element. Actually the
control solution of a user defined PC element is defined by other PC elements. See illustration
in Figure 1-39.
Library of
Control solution user defined
PC elements
AND
VALVEC
USER
ELEMENT
OR LUBE
COUNT OIL
SR
Reuse
Application PC program
Signal in 1 USER OR USER

ELEMENT ELEMENT
Signal in 2 Signal out
LUBE COMPRES
Signal in 3 OIL
USER
ELEMENT
Signal in 4
SEAL
OIL
Figure 1-39. Process Objects Implemented as User Defined PC Elements
By designing your application with user defined PC elements you are gaining:
• Significant reduction in translation time
• Memory saving with reuse
• Similar documentation in Function Chart Builder and On-line Builder
• User defined PC element hierarchy
• Reduced man-hours in commissioning and maintenance.
3BSE 002 414R601 Rev B 1-91

1.7.8.2 Principles of Application Building

Figure 1-40 illustrates how process signals available in the data base are linked to the AMPL
application program.
DO1
DB element
DSDO 120 TYPE defining board, signals
DI 1
DO 1.1
DSDI 110 TYPE
START M1 NAME
DI1.1
START NAME
PC program
PC element
IV
Switch gear
=DI 1.1/START
& S T = DO 1.1/START M1
= DI 1.2/CONDI-
TION D = 10
R
IV
= DI 1.3/STOP
Protection
Figure 1-40. Simple Control Function Realized in AMPL
1-92 3BSE 002 414R601 Rev B

PC Elements and Functional Units

Besides the PC elements, the function library consists of functional units. Functional units are
available to supplement the library for more complex functions. A functional unit is a package
of different program functions such as PC element, data base element and operator’s functions.
This simplifies the realization of combined functions with both the control function and
associated operator’s handling via a display screen and keyboard.
The application can be a closed loop control function or a motor or valve control function
requiring an advanced “face-plate” for the operator.
You can use several functional units in combination.
The functional units are also used individually. Examples of this can include a measuring circuit
with alarm activation/deactivation and display screen presentation or a simple command
function from the operator to the process.
You can freely combine the functional units with other PC elements.
Figure 1-41 illustrates the application of functional units in a complex burner control.
Advant OCS Process
Protection Air Fuel

DI Switch
Local gear
control, ind.
Start
DI Burner Control DO
SEQ
DO & Stopp
DO
IV
SOV
Operator DO
station
Alarm: Flow Temp DI
PIDCON SEQE1 CLAMP REF CV

EXTREF OUT AO
MV
AI F
MAX
Time contr. SP
MIN PIDCON SEQE1 CLAMP REF CV
EXTREF OUT AO
MV
AI F
Supervi. Burner
Oven
Figure 1-41. Principle of a Functional Unit Application
3BSE 002 414R601 Rev B 1-93

1.7.8.3 Control Functions

The main built-in control functions available for application building are grouped and presented
briefly below. Most of the functions are supported by PC elements, that is the PC elements are
the base of the functionality of the Advant Controller 410.
For a listing of those PC elements included in the basic system program module and the
different optional program modules, see Section 1.7.3.3, Program Module Contents.
For detailed function descriptions of the different PC elements, see the separate reference
manual, PC Elements Advant Controller 400 Series.
Logic and Time Delays

• Basic Boolean functions
• Composite Boolean functions
• On/off delay, pulse generation.
Sequence Control
• General structuring functions
• Sequence control influenced by standard IEC 848.
Data and Text Handling

You can arrange text strings to be presented on the operator station display screen or used in
event printouts.
Calendar Time Functions

Date and time can be used when an automatic function shall be started or when a report is
printed out.
Arithmetic
Standard arithmetic expressions as well as special functions are available.
Positioning
Positioning is a general term for position measurement and position control of d.c. and a.c.
motors and hydraulically and pneumatically servo-controlled mechanisms in industry.
A special circuit board, DSDP 140A, is used together with a suitable pulse transmitter such as
QGFA 110, QGFA 110 V or the equivalent. (It is also possible to connect other transducers.)
1-94 3BSE 002 414R601 Rev B

The circuit board communicates directly with PC elements for rapid positioning in which the
pulse generator is used for feedback of actual values. A processor is provided on the circuit
board for the fast calculation in the inner loop of the positioning system. The positioning board
has a flexible design and is intended to perform several functions, together with different PC
elements:
• POS-A(0) Length measurement
• POS-A(1) Positioning with analog output signal
• POS-O(0) Positioning with digital output signal for three speeds
• POS-O(1) Positioning with digital output signal which can be pulsed
• POS-L Length measurement with digital output signal with coincidence.
The following functions and properties are available:
• Position measurement via an incremental pulse transmitter and a direction discriminator
and a hardware counter which updates a software counter at regular intervals.
• Three pulse inputs adapted for the ABB pulse generator QGFA 110: A channel, B channel
and STROBE. Maximum frequency 80 kHz.
• Analog output for speed reference, 11 bits + sign. 0 to ±10 V or 0 to ±20 mA.
• Position control ON-OFF with fast, medium-speed or slow retardation to the interval
“correct position.” Position control ON-OFF with pulsed control. At low speed, the output
signal is not constant but is pulsed forward to the “correct position” with pulse lengths
varying with the deviation from the “correct position.”
• Functions on the board are supervised by means of self-testing. Faults are indicated by the
illumination of LEDs on the board.
For a detailed explanation of the positioning system, see the manual Positioning System.
Pulse Counting and Frequency Measurement

These functions are used for different applications in the industry, such as position
measurement, flow measurement, speed measurement, synchronization of machine movements,
and so on. The pulse-counting function requires special hardware.
• The cycle time for the reading-in program is determined individually with the parameters
in a DB element. After the reading-in, the values are converted to process-related units and
checked against limits. The limits which are exceeded are stored in the data base.
• The pulse-counting/frequency measurement function requires hardware module
DSDP 150. This circuit board is used for both pulse counting and frequency measurement
and has inputs which can be connected to pulse generators with a frequency of up to
10 kHz.
• DSDP 170 is a circuit board which is primarily intended for positioning/length and
speed/frequency measuring. Maximum pulse frequency is 2.5 MHz.
• DP820 is a module which is primarily intended for positioning/length and speed/frequency
measuring. Maximum pulse frequency is 1.5 MHz.
3BSE 002 414R601 Rev B 1-95

Reports
The report function permits you to connect a printer to the Advant Controller 410 system to
print out simple reports.
Figure 1-42 shows an example of a simple report which is “edited” with the help of data base
and PC elements. Values, date and time are transformed into text strings.
PC program
PRINT
MAN control
or
TIMER
D= “SHIFTREPORT BOILER”
TEXT
TEXT
SHIFT REPORT BOILER
PC program D= “Time”
DATE Time 1993-12-24 19:18:04
TIME
Acc. oil cons. 1.76 tons
PC program D = “Acc. oil cons.” Acc. water cons. 280 tons
Totalizer Exhaust gases (peak):
D= “tons”
CO 120 ppm
O2 1.8 %
Figure 1-42. Example of Simple Report
Some notes regarding the printer and report application follow:

• You can direct the printout of a report to a printer connected to another Advant Controller
on the control network.
• Advant Controller 410 has a REPORT PC element, which makes it possible to initiate a
hard copy printout of a display in an operator station.
• The printouts can be made, upon operator demand, event-driven and cyclic.
• The printout of application information, that is data base lists and PC program diagrams,
is done on a printer connected to the configuration tool.
1-96 3BSE 002 414R601 Rev B

As an alternative to a controller-connected printer, you can use the facilities from a large
operator station (Advant Station 500 Series, MasterView 800/1). Actually, this is the most
common way of printing information from any station in a control network. Advanced reports
can be arranged from the contents and layout viewpoint. Also, you can use a local operator
station for reports. In the latter case, the display information from a MasterView 320 is printed
out. Once the report/display is configured, it is possible to remove the MasterView 320. In other
words, MasterView 320 in such an application can be used as a configuration tool only.
For further information regarding report generation in operator stations, see the appropriate
separate documentation.
Supervision
Process supervision has an important role in a control system like Advant Controller 410.
Any logic state transition in the process or application program, or any limit transition of a
process variable or complex calculated variable, can be defined as a point of event.
Events can be time-stamped with a resolution down to 1 ms, which enables you to perform
excellent analyses of the causes and effects in complex situations.
Events can be defined further as alarm points. The operator’s attention can be drawn by audible
signal or a flashing light requiring acknowledgment. Such handling can be built up in an
application program with the support of the powerful FAULT element. An operator station
which is part of the MasterView 800/1 or Advant Station 500 Series provides powerful ready-to-
use event and alarm handling.
Measuring
You can connect process variables with different electrical representations as follows:
• Standard signal types, 4 - 20 mA, 0 - 10 V.
• Pt 100, Thermocouple
• Pulse, Frequency.
Pre-filtering is important in digital systems to obtain interference-free control and logging.
The irrelevant frequency content in the process signals must be limited.
Standard signals for current and voltage are pre-filtered in steep active hardware filters whereas
temperature measurement signals are filtered by integrating A/D conversion. In addition to
hardware filtration, the software can select digital filtration with single pole filters and with the
required break frequency.
In the case of temperature measurement, linearization is performed in accordance with the type
of Pt 100 transducer or thermocouple selected. Linearization through root extraction, for
example with pressure difference measurement, can be selected if required.
3BSE 002 414R601 Rev B 1-97

Feedback Control
Powerful functions for feedback control are provided with a great number of PC elements and
functional units. Examples of applications are:
• Basic PID control
• Cascade-coupled controllers
• Ratio control
• Manual control from central/local operator’s workplace
• Controlling final elements with two- or three-position action
• Override control
• Batch control
• Split range
• Gain scheduling or other adaptation strategies
• User-defined control strategies combining the range of available algorithms P, PI, PDP,
PIP, DER, INT, FILT-1P/2P, P-DEADB and RAMP.
The built-in features in one of the complex loop controllers, the functional unit PIDCON, are:
• Several control modes with built-in priority scheduling
• Automatic tracking for bumpless control mode changeover
• Cascade inputs
• Differentiation, either of the measured value or the control deviation
• Parameter scheduling
• Forcing control of the output signal
• Limitation of set-point and output with respect to amplitude and rate of change
• Limit supervision with event and alarm handling
• Powerful operator interface.
It is easy to combine such a loop controller with supplementary functions, for example
interlocking, start-up and shut-down sequences, calculations, process optimization, and so on.
1-98 3BSE 002 414R601 Rev B

Motor and Valve Control, Group Start

High-level functional units are available for applications such as valve control or group control
of motors. The built-in features in one of the complex motor controllers, the functional unit
MOTCON, are:
• Supervision of control circuits
• Evaluation of interlocking
• Control of on/off
• Supervision of motor current
• Running of tests from the motor site
• Control from central/local operator’s station
• Manual/Auto running
• Forward/Reverse running or selection of High/Low speed.
• Presentation of Motor/MCU diagnostics (MOTCONI).
The functional unit MOTCONI has the same functionality as MOTCON. The difference is that
MOTCONI controls Motor Control Units (MCU) over the LONWORKS Network.
Drives Integration
For large control systems, built on Advant Controller 450, the connection to ACS 600 drive
systems is made via Advant Fieldbus 100. Each fieldbus node connects up to 24 drives through
an optical ring.
Adv a C o m ma n d
A d v a n t C o n t r o lle r 4 0 0 S e r i e s
I/O I/O
AF 100 S 8 0 0 I/O
O p t i c a l M o d u le B u s
Figure 1-43. AC 400 configuration with drives
Information from the drives:

Process values are sent as cyclic data, with an updating frequency decided by the
application engineer. The data enables the control system to have access to basic
information such as speed, current, torque and diagnostic information.
Information from the controller:
A set point for speed or torque in percentage or absolute values can be sent. It is also
possible to give commands to the drive, for example, start, stop and fault reset.
3BSE 002 414R601 Rev B 1-99

The operator support in AdvaCommand includes a number of drive specific displays and
dialogs as well as the possibility to use functions such as system status, alarm and event
handling and trend curves.
In order to minimize engineering efforts, a predefined type circuit is offered. It consists of
control logic for a drive in a system with Advant Controller 410.
Variable Speed Drive Control

Variable-speed motor drives can be directly connected to Advant Controller 410 via a
specialized interface board that resides in the controller. The board contains a pulse counter for
accurate rotational-speed measurement and outputs a compensation signal to an analog
converter. The accuracy normally associated with digital drives only is also made available to
analog drives. The board exchanges setpoints, measured values, start and stop commands and
indications with the drive controller.
Free-programmable Module
For further information, see Section 1.7.4, Free-Programmable Module.
Central Operator Station Support, Adva Command, MasterView 800/1

Using a central operator station, for example Advant Station 500 Series or Masterview 800/1
Series, provides a powerful operator interface to the process control. For further information,
see the appropriate operator station documentation.
The main areas of support from Advant Controller 410 are summarized as follows:
• Object data base
• Alarm and events
• Group Alarm
• Reports
• Trend Data Storage
• Status List
• System Status List.
1-100 3BSE 002 414R601 Rev B

Section 1.7.9 Operator’s Interface
1.7.9 Operator’s Interface

Advant Controller 410 offers a range of interfaces to operators of different categories. A short
presentation is given below. For detailed information, see separate documentation.
1.7.9.1 Maintenance Personnel

The main purpose of this type of interface is to support fault tracing and backup handling of the
application program. There are:
• Start mode selector, LED indicators and character display on the processor module
• Diagnostics LED indicators on most hardware modules
• Configuration tool setup for fault tracing and backup handling.
Otherwise, the normal use of a configuration tool is to configure the controller. It would
also be used to adjust and change the application in a level not reachable from an operator
station.
1.7.9.2 Local Operator
Mimic Panel
Two alternatives are possible:
• Panel units, for example numeric display, keyboard, function keyboard, push button and
thumbwheel connected via Modbus protocol.
• ABB Active Mimic Controller.
An Active Mimic Controller module makes it possible to control active mimic panels from
an Advant Controller 410 via one or more RCOM links.You can use the module for local
collection of inputs from push-button switches (PBs), for updating of LEDs or lamps, and
for control of an alphanumeric text display.
The display unit displays a number of text strings with 20 or 40 characters. These text
strings are programmed according to the customer’s specification and located in a text-
PROM on the Active Mimic Controller module.
You place the module in large control room mimic panels or in traditional control desks,
or use it for small distributed operator panels in the process area.
Local Operator’s Station

Two alternatives are available:
• MasterView 320
• Personal-computer-based operator station.
The operator’s station MasterView 320 is a VT100 compatible terminal connected to
Advant Controller 410. You can connect two MasterView 320 terminals.
You can create and present process displays in each MasterView 320 terminal. Each display can
include both static and dynamic information. The static information, that is those parts of the
display which remain the same during operations, consists of an optional number of text strings.
3BSE 002 414R601 Rev B 1-101

Dynamic variables with optional appearance which are presented on the display screen are
varied by the PC program via the data base and can consist of real numbers, integers or Boolean
variables. The operator can intervene in the process by changing, via the keyboard, the data
presented in the display.
You can also program, directly from the MasterView 320, certain keys to give signals to/from
the PC program, which in turn can affect the process directly. MasterView 320 is provided with
an event-handling function which permits the storage of up to 100 events for each terminal.
Of these events, 16 can be presented on the display screen at one time. The event messages are
sent to the MasterView 320 terminal and can be programmed with a special PC element,
EVENT. You can present the event list on a display and/or you can obtain a copy of the event
list as a printout if required. Dialog and error texts associated with the MasterView 320 function
can be presented in different languages, which can be defined with the configuration tool.
Figure 1-44 below shows a monochrome VT 100 terminal with keyboard.
1 CONVEYER/SCRAP CONTROL 1994-05-19/10:22:00
MODE OF OPERATION STATISTICS

LOCAL SHIFT WEEK
AUTO
DUMPING 15 150
AUTO: START SHORT STOP 1 10
MAN BACKWARD STOP LONG STOP - 3
MAN FORWARD STOP SCR.WEIGHT 1.2 9.3TON
SPEED REF
A 5,5m/s
0 0
B 16,7m/s
A B A
SELECT DISPLAY SELECT VARIABLE OTHER FUNCTIONS RESTART
Figure 1-44. VT100 Terminal and Keyboard for MasterView 320
A feature you are offered when you use a personal-computer-based operator station is that it can
be connected via the communication link RCOM and a dedicated, or a public, telephone
network. However, you must be aware of its limited performance.
1-102 3BSE 002 414R601 Rev B

1.7.9.3 Central Operator

A central operator station of the Advant Station 500 Series or MasterView 800/1 Series provides
a powerful operator’s interface.
Examples of main functions are as follows:
• Presentation of user-designed process displays, standard displays, curve displays and
reports
• An effective operator’s dialog for manual control
• Alarm and event presentation
• Presentation of the status of the control system
• Display design “on-line” directly on the display screen
• Handling of group alarm
• Presentation of the status of signals
• Presentation of trend curves.
The central operator station communicates with the application program and the process is
controlled via the signal and object files in the data base of the Advant Controller 410.
3BSE 002 414R601 Rev B 1-103

All of the information about the process signals connected and the process object are stored in
these files (see Figure 1-45).
Operator
Station
Presentation
Dialog
MasterBus 300

Program module
QC01-OPF11
Data base
PC program
DI DO AI AO Obj.
file
Process
Figure 1-45. Communication, Operator Station-Controller-Process
1.7.9.4 Printer
You can obtain printouts of reports, generated in the report function, or paper copies of event
lists, when a MasterView 320 is included with a printer connected to an Advant Controller.
For further information on the primary use of a printer for generating reports,
see Section 1.7.8.3, Control Functions, under the heading Reports.
The printer requirement specification is given in Section 3.2.6.3, Printer.
1-104 3BSE 002 414R601 Rev B

Section 1.7.10 Availability and Security
1.7.10 Availability and Security

Many factors affect the reliability and availability of a control system. Redundancy is perhaps
the first thing to reflect upon, but it is never the most important factor. Basic system properties
of the Advant OCS are, in general, more important.
Advant OCS is designed to satisfy extreme demands for reliability, availability and security.
For further discussion of various aspects of reliability, availability and security, see separate
documentation. Some keywords follow:
• Solid mechanical and electrical construction
• Security against electrical interference
• High-quality components
• Well-tested electronic units
• Thoroughly developed and tested modular software
• Easily interpreted program language for application programs, AMPL
• Complete documentation
• Integral supervision and diagnostic functions
• Powerful tools for testing
• On-line replacement of faulty hardware units
• After-sale service
• Redundancy.
Below you can find important information regarding security. Descriptions of the provided
diagnostics and the possibilities of redundancy in the Advant Controller 410 also follow.
Process Outputs Behavior at Interrupts

From a viewpoint of security, the behavior of the control outputs to the process in connection to
ordered or unintentional interrupts is very important.
Advant OCS has a straightforward philosophy: all process outputs are controlled to zero (loss of
elevated zero) and relay outputs are de-energized.
3BSE 002 414R601 Rev B 1-105

Unintentional interrupts are caused, for example, by the following events:

• Fault in central processing unit and memory
• Loss of power supply
• Fault in power supply
• Fault in parallel bus communication (backplane bus on CPU and I/O subrack).
In spite of the fact that an Advant Controller 410 is a very reliable system, reset of outputs to
zero cannot be guaranteed during all conditions. Always assume a combination of errors or
incorrect system handling which can cause an output to behave in an unexpected way. This is of
great importance when it comes to personnel safety and preventing expensive technical
equipment from being damaged.
Duplication for Security

Duplication of control system functions is one way to ensure that all tasks are performed
correctly. It is, however, very important to emphasize that the security in a process control
system, when it comes to personnel safety, must never be based on duplication of system
functions alone. You must always consider other measures as well.
Integrated Safety System

In the most critical applications, a special design of the Advant OCS, the Master Safeguard,
is applicable. It is fully compatible with the rest of the Master products, including Advant
Controller 410/450. Master Safeguard operates on the same network and from the same type of
operator stations. Functionally, the Master Safeguard is almost identical to an
Advant Controller 410/450, and is configured and documented in the same way.
1.7.10.1 Diagnostics
System level diagnostics, including the Advant Controller 410, have an error reporting and
indicating structure that makes use of system messages, console diagnostic displays and LED
status indicators to indicate the status of hardware.
Comprehensive system diagnostics not only detect problems, but also let an operator know
where a problem is located. The diagnostic features of the system provide for timely, reliable
detection and notification of both software and hardware errors.
The diagnostic philosophy for the Advant OCS is that single-fault situations are detected and
processed.
The diagnostics support the maintenance philosophy of fault isolation and replacement down to
module or subassembly level.
A survey of the fault announcement in Advant Controller 410 follows. The diagnostics built in
to different modules and system functions are mentioned briefly. You can also find more
information on LED indications, and so on, in connection to module descriptions. For a detailed
description of the use of diagnostics, among other things, see Chapter 5, Maintenance.
1-106 3BSE 002 414R601 Rev B

Run/Alarm Relay
The Advant Controller 410 provides a collective run/alarm relay included in the Backup Power
Supply SB171. The indicating contact can be reached via a connector on the module. Within the
limits of electrical data, you can use this contact in any desired application function, for
example, creating an audible alarm or interlocking certain process objects in the event of a
controller safety shut-down.
The main reasons for de-energizing the alarm relay and opening the alarm contact are:
• Fatal Error in CPU and memory
• Fatal Error in program execution
• Loss of power supply in the I/O subrack housing the processor module
• Switch over depending on loss of communication on S100 I/O bus extension if
redundancy.
NOTE
Only a single contact function per processor module is available. They are
normally closed but are open when there is an error.
LED Indicators
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.
Indications in Application Software

Diagnostics information is available in the data base and in PC elements, which means it is
possible to build up, for example, different control strategies with respect to the status of
relevant functions and hardware modules. It is also possible to arrange external fault
announcement of internal controller disturbances and faults.
3BSE 002 414R601 Rev B 1-107

System Messages and System Status

If the controller is included in a control network with a central operator station such as Advant
Station 500 Series Operator Station or MasterView 800/1, the following facilities apply.
• System messages:
– Give information about probable cause of malfunction in coded form or plain
language.
• System status displays showing fatal or non-fatal errors in:
– Controller total function
– Processor module
– Power supply
– Auxiliary functions like fans, and so on.
– Communication
– Connected terminals and printer
– Process I/O boards and units.
Most of this information is also available with a connected engineering station, but the
engineering station is not arranged to suit an operator.
Diagnostic of CPU and Memory

• Time supervision of operations
• Continuous parity check of RAM
– One-bit errors are corrected automatically
– Two-bit errors result in safety shut-down.
• Total check of RAM during start-up
• Supervision of checksums on program card
• Supervision of bus error.
Program Execution Check

Execution check by “watch dog” is carried out with respect to three priority levels.
Task reference, supervision time and consequences at exceeded time are given below:
• Timer task - 100 ms - safety shut-down
• Application program - 5 s - safety shut-down
• Idle task - 30 minutes - system message about a system too heavily loaded.
1-108 3BSE 002 414R601 Rev B

Diagnostic of I/O Modules

All I/O modules are checked regarding missing hardware or errors in the addressing logic.
It is common to all I/O modules that, if any error is detected, an alarm and a message go to the
operator. The error is also indicated with a red LED on the front of the board. The application
program handles necessary actions via the data base. Different types of I/O modules have
adapted diagnostics and error handling. For further information on this topic, see Chapter 5,
Maintenance.
Diagnostic of Power Supply

• Supervision of the internal 24 V supply and the stabilized 5 V supply
• Applicable supervision of power supply for sensors
• Supervision of the battery backup supply.
Other Diagnostics and Error Handling

Adequate diagnostics and error handling are also available/possible for the following equipment
and functions:
• Communication links
• Terminal/printer connection
• Optional fan or other equipment (free application)
• Redundant functions in general.
Supervision Module
The backup power supply performs certain system supervision.
A connector of the Backup Power Supply SB171 provides the connection of one extra user-
defined supervisory signal (24 V). You can use it, for example, for optional fan supervision.
The signal cable may not be extended outside the controller cabinets due to the risk of
interference.
3BSE 002 414R601 Rev B 1-109

1.7.10.2 Redundancy
In general, the following subsystems and functions are available with redundancy:
• Mains distribution network
• Voltage supply, 24 V
• Voltage regulation, 5 V
• Network communication
• GCOM
• MVI (MultiVendor Interface) communication
• RCOM
• MasterFieldbus
• Advant Fieldbus 100
• I/O module.
You can add redundancy within a specific controller in a flexible way to meet the desired
demands upon system availability.
The controller utilizes different principles of redundancy for included subsystems. Both hot
stand-by and independent parallel operation are used. Duplicated hardware is primarily used in
what is known as 1:1 implementation.
Maintainability is always provided by diagnostics, fault announcement and adequate unit
exchangeability. For short descriptions regarding certain redundant functions, see below.
Mains Distribution Network

Redundant a.c. networks, or a combination of an a.c. network and a d.c. network, are primarily
connected to separate circuit breakers and power supply units. Secondarily, at 24 V level,
the two networks are wired by diodes. The controller always needs an a.c. supply for use by
certain external equipment such as modems. In the case of redundant a.c. networks, automatic
relay devices are used to maintain the power supply in case of a single network error.
The duplicated equipment is normally in parallel operation, sharing the load. In the event of a
single failure, the full responsibility is taken over bumplessly by one piece of equipment.
Power Supply, 24 V
Duplicated power supply units for 24 V d.c., secondarily wired by diodes, are utilized.
This is the same redundancy solution as for mains distribution network. The wiring diodes are
distributed to the Voting Unit DSSS 171.
Voltage Regulation, 5 V
The stabilized 5 V supply is organized as n+1 parallel voltage controller modules sharing the
load current. The n modules are required to meet the demand. The extra module gives what is
known as n+1 redundancy. In the event of a single failure, the full responsibility is bumplessly
taken over by the remaining equipment.
The n is equal to 2 in the standardized Advant Controller 410.
The 5 V supply is distributed as single supply to each module.
1-110 3BSE 002 414R601 Rev B

Processor Module
Processor module redundancy is not available in Advant Controller 410.
Network Communication
Network communication redundancy is available.
Duplicated communication submodules are used.
From a functional viewpoint, the redundant networks work in a hot stand-by implementation.
This means that the primary network has the communication responsibility. The secondary
network stands by to take over in case of a fault in the primary network. In the stand-by mode of
operation, basic messages for diagnostics are continuously sent and received.
GCOM
The information given above for the network communication is also applicable to GCOM.
MasterFieldbus
The communication to a remote unit can be equipped with transmission media redundancy.
This includes:
• One communication interface submodule in the controller
• Two cables including duplicated modems
• One remote unit.
Advant Fieldbus 100

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.
3BSE 002 414R601 Rev B 1-111

I/O Module
The controller primarily uses single process functions, for example transmitter, valve, or switch.
However, for the categories analog input and analog output, there are special I/O modules which
can be duplicated. Different requirements for single loop integrity or signal redundancy are met.
Please refer to Section 1.7.6.1, S100 I/O.
Duplicated hardware is kept together in the data base as one object. From a maintainability
viewpoint, duplicated hardware is handled individually. Functionally, the redundancy is,
however, invisible to the control application program. Duplicated hardware is wired in a
common terminal panel or connection unit.
You can mix redundant and non-redundant I/O modules in any application-adapted way.
I/O subrack
PM150
Board A B
Connection
unit Transducer
E.g., 4-20 mA
Figure 1-46. Arrangement of Redundant I/O Modules
The principle of redundancy is hot stand-by or parallel operation, depending on the design of
each module. For example, analog inputs use hot stand-by. Analog outputs use parallel
operation.
1-112 3BSE 002 414R601 Rev B

Section 1.7.11 Mechanics
1.7.11 Mechanics
1.7.11.1 Cabinets
Available Cabinet Types

An Advant Controller 410 is normally installed in one or two cabinets, depending on the need
for space for connection units for process I/O signals. The cabinet type is RM500 and it has two
versions with different dimensions, RM500V1 and RM500V2, see Appendix B, RM500
Cabinet - Data Sheet.
Single as well as double cabinets are used to house an actual installation.
Cabinet Features
Figure 1-47 shows a cabinet of the RM500 type. Features and applications are listed below:
Figure 1-47. Cabinet, type RM500

• 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.
• RM500V1 features a 19-inch and a 24-inch installation width. The latter is applied to
process connection equipment. The 24-inch installation width and shallow cabinet design
facilitates the installation and the maintenance. RM500V2 only features the 19-inch
installation width.
3BSE 002 414R601 Rev B 1-113

• Entrance to the rear of the cabinet is not necessary. Controller hardware is physically
installed and electrically connected from the front.
Certain equipment, like the S100 I/O subrack, is mounted in a hinged frame in the cabinet.
This enables entrance and possible maintenance and repair of parts of the subrack which
are only accessible from the rear, for example, units for voltage regulation.
• The cabinet front door is hung at either the left-hand or the right-hand side adapted to the
final cabinet configuration determined at the design. Please check that the position of the
hinges is acceptable with respect to the final location of the cabinets on site.
• A double door variant is available for the RM500V1. It is standard starting from
AC410*1.5/2.
• Process wiring usually enters through the floor of the cabinet.
• Normally, there are no intermediate walls between cabinets designated to one controller
installation.
Intermediate walls are used between different controllers in a row of cabinets or between a
controller and other equipment to suppress interference.
Environmental Adaptation
RM500 cabinets are available with the following degree of protection ratings according to
IEC529; IP21, IP41 or IP54.
Independent of the protection rating, the controller subrack is, for cooling purposes, always
equipped with a fan unit.
IP21, the basic version of the cabinet, is ventilated by openings in the lower and upper end of
the door.
IP41 is ventilated by openings in the lower and upper end of the door. The openings are covered
by netting with openings 1mm2 or less.
NOTE
A heating element is mounted in the bottom of the IP41 cabinet. This heating
element shall be activated when the equipment in the cabinet is inactive.
The sealing in IP54 results in a decrease of permitted power dissipation compared to IP21 and
IP41. Please refer to Section B.6, Permitted Power Dissipation. Actions must be taken in certain
applications, for example, a heat exchanger can be installed.
Electro Magnetic Compatibility and CE-marking
Advant Controller 410 meets the requirement specified in EMC Directive 89/336/EEC and in
Low Voltage Directive 73/23/EEC provided appropriate cabinetry is used. You should request
for compliance and CE-marking when you order the equipment. You can obtain CE-marking for
all standard cabinets.
For further information about the environmental immunity, including EMC qualities with or
without CE-marking, please refer to the data sheet “ABB Master Environmental Immunity”.
1-114 3BSE 002 414R601 Rev B

Cabinet Configuration
There is a maximum of one S100 I/O subrack in the Advant Controller 410. Depending on the
need for space for connection units, the controller installation consists of up to two cabinets.
The I/O subrack with the controller is always installed in the left-hand cabinet.
A single or a double cabinet is used.
The I/O subrack with the controller is mounted in a swing sub-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.
Figure 1-48 shows a typical cabinet configuration in a RM500V1 cabinet.
The location of subracks, connection units and power supply equipment is standardized.
However, the design is always adapted to the actual application and shown in the delivery-
specific documentation.
All units in the cabinet are identified in accordance with the item designation system used for
the Advant OCS products. See Appendix D, Item Designations
I/O Subrack
Processor
module
Modem
subrack Connection
units
Power
supply
(SA16x)
Redundant
Power
supply
(SA16x)
Power
switches
Mains net
filters (SE-maked
version only)
Figure 1-48. Typical Cabinet Configuration, Redundant Power Supply
3BSE 002 414R601 Rev B 1-115

1.7.11.2 Subrack
Many of the Advant Controller 410 and I/O components are installed in an I/O subrack based on
a 19-inch standard. This subrack is fitted with guide bars for circuit boards and other plug-in
units.
An I/O subrack holds a processor module and up to 15 I/O boards.
Sub
position
2 3 4
Position: 1 6 7.... .... 20 21
Position referred addressing

is not used in S100 I/O
Figure 1-49. Front of I/O Subrack with a Processor Module PM150 at the Position 1-6
A locking bar at the upper front edge fixes the boards once they are inserted.
An I/O subrack can be powered by a single 5 V - regulator unit or redundant 5 V - regulator
units located at the rear of the subrack.
A connection unit with screw terminal blocks for field connection of the process signals is
provided for each I/O board. You can usually disconnect process objects individually or in
groups with a disconnectible type of terminal block. The connection units are connected to the
I/O board via standard cables and are mounted in the rear plane of the cabinet.
1-116 3BSE 002 414R601 Rev B

Mounting bar for

connection units
Connection to the process
Connection cable
Backplane for parallel

communication bus
Plug-in units
Figure 1-50. I/O Subrack Configuration
The rear side of an I/O subrack must be accessible. In RM500 type cabinets, an arrangement
with a swing hinged frame is used.
1.7.11.3 Processor Module and Submodules

You can achieve much desired functionality by mounting submodules into the processor
module. This is illustrated in Figure 1-51.
3BSE 002 414R601 Rev B 1-117

Processor module
Submodule
Submodule
Insertion of submodules into Side view

the processor module
Processor module
1
Submodule
2 3 4
Submodule
Inserted
submodules
Side view Front view
1..4 indicates
submodule positions
Figure 1-51. Processor Module and Submodule Mechanics
One processor module houses the maximum, four submodules.

In principle, the one submodule is independent of the other submodule. This means you can
insert, start, stop and remove one submodule without affecting the other submodule.
Mechanically, any submodule fits into any submodule position on Advant Controller 410.
The software does not, however, necessarily support all combinations.
1.8 User Interface

A normal controller installation uses different operator’s interfaces. A division into two main
categories can be seen with respect to their applications:
• Operator’s interface for process control.
– Operator stations
– Mimic panels
– Printer.
• “User interface” for the controller seen as a computer resource.
– System maintenance.
These different facilities are presented in the product overview description, see Section 1.7.9,
Operator’s Interface.
The “user interface” application is described in detail in Chapter 4, Runtime Operation and in
Chapter 5, Maintenance.
1-118 3BSE 002 414R601 Rev B

Section 2.1 Site Planning Environment
Chapter 2 Installation
This chapter contains guidelines for planning the installation of your Advant Controller system,
see Section 2.1, Site Planning Environment. In addition, this chapter also describes the concrete
installation procedures on site, specific to Advant Controller 410, see Section 2.2, Setup.
This chapter does not, however, provide a complete list of measures to take with respect to
environment and other conditions on site. The equipment should be adapted to the actual
application by way of thoroughly accomplished system definition, ordering and design. You can
find descriptions of alternative solutions, design considerations, elsewhere in this manual.
Since each Advant Controller system is designed to meet your specific requirements, there is no
standard configuration that describes every system. Therefore, certain areas of the following
instructions are meant only as a guide for planning your specific installation. However, some of
the information covers specific requirements for proper system and equipment operation - you
cannot modify these requirements. The difference between a recommendation and a
requirement is clearly defined as necessary.
Installation of options is often described in dedicated user’s guides. For information about
available documents corresponding to desired options, see Section 1.4, Related Documentation.
All information given in this chapter relates to standardized models. Where alternatives exist,
a typical alternative is described.
2.1 Site Planning Environment
2.1.1 Site Selection and Building Requirements

When you are planning a control system installation, please consider the following points,
among others:
• The surrounding environment and atmosphere.
• The temperature in the room where the equipment is to be located.
This includes an estimate of the resulting temperature rise with respect to the power
dissipation from the planned equipment.
• The proximity of the control room to the process.
• The size and shape of the control room which is to accommodate all the required
equipment.
• The lighting for a control room, which should be powered by a power source independent
of the system equipment. A battery-powered emergency lighting system is recommended.
• The minimum distances from a cabinet to walls and ceiling required to obtain satisfactory
results from different areas.
• The weight of the equipment and the corresponding requirements of the floor construction.
• Ease of access for moving equipment in and out of the control room.
• Space, suitably furnished for maintenance.
3BSE 002 414R601 Rev B 2-1

• The free space in front of cabinets. Also reflect on how much space is required to fully
open either a left-hand or right-hand hinged cabinet door (both exist). There must always
be space left for safety reasons even with open doors.
• Spare area for future enlargement of the equipment.
• A well-developed process connection, with or without marshalling facilities.
• Grounding by an effective net of copper bars.
• Cable routing with respect to installation rules.
• Availability of power and other utilities.
• Standards and legal regulations to be followed.
The following sections examine some of these factors in detail and provide recommendations
and requirements as necessary.
2.1.2 Environmental Considerations
General
The Advant Controller system is designed for a demanding industrial environment. Alternative
cabinetry is available for different degrees of protective rating (IP21, IP41, IP54). Interference
from electrical sources is suppressed by a suitable solid design and particular installation rules.
Equipment is to be located in a control room or an electric room or distributed in the process
area.
The common requirements for the building where the system is to be stored or installed are:
NOTE
The building should provide an environment such that established
environmental conditions are not normally exceeded.
The environmental conditions which Advant OCS products are designed to withstand, during
storage and transport as well as during operation, are specified in a separate environmental data
sheet. Limit values are given to: Corrosive gases, Temperature, Vibration, Moisture, Electro-
Magnetic Compatibility, and so on.
Most applications need no special arrangement. Standard cabinetry and installation according to
the rules suffice. Occasionally, you must consider special protection with respect to particular
situations.
Sealed cabinets are a good basic solution to prevent damage to electronic equipment from,
for example, corrosive gases, moisture and dust. However, sealing prevents the normal cooling
resulting from self-convection or forced cooling by a fan. In turn, this reduces, to a large extent,
the heat dissipation permitted in a cabinet.
2-2 3BSE 002 414R601 Rev B

Section 2.1.3 Electromagnetic Compatibility
Some alternatives, in addition to those offered by other standard cabinets, follow:

• Sealed cabinet pressurized by clean, dehydrated instrument air.
• Gas cleaning by chemical filter.
• Use of dehydrated air.
• Dust filter.
• Sealed cabinet cooled by a heat exchanger.
It is reasonable to assume that a heat exchanger may be inoperative for short periods.
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. Lower temperatures mean increased system reliability and availability.
The lives of wet, electrolytic capacitors and most semiconductors are greatly reduced if the
maximum permitted temperatures are exceeded.
For more information on design considerations, see Section 3.1.11.2, Heat Dissipation
Permitted in Cabinets.
Vibration
The cabinets must stand on a stable floor, deck or supporting structure, free from vibrations.
If the system equipment is installed in a control room adjacent to large machinery such as
shakers or large presses, where frequent major vibrations occur, shock absorbers or an isolation
pad may be required to protect the system equipment. Shock absorbers normally protect the
equipment from sustained low-level vibrations (vibrations that are perceptible, but not
excessive). If vibrations or shock are a major problem, consider more extreme measures to
alleviate the problem.
2.1.3 Electromagnetic Compatibility

Interference-free operation requires well-considered planning and realization of the installation,
especially with respect to grounding, cable selection and cable routing. Some notes are given in
the following sections from a planning viewpoint, while the setup instructions give you detailed
information about the actual realization of the installation.
For more information, both theoretical and practical, on the subject of Electromagnetic
Compatibility including interference, interference sources and suppression measures,
see separate reference documents.
You can obtain CE-marking according to EMC Directive 89/336/EEC for your Advant
Controller 410 provided appropriate cabinetry is selected. Please, refer to the ordering
documentation.
3BSE 002 414R601 Rev B 2-3

2.1.3.1 Summary of CE-marking Aspects

CE-marking of the Advant OCS products implies some minor but important changes of the
design with respect to cabinetry, mains supply filtering and handling of cable shields at the
enclosure port. All to ensure conformity to the EMC-Directive 89/336/EEC.
The following is a summary of the most important changes.
Cabinet Floor Cover Plates

From an EMC Viewpoint mounting of floor cover plates is not necessary when EMC standard
cabinets of the types RM5xx is applied. The close distance to the normally good floor earth
plane is the reason.
Avoid the erection of fixed installed radio equipment close to and beneath the Advant
Controller. For example in underlying floor plane.
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 410 shall be
located in a EMC-proof cabinetry. Please note that the requirement is valid to controller cabinet,
I/O cabinet and connection unit cabinet, if separated.
Standard cabinet RM500 is EMC-proof in its basic design for protection class IP21, IP41,
and IP54.
Open compartment is not permitted for any part of the controller and its I/O including
distributed connection units.
Immunity against electromagnetic fields can generally be guaranteed with the cabinet
containing metallic doors only.
Arrangement of Cabinets
Advant OCS mounted in a RM500 cabinet, can be set up side by side with other cabinet types
and other equipment types, but the cabinet side plates must be ordered or not be removed if
included at the delivery.
Where several electronics cabinets of the same type, related to one controller with
S100 I/O, are to be set up in the same row, however, it is permissible to leave out or remove the
side plates between the cabinets.
Mains Net Filter

Protection against line conducted radio emissions is obtained by means of a special filter placed
in the bottom part of the cabinet on the incoming supply. One filter for each supply is utilized.
Communication Cable Shields

Communication cable shields which are to be directly grounded in the cabinet must be grounded
to the cabinet chassis.
Shielded communication cables which are not directly grounded in the cabinet are to be
connected via a capacitive decoupling device, located in the bottom of the cabinet.
2-4 3BSE 002 414R601 Rev B

Section 2.1.4 Standard Layout and Disposition of Cabinets
2.1.4 Standard Layout and Disposition of Cabinets

A series of rules for mounting the controller and I/O in RM500 cabinets follows.
These configuration rules are applied when the customer has no preconceived ideas regarding
the design. This is the standard solution, which is important to know when you are planning a
control system. The complete list of rules are presented in ordering documentation.
General
• Advant Controller 410 ordered on one set of price lists, is designed with cabinets that are
to be placed side by side (no plates between the cabinets).
• Advant Controller 410 is delivered in a single or double cabinet.
• Configuration is according to Figure 2-1.
CPU + I/O
Connection
Units
1 2
Figure 2-1. Standard Cabinet Configuration (maximum)
• Normal start configuration is a single cabinet (1).

• With the controller cabinet to the left, the building direction is to the right.
• One set of power supplies for field equipment is placed in cabinet no. 2.
• Boards are placed in the I/O subrack in the order AI, AO, DO, DI.
You can obtain information about deviations from these rules upon request.
2.1.5 Grounding
Grounding in General
The signal processing electronics in Advant OCS, as well as all interference suppression for
external signals, are normally directly grounded to chassis and plant earth.
The plant earth potential must be stable and well defined, even in the event of ground fault in
low- and high-voltage equipment or lightning stroke. This claim for a grounding system is
common to the high-voltage equipment. The earth line joining the grounding systems should be
≥35 mm2 Cu.
3BSE 002 414R601 Rev B 2-5

Cabinetry
or equal
Protective
earth
Earth line
≥35 mm2
Figure 2-2. Grounding of Electronic Equipment
Protective Earth
Always provide Advant OCS cabinets supplied with 230 V a.c. with a protective earth.
Grounding of Signals and Voltage Supply

For minimum interference and maximum accuracy, it is normally most effective to ground the
signals from transducers directly in the grounding bar in the Advant Controller. For freedom
from interference, it is also advantageous to ground supply voltages for transducers, sensing
voltage for contacts, load supply voltage, and so on.
You may have to deviate from these two basic rules in order to adapt to other requirements such
as measurement techniques or safety regulations. In such cases, you must ensure that,
for example, differential inputs for analog input signals are used or that digital inputs and
outputs are divided into groups in the connection unit, with the possibility of supply voltage
distribution and earthing in other equipment.
A consequence of requiring local grounding of a signal at the transducer location may be a
requirement for a completely individual voltage supply to each transducer. This normally
hinders the use of connection units for voltage distribution. In such cases, you can use a bar with
the terminal block and fuse equipment required by the application.
If the transducer has galvanic isolation of the supply from the electronics otherwise, you can
ground its signal zero freely and where it is most suitable for measurement accuracy without
special voltage supply requirements such as group division, fusing and grounding.
2-6 3BSE 002 414R601 Rev B

Section 2.1.6 Cables
2.1.6 Cables
When you are planning for the cable routing in the plant and selecting suitable cables to use,
there are some restrictions and rules to follow. These touch upon, among other things:
• The distance between Advant OCS cables and non-Advant OCS cables.
• The routing of communication cables.
• Mixing of signals and signal types within cables.
• The need for shielded cables.
For further information, please refer to the general document, Interference-free Electronics
Design and Applications, which also gives examples for choosing cables.
All cables are normally guided into a cabinet from below.
2.1.7 Power Supply and Fusing
General
Normally, supply voltage to Advant OCS supply units and for field equipment can be obtained
from the plant a.c. or d.c. supply.
A summary of the main requirements of the supply from a planning viewpoint follows.
Primarily an A, B and C network should be available as applicable.
Supply A and B refer to redundant networks.
Supply C is feeding the battery backup unit and modems which use a.c. power supply. In the
tropical cabinet version the heating element is also included.
Supply C is always an a.c. supply, regardless of whether a.c. or d.c. is utilized otherwise.
Preferably supply C should be an uninterruptable power supply. In situations where redundant
network A/B is used you can order a power distribution unit, SV542/543, which includes a
selector relay and an isolation transformer. The relay selects between, for example network A
and B and the transformer makes a secondary grounding of the network possible (adaption
class III/class II).
Class II, class III states the network quality with respect to for example, level of disturbances,
voltage variations, and so on. (according to IEC standards). Class II denotes higher quality than
class III.
You can use power supply units made by other vendors for, for example sensor supply, and
locate those units in an I/O cabinet. Such units must satisfy interference requirements in
accordance with the relevant standards in the same test classes as the Advant OCS equipment
and they must be CE-marked if equipment is going to be used within the EU and EFTA area.
3BSE 002 414R601 Rev B 2-7

Safety Switch
Close to the controller installation, there should be a safety switch enabling total power supply
disconnection of the equipment. This means a common switch for all supply voltages,
for example networks A, B and C discussed above.
The main use of the safety switch is to disconnect the power supply in a clear and safe way
during work in the cabinet.
Install the safety switch in a visible place (outside any cabinetry) within 3 m of the controller
installation.
a.c. Supply
Essential information includes:
• For the supply A (and redundant B) class II or class III a.c. networks can be used
alternatively as a standard solution.
• For the supply C there are different options. Select a suitable power distribution unit with
respect to available class II and class III networks and your requirement on redundancy.
See Table 1-10.
• Single and return (class II), as well as two-phase (class III) connection, of a standard
controller are possible.
d.c. Supply
Essential information includes:
• When using a d.c. supply, only battery-supplied systems with a non-grounded battery can
be used for direct supply of Advant OCS. With this type of supply, the battery is grounded
in the Advant OCS equipment.
• Supply from a grounded battery requires an isolating d.c./d.c. convertor.
• Supply C is always an a.c. supply, see heading above.
Protective Earth
Always provide Advant OCS cabinets supplied with 230 V a.c. with a protective earth.
Current Consumption and Fusing

Instructions for current consumption calculations are provided in Section 3.1.4, Power Supply.
This section also gives dimensional rules for distribution board fusing.
For a quick guide to the power consumption to use whenever you need estimated figures is also
located in this section.
Uninterrupted Power Supply

In certain applications, you must guard against brief voltage failures by using an uninterruptable
supply. See Section 3.2.2, Power Supply for important considerations in doing so.
2-8 3BSE 002 414R601 Rev B

Section 2.1.8 Process Connection
2.1.8 Process Connection

Process signal cables are connected to connection units. Connections between I/O boards and
the associated connection units are made with prefabricated ribbon or multi-core cables.
The cables are available in the price list in one standard length. Other lengths up to 15 m (50 ft.)
can be ordered separately. Any marshalling can be distributed accordingly.
There are certain restrictions regarding:
• Internal cable routing
• Signal earthing
• Shield earthing
• Earthing of connection units, mounting rails, cable channels
• Bounding of the marshalling racks (chassis) to the relevant cabinet housing the electronics.
Pay special attention when using non-ABB cabinets.
• 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.
2.1.8.1 Connection Principles, Fusing and Voltage Distribution

Advant Controllers are delivered with connection units containing interference-suppression
components and screw terminals for connection of process signals.
Each I/O board is normally provided with a connection unit and the signals are distributed by
dividing the cables entering the cabinet and connecting the separate conductors to different I/O
board’s connection units. You can install delivery-adapted cross-couplings in the cabinet,
making it convenient to use the connection units as the board-oriented half of the cross-
coupling. As an alternative there is a series of connection units for object oriented connection.
These facilitate the connection of field cables without using any marshalling or process cable
split-up. An illustration and principal description is given in Section 1.7.6, Process Interfaces.
Examples of different solutions include standard installation of the connection unit in the
terminal cabinet or installation in open compartments adjacent to the controller system.
However an open compartment is not a CE-marked design.
In addition to terminal blocks for connecting signals, the connection units contain terminal
blocks for supply distribution and fuses. The alternatives available in standard connection units
in the form of extra terminal blocks for 0V and voltage distribution, number of fuses, and so on,
vary among different types and are presented in the S100 I/O Hardware Reference Manual.
The standards optimize function, price and space requirements, for example, a common fuse for
the voltage supply to a group of eight outputs. Individual fusing of objects can be provided for
particular connection units.
You can use a DIN terminal bar with connection terminal blocks and fuses for a particular
application as a supplement to voltage distribution and terminal fusing in connection units.
3BSE 002 414R601 Rev B 2-9

Consider such an alternative at an early stage in the design to ensure that it is located in the
cabinet to give optimum cable lengths.
Wiring is routed to different transducers and loads in the installation from the marshalling.
It is important that the leads to and from a transducer for an electric signal be in the same cable.
This requirement means that it is logical to distribute the voltage supply and the neutral from the
controller or marshalling. The costs of cable and cable installation work can often be reduced by
routing a multi-core cable to coupling boxes mounted nearby, from which cables can be
connected to individual objects. More detailed voltage distribution and object fusing is possible
in a coupling box than in a connection unit. The fusing used in the connection unit can then be
dimensioned to protect the cable in the event of a short circuit.
Connection - +
unit
- Box 1
+ 0.1 A
Obj.1
0.1 A
1A Cable 1
1A
Obj.2
Box 2
0.1 A
Obj.3
0.1 A
Channel 1 Cable 2
0.1 A
.
. Obj.4
5
Obj.5
Figure 2-3. Connections with Multi-Core Cable and Coupling Boxes
2-10 3BSE 002 414R601 Rev B

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. However, certain barrier brands provide rational connection facilities
adapted to the Advant Controller 400 Series thus making these brands especially advisable.
The weighing board type DSXW 111 is an exception. It is intended for use in an explosive
environment.
2.1.10 High Voltage Switch-gear Applications

Normally, Advant OCS equipment is not designed for direct connection to high-voltage
switchgear. You use intermediate relays for digital input and output signals as a connecting link.
For analog signals, use special measured value converters tested in accordance with Swedish
standard SS 436 15 03 class 4.
2.1.11 Lightning Stroke Protection

Industrial installations and power plants are normally provided with well-integrated grounding
nets installed together with the power distribution system. In installations with such grounding
systems, it is not necessary to install lightning stroke protection unless you are using overhead
wiring or suspended cables outdoors.
Large dispersed plants (water supply installations, refineries, and so on) can, however, have an
inadequate grounding system and signal cables can be routed above ground. In such cases,
lightning stroke protection must be used.
Cables outside the grounding system (even for short distances such as 10 m) always require
lightning stroke protection.
For installation rules, see the general document Interference-free Electronics Design and
Applications.
2.1.12 Weight and Mounting Dimensions

When placing a control cabinet, you must provide a number of minimum distances from the
cabinet to walls and the ceiling in order to ensure satisfactory results. These minimum distances
are indicated below.
When cabinets are located next to each other, you can omit from the cabinets the wall cladding
on the sides in contact, except from a cabinet which contains equipment which generates any
degree of interference (for example electromagnetic relays with no interference suppression).
Consider this when you are ordering the equipment.
3BSE 002 414R601 Rev B 2-11

Figure 2-4. 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. When cables enter the cabinet from above, the space available should be at least
1000 mm high to provide working space.
The distance between the rear and the sides of the cabinet and an adjacent wall shall be no less
than 40 mm. This also ensures good ventilation.
If hinged frames or front doors of end cabinets are to open fully without touching adjacent
walls, increase the distance as follows:
• At hinged side of hinged frame
– cabinet RM500V1 - 300 mm (11.8”)
– cabinet RM500V2 - 350 mm (13.8”).
• At hinged side of single door cabinet
– cabinet RM500V1 - 760 mm (29.9”)
– cabinet RM500V2 - 660 mm (26.0”).
• At hinged side of double door cabinet
– cabinet RM500V1 - 382 mm (15.0”).
The free space in front of the cabinet should be the width of the door plus the width of the aisle.
2-12 3BSE 002 414R601 Rev B

Section 2.1.13 Transportation and Storing
If a double door alternative is used, reflect the space required for any hinged frame. There must
always be space left for safety reasons even with open doors or frames bent outwards.
For dimensions of the RM500 cabinet type, see Appendix B, RM500 Cabinet - Data Sheet.
You can also find the estimated weight of a cabinet in that section.
2.1.13 Transportation and Storing

Cabinets are packed in a manner appropriate to the means of transport. A pallet is commonly
used, so a fork-lift truck or a hand truck is usually the most suitable means of transport on site.
Cabinets are fitted with lifting eyes to facilitate transport with a crane.
NOTE
Please, observe lifting instructions enclosed with the cabinet!
Store cabinets in a dry place, protected against dust.
2.2 Setup
The goal of this section is to tell you “how to” set up the product.
Follow the sequence of activities prior to power-up described below.
It is assumed that the equipment is assembled and delivered in type RM500 cabinets. If you are
using other types of cabinets, see separate documentation regarding questions such as proper
levelling and how to screw cabinets together.
The equipment to be set up is ordered for and adapted to a specific application. When process
I/O Series 100 is used, the delivery is normally comprised of several cabinets (single or double)
which are to be placed side by side.
Apply the setup instructions with respect to the specific design!
See Section 2.2.1, Safety Regulations through Section 2.2.7, Power Supply Connection for
general information, followed by individual setup descriptions for different parts of the
automation system. You can find this information under the following headings, if relevant:
• Assembly
• Electric Installation (including Power Supply)
• Functional Measures
• Preparation for Start-up.
Ordinary installation drawings, terminal diagram forms and connection documents for site
preparation and installation of electrical equipment also apply.
3BSE 002 414R601 Rev B 2-13

Necessary Outfit
The following kit is a minimum requirement:
• Ordinary hand tools.
• Universal instrument, for example digital multimeter.
• Test leads with 4 mm banana contacts and reducer contacts for a 2 mm test jack.
• Necessary parts of the documentation listed in Section 1.4, Related Documentation.
• Specific documentation enclosed at delivery, drawings and so on.
2.2.1 Safety Regulations

Always follow the instructions below when installing and operating an Advant Controller
system to minimize the risks of injury to personnel and damage to the equipment.
Local statutory regulations, to the degree that they are stricter than the following instructions,
take precedence.
2.2.1.1 Personnel and Process Safety
DANGER - CAUTION
Observe the following:
• Use only approved hoisting equipment when lifting cabinets. See lifting instructions
enclosed with the cabinet.
• Never switch on the voltage supply of the cabinet during installation work.
• Work with care when supply voltage is applied in the system. The voltage in the
cabinet can cause injury and can even kill a human being.
• Make sure that everyone working on the installation knows the location of the safety
switch and the main power supply switch to the Advant Controller 410 equipment and how
to use it.
• When the subsections of the process are checked and a test run has been performed,
a responsible person is to check out interlocking chains, and so on.
Inform all assembly personnel about test runs to be performed.
• Process technicians are to be present when testing and operating the process objects.
• Never press the system ENTER (initialization) button if you do not know what happens in
the system with an initialization (see Section 2.4, Start-up Procedures). The command
RECONFIG is equivalent to an ENTER in the CLEAR mode.
That is a cold start takes place.
• Remember that the control system can be controlled from an engineering station connected
at another node via a MasterNet. For example it can be stopped, configured and started
remotely.
• Remember that an Advant Controller 410 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 410 by setting the START MODE selector in the STOP
position.
2-14 3BSE 002 414R601 Rev B

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.
• Use the grounded wristband installed in the cabinet when handling parts of the system.
• Handle the circuit boards carefully, particularly those which contain MOS components
which can be damaged by static electricity discharges. Note the warning label on the
circuit boards.
• Use, as far as possible, the grounded wristband when handling boards not stored in
envelopes of conductive plastic. This gives optimum protection against static electricity
discharges.
• Always store circuit boards in envelopes of conductive plastic when not installed in the
system rack.
• Always switch off the voltage before extracting a board which cannot be exchanged while
under voltage. See Chapter 5, Maintenance. Wait a sufficient time for the capacitors to
discharge.
• Switch off voltage to the system and withdraw all boards at least 20 mm before electrical
welding is performed near the controller system.
• A warning label is fixed in the system to draw attention to possible damage by ESD
(Electro Static Discharge).
All elektronik är känslig All electronic devices are

för ESD (elektrostatisk sensitive to ESD (electro-
urladdning). För att und- static discharge) effect.
vika onödiga skador vid To avoid accidental dam-
hantering av kretskort ages while handling PC
rekommenderas använd- boards, it is recom-
ning av systemjordat mended to wear wrist
handledsband med in- strap earthed to the
byggt skyddsmotstånd chassis. Wrist strap has
samt antistatisk förva- to have built-in protective
ringspåse för korten. resistor. Antistatic bag
has to be used to store
and transport the PC
boards.
Figure 2-5. Warning Label regarding ESD
3BSE 002 414R601 Rev B 2-15

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. If these remain in place too long, the surface can be
affected.
Use care when unloading and transporting cabinets. A fork-lift truck is usually the most suitable
means of transport.
Cabinets are fitted with lifting eye bolts to facilitate transport with a crane.
NOTE
Please, observe lifting instructions enclosed with the cabinet!
Temporary Installation of Heating Element

If a cabinet is provided with a heating element, activate it as soon as possible after the cabinet is
unpacked to prevent corrosion.
Connect the mains supply a.c. (phase, return and protective earth) directly to the terminal blocks
of the element unit.
Make the connection temporarily. See the delivery documentation for information on element
location and terminals to be used.
When the cabinet is finally installed, supply the element according to the information given in
Section 2.2.7, Power Supply Connection.
2.2.3 Location
The cabinet is to stand on a stable floor, deck or supporting structure, free from vibrations, and
is to be screwed to the surface. Minimum distances to walls and ceiling are listed in the
Figure 2-4.
Access to the rear of the cabinet is not necessary.
If required, you can remove the side plates on the sides in contact when two or more cabinets
related to one controller with I/O are installed next to each other. The width of the cabinets is
reduced by 20 mm for each end panel removed. The side plates should remain in place, as
protection, on any cabinet which generates any degree of interference.
2.2.4 Arrange the Cabinets

The floor should be level and well suited for arranging (Swedish building standard-AMA
tolerance 3B or class 2), so that a number of cabinets can be bolted together without any
additional work being required.
If the floor is not sufficiently level, the cabinet base may be askew, making it difficult to open or
close doors.
Information about how to screw the cabinets together and fixing them to the floor is given in
Appendix B, RM500 Cabinet - Data Sheet.
2-16 3BSE 002 414R601 Rev B

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. It also gives alternative
solutions adapted to specific plant requirements.
2.2.5.1 General
A RM500 cabinet forms a stable ground plane for all equipment accommodated.
The signal processing electronics in the controller, as well as all interference suppression for
external signals, are normally directly grounded to chassis and plant earth.
2.2.5.2 Protective Earth

The mains distribution normally includes a protected earth (PE) wire. Connect this to the PE
terminal block on the primary Power Switch Unit or the Mains Net Filter, if included. (See the
circuit diagram enclosed at delivery.)
You are directed to use cable lug connectors when connecting to any earth screw.
2.2.5.3 Earth Line

Ground the cabinet with a copper lead (≥ 35 mm) to the plant earth line.
Use any of four earth screws placed in the corners of the cabinet floor.
You are directed to use a cable lug connector.
Individually connect several cabinets in a row to the plant earth line.
2.2.5.4 Grounding of Process Cable Shields
General
Advant OCS or rather the application itself put some limited requirement on cable shielding.
Only a few types of process signals must be shielded and treated in a special way in the
controller cabinet. In the continued description of CE-marked and not CE-marked controller
design these cables are denoted category A and they include:
• Low level analog input signals
– Accuracy requirement shall be greater or equal to 12 bits
– Pt 100 and Thermocouple.
• High-frequency pulse transmitter signals.
Normally a single shield is used and it is grounded in the controller end of the cable.
Sometimes the application require a local grounding of the cable shield close to the transducer.
Specific rules apply then.
3BSE 002 414R601 Rev B 2-17

By different reasons other field cables may be shielded too. For example following a
company/plant standard. There is no requirement from the controller viewpoint. These field
cables are denoted category B.
Unshielded process I/O cables can be mixed with shielded process I/O cables.
Common to all cabinet designs is the horizontal mounting bar at the left hand side of the cabinet
inside, close to the bottom of the cabinet. They can be used to mechanically anchoring all types
of field cables, shielded and unshielded, when entering the cabinet.
CE-marked Design
Shields of category A cables which are to be directly grounded in the cabinet must be grounded
to the cabinet chassis, cable ducts or connection units, according to Figure 2-6. Use a short lead
(<50 mm) and thread-cutting screws.
Example of application with S100 I/O

X
Connection unit
≤ 5 mm (2”)
Connection of shield
X in cable duct with
tapping screw ST3.5x9.5
Process
I/O Cable
Side view X-X
Figure 2-6. Handling of Process I/O Cable Shields in a CE-marked Cabinet
If there is a requirement of local grounding of a cable shield for, for example, a thermocouple
application, cable with double shield should be used. The inner shield is grounded locally at the
transducer while the outer shield is grounded according to Figure 2-6.
Shielded cables of the category A which are grounded locally at the transducer are alternatively
to be connected via a capacitive decoupling device, located in the bottom of the cabinet.
That is similar solution to that used for certain communication cables. See Section 2.2.5.5,
Grounding of Communication Cable Shields.
Shields of category B cables can be handled in the same way as category A cables.
2-18 3BSE 002 414R601 Rev B

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 2-7. The shield of a category A
cable must furthermore be run all the way up to the relevant connection unit. A suitable point of
grounding in the connection unit is shown in Figure 2-6. Use a short lead ≤ 50 mm and thread-
cutting screws.
Signal or main cable
Cable shield (exposed or not acc. to application)
Horizontal mounting bar

(Anchoring bar C-profile)
Cover
Cable holder with

covers
Figure 2-7. Handling of Cable Shields in a not CE-marked Cabinet

Shielded cables of the category A which are grounded locally at the transducer shall be left
ungrounded in a cabinet which is not CE-marked.
After anchoring and grounding of a category B cable shield in the horizontal mounting bar you
are free to cut the shield wherever it is most practical.
2.2.5.5 Grounding of Communication Cable Shields

General
Communication cables shall be routed directly to the actual connection unit, modem or
communication module in a subrack. Never open up a cable shield when entering the cabinet.
The grounding of the shield to the chassis, directly or via a capacitor is normally determined by
the type of communication. You must reflect the whole installation of the communication bus to
comply with a main rule: A bus communication cable shield must be directly grounded but only
in one end of the bus. That is in the cabinet where the first/last connected Advant Controller (or
other node) is located.
There is a supplement to the installation information given in separate communication user’s
guides.
3BSE 002 414R601 Rev B 2-19

CE-marked Design
I addition to the general instruction found above, further interference suppression of the cable
shield is made at the enclosure port by individual methods adapted to the different types of
communication. The schematic principles of direct grounding and h.f. grounding by a capacitor
are shown in Figure 2-8.
Direct Grounding Grounding by Capacitor

Cabinet Field Cabinet Field
In one end
only
Modem/ Cable Holder Modem/ Capacitive

Circuit board/ Circuit board/ Decoupling
Connection unit/ Connection unit/ Unit
Terminal block Terminal block
Figure 2-8. Principles of Grounding of Communication Cable Shields in a CE-marked Design
At direct grounding of the communication cable shield, the illustration in Figure 2-7 is
applicable.
The grounding via a capacitor is based on a Capacitive Decoupling Unit, which is mounted on
the horizontal mounting bar. The cable then passes the cabinet bottom unstripped.
See Figure 2-9.
2-20 3BSE 002 414R601 Rev B

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 2-9. Communication Cable Shield Grounded by Capacitor and Ferrite Coil
Each unit takes up to four communication cables and it also provides the mechanical anchoring
of the cable. Two units can be mounted side by side or, if necessary, on top of each other.
Certain spacers are used then. This imply a maximum of 4 units on a mounting bar (16 buses).
A split ferrite core should be used on each communication cable. They should be mounted at the
cabinet entry, see Figure 2-9, and have a series impedance of at least 100 ohms in the frequency
range 50-300 MHz. The application of method with respect to communication type is given in
Table 2-1.
Table 2-1. Methods of Handling Communication Cable Shields
Grounding of Shield Grounding of Shield

Type of Communication
Directly via Capacitor
Advant Fieldbus 100, Coaxial -- Yes
Advant Fieldbus 100, Twisted pair -- Yes
MasterFieldbus, Long Distance Bus -- Yes
MasterFieldbus, Short Distance Bus Yes (in both ends!) --
MasterBus 300 (300E), GCOM, Yes --
drop cable
RCOM, EXCOM, MVI Yes --
3BSE 002 414R601 Rev B 2-21

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 Yes
pair
PROFIBUS-DP Yes
V24/RS-232-C, for example for a Yes --
printer
Bus Extension to S100 I/O Refer to Section 2.2.9, S100 I/O

The description given under the heading General is adequate. The cable is mechanically
anchored to the horizontal mounting bar close to the bottom of the cabinet. Leave the cable
unstripped. Use a cable clamp to press the cable against the bar or adjacent cable if several
cables are pressed together.
2.2.5.6 Grounding of “Internal” System Cable Shields, Connection Unit -- I/O Board
General
Use shielded cables to join distributed (> 3 m) process connection units and I/O boards in a
subrack. Note that the internal cable must be routed separated from other cables.
Ground the shield in both ends. Use sheet cable lugs and self-tapping screws
ST3.5x9.5 (B6x9.5). See Figure 2-10.
I/O
subrack Connection Process
unit connection
I/O
board
Shielded cable Tinned
> 3 m (10 ft.) surface
Figure 2-10. Grounding of Cable Shield, Connection Unit - I/O Board
2-22 3BSE 002 414R601 Rev B

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 2-10.

The description given under the heading General is adequate. The cable is mechanically
anchored to the horizontal mounting bar close to the bottom of the cabinet. Leave the cable
unstripped.
2.2.5.7 Grounding of Process Signals

There are three applications of signal grounding directly to the chassis. (High-frequency
grounding by capacitors is always provided and not discussed in this context.)
1. Signals are automatically grounded to the chassis by the connection unit. This quality is
determined by the selection of I/O unit or connection unit. Some board types require
grounded signals while others can be applied to non-grounded signals (and grounded).
Please see the connection unit documentation on a case-by-case basis.
2. Signals can be commonly grounded by grounding the reference 0V of centralized power
supply for loads and sensing. Such a power supply system must be grounded to the same
earth line as the Advant OCS.
If the power supply unit is placed in the controller or I/O cabinet, 0V is grounded to the
protective earth screw.
Local grounding of loads and sensors is then impossible!
3. Individual grounding of a signal in the controller cabinet is possible (if it is applicable with
respect to board type and connection unit type selected).
The 0 V signal connection at the connection unit is reconnected and grounded to the
mounting rail. Lead length is not critical.
Use a self-tapping screw. See Figure 2-11.
Such an application requires that the signal not be grounded otherwise, for example, not
locally grounded at load/sensor or not grounded via a power supply grounding.
3BSE 002 414R601 Rev B 2-23

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)
0V lead
ST 3.5x9.5
(B6x9.5)
Cable duct
Connection unit
Cable
Mounting rail
Figure 2-11. Individual Grounding of Process Signal
2.2.5.8 Grounding of Additional Equipment

Treat additional power supply units of different types, aimed at load/sensor supply and modems,
and so on erected in the controller or I/O cabinet, in the following way with respect to
grounding:
• Connect the apparatus chassis (or PE terminal) to the protective ground via one of the
power distribution sockets on the power switch unit or directly to the cabinet chassis.
• Consider application-adapted grounding of power supply 0 V. If desirable, connect the 0 V
terminal to the chassis. It is preferable that you use the protective earth screw.
2.2.5.9 Spare Conductors

Spares in field cables are to be grounded within a cabinet, in case of a CE-marked design.
2.2.6 Cable Routing in Cabinets

Cables are practically routed on either side of the cabinet depending on the final destination.
The physical item destination for an actual apparatus, and thereby the connection point, appears
in the circuit diagrams and other installation drawings enclosed at delivery.
The assigned space for cables that are entered in the floor opening is shown in Figure 2-12.
For your information, the space for the factory assembled cables is also indicated in
Figure 2-12. Regard the latter cables and leads as sensitive to disturbances and keep them away
from cables coming from the plant. You will encounter these areas only when the system is
enlarged by additional equipment, for example a circuit board and connection unit.
2-24 3BSE 002 414R601 Rev B

Section 2.2.6 Cable Routing in Cabinets
Cabinet seen from above

Internal 24 V and so on
Space for cables joining

connection units and I/O boards
mounted in the same cabinet
Front Enclosure port in the floor

Cable shield/relieving bar
Indicates contours of subracks (controller, I/O)
and bar with connection units.
Indicates space for plant cables
Category 1-3 acc. to Table 2-2
Indicates space for internal cables
Figure 2-12. Assigned Space for Cables in a Cabinet
There are some restrictions in mixing cables within a cabinet due to the risk of interference.
To describe the simple rules applicable at site installation, cables are divided in categories.
See Table 2-2 and the following rules:
• Within a category, you can mix cables arbitrarily.
• Keep the distance between cables belonging to different categories ≥50 mm.
• “Cabinet internal” couplings have their own defined spaces for routing.
Always keep the distance to other cables ≥50 mm.
Table 2-2. Cable Categories in a Cabinet
Cable/Application Category
Power supply a.c. or d.c. 1
Process I/O, shielded and unshielded cables 2
Communication 2
Clock sync. STAL alarm, and so on 2
Distributed connection unit 3
Route cables in horizontal cable ducts when applicable.

Fix cables with cable straps.
3BSE 002 414R601 Rev B 2-25

2.2.7 Power Supply Connection

2.2.7.1 General
Cabinets erected side by side, including a controller and I/O configuration, are regarded as a
unit which is joined to the power supply network at one single connecting point, a centralized
power switch unit. The switch unit is normally located in the controller cabinet.
The power supply is distributed to another cabinet according to application. The power supply
units in cabinet 2 are connected to the switch unit via ready-made cables and plug-in contacts.
Cabinet 1 Cabinet 2
Controller Connection
with I/O units
Power supp. Power supp.
Power
Switch
Supply 3-wire cable

Protective earth
Figure 2-13. Main Principle of Power Supply Connection and Distribution
2.2.7.2 Installation
General
Ordering documents show which power supply alternative is applied.
An a.c., d.c., redundant or non-redundant supply is connected to the controller in the same way,
in principle. A terminal diagram form enclosed at delivery shows the relevant physical item
designations and connection points in the cabinet. You will also find the denominations supply
A, B and C applicable.
A summary of the main requirements of the networks A, B and C are given in Section 2.1.7,
Power Supply and Fusing.
The installation work to be done, supported by the terminal diagram form (circuit diagram), is:
• Connect network A
• Connect network B (if redundancy)
• Connect network C
• Connect the power supply units located in a process connection cabinet which may
become extra. Use the ready-made cables and plug-in contacts. They are marked with the
destination item designations.
2-26 3BSE 002 414R601 Rev B

Section 2.2.7 Power Supply Connection
CE-marked Design
Protection against line conducted radio emission is obtained by means of a special filter placed
in the bottom part of the cabinet on the incoming supply. One filter for each supply is utilized.
The cable length between the entrance of the cabinet and the net filter should be as short as
possible and mounted inside a protective screen. After connection to the net filter(s) the
protective shield plate should be remounted.

No additional information than that given under the heading General apply.
2.2.7.3 Heating Element

If a heating element is included in the cabinet, connect it appropriately with respect to external
safety switches. Do not disconnect it by the cabinet power switch unit.
2.2.7.4 Preparation for Start-up

Check that the circuit breakers on the power switch units are switched off.
3BSE 002 414R601 Rev B 2-27

2.2.8 Controller
Assembly
All equipment included in the controller is factory assembled. Cabinet arrangement and similar
questions are dealt with in the general setup instructions above.
Electric Installation
Apart from the process I/O connections and communication connections, which are treated
separately, there is little electric installation. Grounding of the cabinet, equipment, cable shields,
and power supply connection are covered in the general setup instructions above. In addition to
that, make the following connections of functions when appropriate:
• Run/Alarm relay
• External clock synchronization
• Additional supervisory inputs.
The location of the connections within the cabinet are specified in the terminal diagram form
enclosed at delivery.
Run/Alarm Relay
External alarm AC 410

announcement SB171
Supply
RUN-COM
X2:6
Indication RUN-NO
X2:5 RUN (Processor Module PM150)
“normal closed”
Configuration: No
Figure 2-14. Connection of Run/Alarm Relay
2-28 3BSE 002 414R601 Rev B

Section 2.2.8 Controller
External Clock Synchronization
AC 410
External clock SB171
SYNC+
X2:3
SYNC-
X2:4
Configuration: DB element Clock Synch
Figure 2-15. Connection of External Clock Synchronization
Additional Supervisory Inputs
AC 410
SB171
System status
+ *) F1+
display in
operator station
Alarm output X2:1
- F1- F1
X2:2
Description/Configuration: DB element AC410
*) Free disposition within cabinets

24 V d.c.
Passive signal (0 V) is defined as error signal
Signal cables may not be extended

outside the controller cabinets due to
the risk of interference.
Figure 2-16. Connection of Additional Supervisory Inputs
The status information is available:

• On the AC410 data base element for use in any application program.
• On the Advant Controller system status display presented on central operator station
display screen.
Configuration, that is, defining the texts to be presented in the status displays, is performed in
the AC410 data base element.
Functional Measures
• Adjust all included communication modules designated CS513 or CI547 (MasterBus 300,
MasterBus 300E) with respect to the actual configuration before a power switch on.
3BSE 002 414R601 Rev B 2-29

You are directed to set the following by jumpering:

– Network number
– Node number
– Slave number
– Protocol type.
For instructions, see the manual MasterNet, User’s Guide.
The data base elements in Advant Controller holding the corresponding data are
automatically updated at power-on/initialization.
• Set the start mode selector on the CPU module front (PM150) in the CLEAR position.
Preparation for Start-up

Please see the general checklists in Section 2.2.14, Checklists.
Leave the battery for memory backup disconnected until the mains supply is switched on and
the application configuration is started. Otherwise, it will be discharged in a few hours.
2.2.9 S100 I/O
Assembly
Circuit boards and connection units are normally factory assembled. For information regarding
the location of equipment, see the actual delivery documentation. Assembly drawings,
for example, also give the cross-reference between the following structures:
• Physical location of circuit boards and connection units
• Functional item designation of circuit boards and signal channels
• Board address.
The functional item designation, for example, AI1 and the board hexadecimal address, H’20 are
hard related to each other and supported by the configuration tool when creating the data base.
(Normally, this relation is never changed.) However, the relation to the physical location is
determined when the equipment to be delivered is designed. Initially, standard location is
followed, see Section 2.1.4, Standard Layout and Disposition of Cabinets. Customized layout is
possible whenever applicable.
Reorganization of boards and connection units is “theoretically” possible. I/O board addresses
are not hard related to physical location. The board itself is carrying the address. The question
is, are there sufficient cable lengths (board-connection unit) to do the work?
A reorganization also calls for changing the documentation of the equipment.
2-30 3BSE 002 414R601 Rev B

Section 2.2.9 S100 I/O
Electric Installation
Distributed Connection Units
Distributed (3 m - 15 m) connection units are joined to the I/O boards by adapted shielded
cables with plug-in connectors. The following instructions apply:
• Outside the I/O cabinet, route the cables separately from other cables.
– 100 mm distance in general to other cables
– 300 mm distance to cables conducting power supply >250 V a.c.
• Cable routing in cabinets, see Section 2.2.6, Cable Routing in Cabinets.
• Grounding of cable shields, see Section 2.2.5, Grounding.
Process Signals
Process signals are connected to the connection units according to site installation drawings
supported by:
• Assembly drawings enclosed at delivery
• Terminal diagram forms enclosed at delivery
• Connection examples in S100 I/O Hardware Reference Manual.
The following instructions apply:
• Grounding of process signals, see Section 2.2.5, Grounding.
Regarding cable selection and external cable routing, see general information in Interference-
Free Electronics Design and Applications.
A carefully accomplished electric installation is the basis of future interference-free operation.
Functional Measures
Address Jumpering
All circuit boards are adequately jumpered with respect to address at the factory.
If you need them, you can find instructions on how to set an I/O board address in the
S100 I/O Hardware Reference Manual.
Functional Jumpering
There are some board types that require jumpering to determine an application function,
for example, selection of current/voltage signal, mains frequency, grounding, and so on.
Functional jumpering applies to the board types and connection unit types listed in Table 2-3.
Please check the relevance for your application and follow further instructions for the specific
board type/connection unit type given in S100 I/O Hardware Reference Manual.
3BSE 002 414R601 Rev B 2-31

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
DSAO 120A Current/voltage
DSAO 130 Current/voltage, 10/20 mA
DSDP 140A Filter time, function mode
DSDP 150 Function mode, voltage level
DSDP 170 Interrupt level, measuring interval source and
time, filter time for inputs
DSTX 170 Input signal level, grounding
DSDC 111 References
DSTX 110 External/internal supply
DSTY 101 Signal range
Readjustment
AO boards are factory adjusted for voltage output signals. If current signal is desired/jumpered,
you must readjust for maximum accuracy. Please follow the instructions found in Section
5.4.12, Channel Adjustment on AO Board.

Check of the External Wiring
Judge the level of workmanship case by case. The result determines the need to thoroughly
check all connections before the system is powered up.
You can, of course, check with a buzzer or similar device that the external wiring to the process
equipment is correct and that all conductors are intact.
Without activating the control equipment, you can also check that transducers and actuators
(including all process wiring) function correctly. This makes it necessary to connect voltage to
these units and develop suitable checking methods, which are time-consuming activities.
2-32 3BSE 002 414R601 Rev B

Section 2.2.10 S800 I/O and S400 I/O
An alternative method is to make an integrated check of the process equipment and wiring and
the corresponding controller function, which can be accomplished with a circuit-by-circuit
procedure. Preferably, the controller is loaded with application data base. The data base is then
used as one checkpoint. Status/values can be read and control signals to process objects can be
simulated by an engineering station. When an operator station is included in the system, it is
most effective to maintain the check from the automatically generated process I/O object
displays. 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.
2.2.10 S800 I/O and S400 I/O

S800 I/O modules and S400 I/O units are normally arranged in suitable cabinetry. The necessary
communication modules and modems are assembled in the controller cabinet. For information
regarding the location of this equipment, see the actual delivery documentation. For other
information, including all questions of installation, see the separate documentation:
• For S800 I/O the manuals:
– Advant Fieldbus 100, User’s Guide.
– S800 I/O, User’s Guide.
• For S400 I/O the manual:
– MasterFieldbus and S400 I/O, User’s Guide.

The general information given for a check of external wiring in Section 2.2.9, S100 I/O apply.
2.2.11 Peripheral Units
Power Supply
If you do not use a modem when communicating with a printer or a video terminal, you must
take an a.c. voltage supply with a protected earth (PE) from the Advant Controller cabinet, it is
not acceptable to use the closest or otherwise most convenient supply receptacle.
Make the connection as shown in Figure 2-17. The significant aspect is that the peripheral unit
should be grounded in the controller protective earth.
3BSE 002 414R601 Rev B 2-33

Advant
Controller
Printer /
Video terminal
a.c. powered system
N L PE
a.c. mains (C) socket
Advant
Controller
Printer /
Video terminal
d.c. powered system

a.c. is available
N L PE
a.c. mains (C) socket
Advant
Controller Printer /
Video terminal
d.c.
a.c. d.c. powered system
no a.c. available
Preferably, you will use

a modem and separate
a.c. supply voltage in
this application.
Figure 2-17. Supply of Peripheral Unit without Modem
You are directed to always check that the utilized a.c. power supply meets the quality
requirements of the peripheral unit, (for example the class of the network).
Take into consideration the extra load caused by any peripheral unit:
• When an intermediate isolating transformer is used in the cabinet to convert a two-phase
network to a single-phase network.
• From a fusing viewpoint.
Given the above rules, you can use any spare power outlet in the cabinet or you can arrange for
an additional branching socket.
2-34 3BSE 002 414R601 Rev B

Section 2.2.11 Peripheral Units
2.2.11.1 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 with a
standard cable TK520V150. Use the front connector marked X6.
Cable routing in the cabinet is shown in Section 2.2.6, Cable Routing in Cabinets.
Because of the lack of isolation between the printer and the controller, it is important that they
be powered from the same mains supply. See general instructions in Section 2.2.11, Peripheral
Units, heading Power Supply.
CE-marked design (additionals)

Direct grounding of cable shield
Advant Controller Use the cable clamp at the enclosure port
Comm. Module
Cable
TK520V150
CI531
15 m (49 ft.)
Mains Supply (C) Socket
Phase
Return
Protective
ground
Figure 2-18. Short-Distance Connection of Printer
Long-Distance Connection
If you use a communication modem, the distance between the controller and printer can be a
maximum of 300 m.
The different cables prescribed are shown in Figure 2-19 below. Rules for cable shielding are
given in Figure 2-20.
See the actual delivery documentation for the controller for information regarding location of
the processor module and the modem.
Cable routing in the cabinet is shown in Section 2.2.6, Cable Routing in Cabinets.
3BSE 002 414R601 Rev B 2-35

From the viewpoint of the Advant Controller, there are no restrictions on the mains power
supply of the printer, for example, no requirement for earthing and same supply. The controller
and the printer are galvanically isolated from each other by the communication modems.
Advant Controller
Processor Module Modem Cable

DSTK 156V0.5
PM150 0.5 m (0.6 ft.)
TC562 Modem
TC562
Cable
TK577
Cable:
Two twisted pairs, each pair
individually shielded,
min. conductor area 0.22 mm2
max. length: 1000 m at 19200 bps
Figure 2-19. Long-Distance Connection of Printer
CE-marked design (additionals)

Direct grounding of outer cable shield
Use the cable clamp at the enclosure port
Line
Modem connections Modem
TC562 1 3 DSTC
2 4
3 1 X008
4 2
Shield 5 5 Shield
N L PE
Supplied Note: Shield grounded

Mains
internally in one end only
in the controller
Figure 2-20. Connections and Grounding of Communication Cable Shields
2-36 3BSE 002 414R601 Rev B

Functional Measures, General

The following instructions apply.
Processor Module PM150: No measures needed.
Modem: XON / XOFF 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. 120 V. Instructions are enclosed with the modem.
Printer: Set the printer to meet the requirements stated in Table 2-4.
Table 2-4. Printer Settings
Data Value
Character code Standard 7 bits ASCII
Parity None
Number of stop bits 1
Data word length 8 bits
Type of interface RS-232-C
Baud rate 9600 bits/s
Protocol XON /XOFF
No. of characters per 72
line
Printer speed 160 characters/s

Check that the printer and any modem are adapted to the mains voltage at hand.
2.2.12 Communication
Please refer to the following separate documentation:
• The user’s guide for the actual communication link.
• Assembly drawings, terminal diagram forms, and so on, enclosed at delivery of the
Advant Controller. These show you the location of the hardware.
The following instructions apply:
Regarding cable selection, external cable routing, and so on, see general information in
Interference-Free Electronics Design and Applications.
A carefully accomplished electric installation is the basis of future interference-free operation.
3BSE 002 414R601 Rev B 2-37

2.2.13 Engineering Station

The following apply to an engineering station type Advant Station 100 Series ES when
connected directly to the Advant Controller 410.
Electric Installation (incl. Power Supply)
Plug the communication cable enclosed with the engineering station into the X27 SERVICE
connector on the processor module front.
From the viewpoint of the Advant Controller, there are no restrictions on the mains power
supply of the engineering station, for example no requirement of earthing and same supply.
The controller and the engineering station are galvanically isolated from each other by the
communication interface.
2.2.14 Checklists
In the setup instructions, you are occasionally referred to a separate document,
Interference-Free Electronics Design and Applications.
The following checklist is a summary of important information addressed to the actual
2.2.14.1 Grounding Philosophy, Earthing Line System

Table 2-5. Grounding Philosophy, Earthing Line System
Item Concerning Action

Grounding philosophy Ground system Grounding only to power earth line network.
Only one ground system. No exceptions.
Earth line system Design The earth line system of the installation must be
carefully installed and must incorporate the
switchgear.
2-38 3BSE 002 414R601 Rev B

Section 2.2.14 Checklists
2.2.14.2 Process Cabling, Shielding, Grounding, Maximum Length

Table 2-6. Process Cabling, Shielding, Grounding, max. Length

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)
Signal wire and return wire in same cable
Shielding: Single Grounding: Same position as signal circuit
shield AI, AO, DI, DO,
Modem DSTC
X008/TC562
Grounding: At both ends
Communications
pulse transducers
Shielding: Double Grounding:
shield Outer shield Both ends
Inner shield As signal circuits
Cable without Grounding All signal circuits grounded at the same end
shield
a.c. digital inputs Max. cable length Approx.: 115 V - 230 m
120/230 V 230 V - 115 m
Shield connections Connection Cable shields which are grounded in the cabinet
in EMC cabinet must be grounded according to separate
instructions. See Section 2.2.5, Grounding.
Shielded cables not Connection Capacitive decoupling is to be used in the cabinet.
grounded in the Or a cable with double shield can be used where the
EMC cabinet outer shield is grounded in the cabinet.
3BSE 002 414R601 Rev B 2-39

2.2.14.3 Supply
Table 2-7. Supply

a.c. Mains Connection in cabinet Phase (check for correct voltage)
Return
Protective earth (if distributed)
Note: There must be no breaks in the protective
earth line before the connection to the PE terminal.
Fuse In phase (phases)
Connection of network: No unsuppressed load on same finale circuit from

distribution box
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 Negative pole to PE terminal of cabinet directly at

(floating battery) entry to cabinet.
d.c. Connection Via d.c./d.c. converter

(earthed battery)
Subrack supply Max. power output < 90% of stabilizer capacity
2.2.14.4 Lightning Protection

Table 2-8. Lightning Protection

Lightning protec- Actions are compulsory for all circuits in:
tion Overhead lines
Cables above ground
Cables that leave the general earth line network
2-40 3BSE 002 414R601 Rev B

2.2.14.5 Subrack, Connection Unit, Circuit Board

Table 2-9. Subrack, Connection Unit, Circuit Board

Mounting rail Ground connection to cabi- If problems, check R < 100 mΩ,
(for connection net chassis via mounting measured with equipment switched off and
units) screws ribbon cables disconnected
Subrack Ground connection to cabi- If problems, check R < 100 mΩ,

net chassis via mounting measured with equipment switched off and
screws ribbon cables disconnected
Connection unit Ground connection to All screws fully tightened

mounting rail via mounting
screws
Mounting rail Electrical connection to R < 100 mΩ,

mounted outside cabinet from both ends of A = 10 mm2 in tele rack
the cabinet (1) mounting rail.
2,5 mm2 in the cabinet
or in nonstandard Internal or external cabling
cabinet Spacing > 100 mm
to connection unit must be
kept apart.
Circuit board with Grounding of 0V Connection to chassis from X2 0V
0V at X2 < 50 mm
Connection Quality Only correctly made, screwed or clamped

connections are approved
Note: Inspected and approved tools must be
used
Circuit boards Variant reference Check for lowest revision approved variant to
be used for the equipment and use replace-
ment of the same or higher revision number.
This item is mainly relevant to maintenance
and use of spare parts.
Circuit boards Assembly Check that all units located in the subracks
are properly inserted.
Analog input circuit Full accuracy in the fre- DSAI 130 + DSTA 135 (131)
boards quency range
The other analog units can have for some
frequencies in frequency range 0.15 MHz to
60 MHz error > 0.2 %
(1) This application does not meet the limits for emission and therefore is not generally allowed within
the EEC area (EU, EFTA).
3BSE 002 414R601 Rev B 2-41

2.2.14.6 Cabinets, Internal Cables
Table 2-10. Cabinets, Internal Cables

Row of cabinets Electrical connection Through short 35 mm2 copper conductors
(grounding) joining the PE terminals in each cabinet.
Hinged frame Electrical connection to 2 cables, top and bottom of hinged frame
chassis (copper bar) L < 250 mm, A = 10 mm2
Cabinet parts All parts electrically R < 100 mΩ
(plates) connected to each other
and to the copper bar
Divided cabinets Connection with special screws and nut bars
Earthing in cabinet Design Only a single grounding system for
Advant OCS equipment NO EXCEPTIONS
Lighting At maintenance Only by filament lamp
Temperature in Max. permitted Max. permitted temperature for continued
cabinet temperature for operation in cabinet is 55°C.
continued operation. Measured just above the subracks.
If this value is exceeded the number of circuit
boards must be reduced.
Radio emission Emission Where EN or FCC requirements must be met,
only EMC-proof cabinet is adequate.
Shielded cable/ Design Communication, pulse transducers and ana-
ribbon cable log circuits for Low Level (Pt, thermocouples)
must be shielded up to the circuit boards
Internal cables Routing See Section 2.2.6, Cable Routing in Cabi-
nets.
Check that there is no tension in the wiring.
2.2.14.7 External Cables

When you are selecting suitable cables to use and when the cables are placed in the plant,
be aware that there are some restrictions and rules to be followed which involve, among other
things:
• The distance between Advant OCS cables and non-Advant OCS cables.
• The routing of communication cables.
• Mixing of signals and signal types within cables.
• The need for shielded cables.
See the electrical installation rules given in the sections above and the general document
Interference-Free Electronics Design and Applications, which also gives examples of the
available cables.
2-42 3BSE 002 414R601 Rev B

2.2.14.8 Communication, Communication Cables
Table 2-11. Communication, Communication Cables

Communication Electrical connection ≤50 mm (1.9 inch) (1)
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

tion cables to chassis point only (1)
Max. length Max. specified length must not be exceeded
Communication with- Routing of cables More than 100 mm (3.9 inch.) away from
out modem other cables
MasterBus 300 Cable length Multiple of 23.4 m max. 500 m (1640 ft.)
MasterBus 300E Joints At odd multiple of 23.4 m (77 ft.) (1, 3, 5 . . . .)
GCOM
(Ethernet) Outdoor installation Teflon cable in conduit which is grounded at
both ends.
An additional earth line > 35 mm2 routed in
parallel with the conduit and grounded at
both ends.
Routing 300 mm (11.8 inch.) away from other cables

or on separate cable rack.
For outdoor installation: underground in steel
pipes.
Transceiver Positioned at cable marking.

Insulated from the ground plane >100 mm
(3.9 inch.).
Not covered with other cables
Drop cable Separated from other cables >100 mm

(3.9 inch.)
All shields must be connected together at
both ends
(1) Special rules apply to a CE-marked design. Refer to Section 2.2.5.5, Grounding of
3BSE 002 414R601 Rev B 2-43

2.2.14.9 Miscellaneous
Table 2-12. Miscellaneous

Relays and contac- Suppression Cabling to non-suppressed inductive loads in
tors 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-

tion on DSTA 155/155B is taken from the
cabinet.
Position of “CJC”
(compensation unit for DSTA 155/155B must be placed as close to
cold junction the object as possible. Located in the cabinet
DSTA 155/155B) only if original (old) cabling is to be used.
Analog inputs/outputs Type Correct type: For grounded transmitters/

actuators/loads the inputs/outputs must be
differential or isolated.
2.2.15 Final Procedures Before Start-up

Remove all debris remaining from the work performed and clean off all grease and dirt.
Check that no tools or assembly material are left in the cabinets. Vacuum-clean the cabinets.
2.3 Shut-down Procedures

Before power supply switch-on and start-up of the equipment, it is important that you know how
to shut down in different situations.
Necessary Outfit
No special kit needed.

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. One instruction is highlighted:
DANGER
Work with care when supply voltage is applied in the system. The voltage in
the cabinet can cause injury and can even kill a human being.
2-44 3BSE 002 414R601 Rev B

Section 2.3.2 Controller and I/O
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.
NOTE
Check the location of the emergency stop and use it in an emergency
situation.
From an electrical and functional viewpoint, an emergency stop has the same consequences to
the controller and attached equipment as a safety shut-down. See below.
Safety Shut-down
The controller and its S100 I/O are, from the mains power supply viewpoint, an entity. Safety
shut-down aimed at disconnecting the controller from the mains is carried out in two ways:
• As prescribed in the site planning section, Section 2.1.7, Power Supply and Fusing, there
should be a common safety switch installed within 3 m from the cabinets.
NOTE
Check the location of the safety switch and use it when working with the
equipment.
The safety switch should shut down the power supply of not only the electronics system
but also the adequate transducers and other process objects. In other words, a total power
shut-down for the plant section controlled.
Since the safety switch is a plant component, this document cannot stipulate and describe
the design exactly. Please check the plant documentation in this respect carefully.
Instructions indicating the extent of the power supply shut-down should be attached to the
safety switch.
• You can also create a selective power shut-down of the entire electronics system using the
mains circuit breaker in the lower part of the cabinet where the controller subrack resides.
The breaker is labeled S1.
This circuit breaker sometimes also disconnects the field equipment supply for the plant.
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.
• The RAM, including system software and application program, is secured against loss of
power by a supply of power from a battery backup.
• Important process values, for example totalized flow values, register content, and so on,
can be stored automatically if measures are taken when the application start program is
designed.
3BSE 002 414R601 Rev B 2-45

• The system is ready for a restart. You perform a restart by operating the actual mains
switch when the reason for the shut-down is resolved.
The application start program also facilitates a different way to start up the application,
depending on the time of power supply disconnection.
A note about the application of S400 I/O and S800 I/O:
If this I/O system is powered from the central system (the mains distributed), then the
instructions and consequences in connection to a shut-down given above are relevant.
If, however, the S400 I/O system and S800 I/O system are powered by a separate mains,
separate safety switch, and so on, then you must make a distinction between a “central” and
“local” shut-down.
S400 I/O
A central shut-down causes the S400 I/O outputs to freeze or go to zero, as applicable.
A local shut-down causes the S400 I/O outputs to go to zero.
S800 I/O
A central shut-down causes the S800 I/O output to freeze or go to a predefined value,
as applicable.
A local shut-down causes the S800 I/O outputs to go to zero.
Regarding the output behavior attached to S100 I/O, S400 I/O and S800 I/O, please be aware
that zero output is the designed state. It cannot be guaranteed under all conditions, for example,
in the event of a failure.
Manual Stop
Besides the most drastic shut-down method—disconnecting the power supply—other methods
of “stopping” the controller are available to you.
You can stop program execution as follows:
• Use the operator’s interface on the processor module front.
– Set the start mode selector in STOP position.
– Depress the ENTER button and the system stops.
• Use an engineering station connected to the controller.
– Command ECONFIG in an adequate session.
The result of a stop and its consequences are compatible for the two manual stop methods:
– Application program execution immediately stops.
– There is zero output to the process objects.
– Output relays are de-energized.
– There is no loss of process data (besides what is happening in the process in the
meantime).
– The system is ready for a restart. To perform a restart:
Set the start mode selector in the AUTO position and depress the ENTER button or
Command DICONFIG.
2-46 3BSE 002 414R601 Rev B

Section 2.3.3 Peripheral Equipment
Automatic Stop
For the sake of completeness, the main reasons for an automatic stop are listed below:
• Loss of power supply
• Fault in power supply
• Fault in central processing unit and memory
• Other fatal error.
The result of an unintentional stop and its consequences are, from the viewpoint of design
philosophy, the same as for a safety shut-down (see above). However, when there is a fault
involved, other behavior must be taken into account.
After necessary measures, a restart can take place.
2.3.3 Peripheral Equipment

Shut-down of peripheral equipment, like printer or local operator station MasterView 320, is
treated below from the viewpoint of power supply disconnection only.
Regardless of whether the peripheral equipment is powered common to the controller or from a
separate mains, you can shut down by disconnecting the mains whenever necessary. Any faults
or disturbances that may occur are local to the peripheral equipment only, for example a missing
printout.
You can restart by switching on the power supply whenever you like with respect to the
controller function. The peripheral equipment is self-initialized.
2.4 Start-up Procedures

Activities up through “ready for application program loading” are described in this section.
This includes power-up and the first definition/configuration of the system resources.
A visible result of the start-up procedures is that all red LEDs on module fronts are turned off
and all green LEDs are turned on.
Necessary Outfit
• Universal instrument, for example a digital multimeter.
• Specific documentation enclosed at delivery.
• Advant Station 100 Series Engineering Station.
3BSE 002 414R601 Rev B 2-47


DANGER
2.4.2 Controller and I/O

Conditions given by “Setup”
If you finish the setup activities by using the checklists given in Section 2.2.14, Checklists,
the equipment is almost ready for start. Please read the following security information first.
Measures by Security Means

Power-up of a controller and I/O presents a small but real risk of spurious output signals to the
process due to a faulty hardware module.
Because this risk is very small, a general safe method, for example extraction of all output I/O
hardware during the first power-up, is not recommended. You are directed, however, to be
careful on a case-by-case basis.
Always identify and isolate critical process objects in some way if the process is energized.
Examples include:
• Opened safety switch.
• Disconnected power supply.
• Use of disconnectible terminal.
• Unplugged terminal block.
• Extracted output circuit board.
Perform succeeding operations after power-up, including necessary tests, carefully.
2.4.2.1 Power-up
If, for some reason, you desire a limited power-up, the minimum equipment necessary is:
• Processor Module PM150
• Inserted program card.
1. Check that the circuit breakers on the power switch units are switched off.
There is one breaker for mains A (labeled S1) and one for mains C (labeled F1).
Redundancy adds another circuit breaker for mains B (labeled S1).
2. Set the start mode selector on Processor Module PM150 in the CLEAR position.
NOTE
The CLEAR position is the only possible choice when you power up for the
first time.
2-48 3BSE 002 414R601 Rev B

3. Switch on the mains supply to the cabinet and check for correct mains voltage with a
multimeter at the connection terminals on the power switch unit. See the terminal diagram
form enclosed at delivery.
4. Switch on the circuit breaker S1 on the power switch unit(s) in any order (mains A and B).
Also switch on the miniature circuit breaker F1 for mains C.
Several power switch and distribution units can exist in the controller cabinet or in
adjacent I/O cabinets.
5. Check for the following positive indications of a successful power-up:
– Distribution unit SX554 green LED LIVE
– Regulator SR170 (Redundancy applied) green LED LIVE
(Regulator SR 122 has no indications)
– Processor Module PM150 green LED RUN
display ind. P2
(Indicating working mode CONFIGURATION)
See Figure 2-21.
There are also some negative indications, for example:
– S100 I/O boards red LED F(Fault)
(Indicating that the boards are not implemented.)
6. If a LAN communication interface CS513 or CI547 exists and if it is addressed and set
properly by on-board switches during the setup (see Section 2.2, Setup), it gives the
following indications:
– Communication module CS513 or CI547 green LED RUN
ylw LED TX/LAN (flash)
ylw LED RX (flash)
(Indicating a successful automatic configuration of the LAN communication.)
7. The target system is now ready for configuration, either by connecting the engineering
station directly to the processor module or via the network, if applicable and desirable.
8. Finally, set the start mode selector on Processor Module PM150 in the AUTO position.
WARNING
Do not push the ENTER button!
If correct indications fail to appear, trace the fault in accordance with the instructions in
Section 5.4, Fault Finding and User Repair.
3BSE 002 414R601 Rev B 2-49

Controller cabinet
PM150
P2 Display
Green LED, RUN
SX554
Green LED, LIVE (24 V)
Circuit breaker(s)
S1
Figure 2-21. Power-up, Circuit Breakers and Positive Indications
2.4.2.2 Initialization
The power-up achieved by following the above instructions produces an automatic
initialization.
In general, you can start an Advant Controller 410 in four different ways, as selected with the
selector Start Mode on the processor module front. These ways and applications are described in
Chapter 4, Runtime Operation.
2.4.2.3 Connection of Engineering Station

If it is not installed during the setup phase (see Section 2.2.13, Engineering Station), you can
plug the engineering station communication cable into the service port X27 on the
Processor Module PM150 front at any time.
• First connect the communication cable.
• Then switch on the power supply to the engineering tool.
Prepare for a session of programming Advant Controller 410.
Follow the instructions on the screen.
Work with the engineering station is supported by adequate documentation.
For detailed information about different configuration activities using an engineering tool,
see the manual AMPL Configuration Advant Controller 400 Series.
If the actual Advant Controller 410 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.
2-50 3BSE 002 414R601 Rev B

2.4.2.4 Controller System Configuration

Procedures, Overview
The initial design work with the controller should result in a system definition which is used as
a basis for the next step of the start-up procedure, the controller system configuration. This is
performed in the working mode CONFIGURATION. The start mode selector on the processor
module front is kept in the AUTO position, which was set after the power-up.
The controller system configuration is the practical work required to create the infrastructure of
the controller, that is the computer resources to maintain the application functions.
Configuration/application building is not part of the installation work described here. It is
regarded as a separate activity and is treated in Chapter 3, Configuration/Application Building
and in separate documentation. However, application work and the work to define the system
resources are in some way related. This is illustrated in Figure 2-22.
The most important conclusion is that dimensioning of the system requires information from the
application work, for example, definition of number of I/O boards, PID controllers, trends,
number of PC programs, and so forth.
Dimensioning in this context means distribution of the available memory to functions that
particularly require memory.
You can redimension at a later stage, but it is time-consuming work. The general rule is to plan
well from the start. Always dimension the spares!
Application
analyses
System
definition
Controller
system
configuration
Dimensioning
Creating
Data entry
(fill in)
Configuration/Application building
Figure 2-22. Controller System Configuration in a Broad Outline
3BSE 002 414R601 Rev B 2-51

From a configuration viewpoint, not all functions to create the infrastructure of the controller
are treated in the same way. Some of them are touched by all activities illustrated in the figure
above. Some are automatically included in the controller system and need only limited data
entry. For an overview, see Table 2-13, which features an outline of controller system
configuration information.
Dimensioning, creating and data entry are described in detail in separate documentation.
For a detailed description of the principles of the controller system configuration work,
the dimensioning and creation of records, and the interactive work using an engineering station,
see the reference manual AMPL Configuration Advant Controller 400 Series.
See Chapter 3, Configuration/Application Building for considerations, the maximum number of
items, and so on.
For data entry details, see the manual Data Base Element, Reference Manual.
Function List with an Outline of Controller System Configuration Information
Table 2-13. Function List with an Outline of Controller System Configuration Information
Data Base Element

Data
Function/ Dimen- Creating Item. design.
(1) Call name entry Comments
occurrence sioning (default name) (2)
(3)
(4)
The controller entity No Autom. (AC410) AC410_1 Demand

(Incl. superv./system status)
Processor Module incl. No Autom. (PM150) PMx No

system SW backup
Additional system SW backup No Autom. (MB510) SSWx No
System clock (external No Autom. (CLOCK CLS1 Demand

synchronization) SYNCH)
Free-programmable Module No CRDB PU535 FMPx Demand
RAM disposition See text

below
LAN, Local Area Network No Autom. CS513 LANx No CI547 is also handled by this
--MasterBus 300 DB element.
--MasterBus 300E
GCOM Yes CRDB CI543 MVIx Demand
S100 I/O boards Yes CRDB Misc. (5) Misc. (5) Demand
ABB MasterFieldbus No CRDB CI570 MFx Demand
S400 I/O units Yes CRDB Misc (5) Misc. (5) Demand
2-52 3BSE 002 414R601 Rev B

Table 2-13. Function List with an Outline of Controller System Configuration Information (Continued)
Data Base Element

Data
Function/ Dimen- Creating Item. design.
(1) Call name entry Comments
occurrence sioning (default name) (2)
(3)
(4)
Advant Fieldbus 100 Yes CRDB CI522A AF100_x Demand
AF 100 Stations: Yes - - - Number of AF 100 Stations

--AC 70 (PLC) CRDB AC70 AC70_x Demand incl. AC 70, AC 110, General
Stations and S800 I/O stations
--AC 110 (PLC) CRDB AC110 AC110_x Demand
must be dimensioned
--General Station CRDB AF100S AF100S_x Demand
--S800 I/O Station (single) CRDB CI810 AF100IOS_x Demand
--S800 I/O Station (red.) CRDB CI820 AF100IOS_x Demand
(5) (5)
S800 I/O modules Yes CRDB Misc. Misc. Demand
Data Set Peripheral Yes CRDB DSP DSP_x Demand Basic cycle time can be
changed via APP command
PROFIBUS-DP: Yes CRDB CI541 PBx Demand

--PROFIBUS Slave CRDB PBS PBSx Demand
--PROFIBUS Slave Descr. CRDB PBSD PBSDx Demand
LONWORKS: Yes CRDB LON LONx Demand When LON is created it

LONWORKS Device Yes CRDB LONDEV LONDEVx Demand automatically creates 2
LONCHAN channel data base
LONWORKS Network Yes CRDB LONNVI LONNVx Demand
elements, specify type CI572
variable of input type
LONWORKS Network Yes CRDB LONNVO LONNVx Demand
variable of output type
LONWORKS Multiple Yes CRDB LONMNVI LONMNVIx Demand
network variable
LONWORKS Event Yes CRDB LONEVTR LONEVTRx Demand
treatment
LONWORKS Multiple No CRDB LONMREF LONMREFx Demand
references
EXCOM No CRDB CI531 RS232_x Demand When config. of CI531 the
disposition of HW module
V.24/RS-232-C No CRDB CI531 RS232_x Demand CI531 channel 1,2 is entered.
(Terminal, Printer) Possible values are:
PRI_01, XCOM_1, XCOM_2,
TERM_1, .....TERM_4
RCOM No CRDB CI532 MVIx Demand Function variant, RCOM or

MVI type, is defined by the
MultiVendor Interface Yes CRDB CI532 or MVIx Demand used hardware module. For
(Standard protocol) MVIMOD (6) example RCOM uses
CI532V01
MVI Free-programmable Yes CRDB CI535 MVIx Demand DB element CI535 for module
communication CI535 and MVIMOD for
module CI538
3BSE 002 414R601 Rev B 2-53

(1) CRDB stands for the engineering tool command CReate Data Base.
(2) No data entry means that default values exist and it is not necessary to enter any data.
User- unique names can be introduced if desirable.
(3) The call name is used in connection to command CRDB.
A parenthesized ( ) call name indicates that the call name cannot be used with the command CRDB.
(4) The item designation (default name) or a user-defined name is used to access an element
with the command MDB, Modify Data Base. The item designation can always be
used independent of whether or not a user-defined name exists.
(5) Miscellaneous refers to different elements for different I/O board, I/O unit or I/O module types.
(6) Depending on protocol.
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.
Dimensioning of the Data Base, DIMDB Command

Process I/O
Number of MFB Units (MasterFieldbus)
(incl. number of CV units for communication with Drives system
and PX units for MasterPiece 51)
Number of REDUNDANT / OBJECT BOARDS
Number of S800 AI MODULES
Number of S800 AO MODULES
Number of S800 DI MODULES
Number of S800 DO MODULES
Number of S800 DP MODULES
Number of AI-BOARDS
Number of AO-BOARDS
Number of DI-BOARDS
Number of DO-BOARDS
Number of AI-SIGNALS
Number of AO-SIGNALS
Number of DI-SIGNALS
Number of DO-SIGNALS
Data Transfer & Communication
Number of DAT
Number of DS
Number of MS
Number of TEXT
Number of TS
Number of DSP
Number of EVENT SETS
Number of MVI MODULES
Number of MVI CHANNELS
Number of MVI NODES
Number of MVI BLOCKS
2-54 3BSE 002 414R601 Rev B

Fieldbuses
Number of AF 100 FIELDBUSES
Number of AF 100 STATIONS
Number of PROFIBUS FIELDBUSES
Number of PROFIBUS SLAVES
Number of PBS DESCRIPTIONS
Number of LON COMMUNICATION MODULES
Number of LON DEVICES
Number of LON NETWORK VARIABLES
Number of LON MULTI NETWORK VARIABLES
Number of LON EVENT TREATMENT
MasterView 320
Number of DISPLAYS
Number of VARIABLES
Data Tables & Trend Data
Number of TTD_LOGS
Number of TTD_VARIABLES
Number of TBL_CLASSES
Number of TABLES
Number of TBL_PARAMETERS
Size of DATA TABLES (kB)
Number of FILE ELEMENTS
Size of FILE DATA (kB)
Functional Units & Group Alarm
Number of SEQ_CTRL
Number of GENOBJ
Number of MMCX
Number of PIDCON
Number of MANSTN
Number of RATIOSTN
Number of GRPALARM
Number of GRPMEMB
Drives
Number of DRISTD
Number of DRIENG
Fire & Gas
Number of GI_BOARDS
Number of FI_BOARDS
Number of GI_SIGNALS
Number of FI_SIGNALS
3BSE 002 414R601 Rev B 2-55

Redimensioning of the Data Base

You can redimension at a later stage.
1. Make a copy of the data base. Use the command DUTDB.
This copy includes the DIMDB information.
2. Load the copy. Use the command LOTDB.
When loading, you can select, among other things, REDIMENSION from a dialog.
Dimensioning of Space for PC Program

Size of PC program tables
Number of PC programs
Number of scan places in interpreter A, B, C, respectively
Size of USER disk application segment area
Redimensioning of Space for PC Program

You can redimension at a later stage.
1. Make a copy of the PC program. Use the command DUTPT.
This copy includes the DIMPC information.
2. Load the copy. Use the command LOTPT.
When loading, you can select, among other things, REDIMENSION from a dialog.
2-56 3BSE 002 414R601 Rev B

2.4.2.5 Configuration/Application Building

Configuration/application building is not part of the installation work described here.
It is regarded as a separate activity and is treated in Chapter 3, Configuration/Application
Building of this manual as well as in separate documentation, for example the reference manual
AMPL Configuration Advant Controller 400 Series.
The configuration/application building ends up in an application program. This program is
divided into a data base part and a PC program part.
Primarily, the application language AMPL is used during program design.
Enter the program manually or load it from a diskette. An engineering station is used.
If an application program is already created, for example in an identical system which is already
tested, a program copy (dump) is loaded from this system.
2.4.2.6 Dumping and Loading

At regular intervals, make a backup copy of the data base content and the PC program.
After dimensioning and populating the data base in working mode CONFIGURATION, dump it
and re-load it with compression to minimize the memory space occupied.
See the list below of available dump and load commands, which are further described in AMPL
Configuration Advant Controller 400 Series, Reference Manual.
For a description of source code handling aimed at making the data base and PC program
transferable between different Advant Controller systems, see the manual Source Code
Handling.
Because of the division of data base and PC program, dump/load commands are directed to the
individual parts and to the total application program. They are used in different situations as
follows.
Table 2-14. Dump and Load Facilities
Description of use Dump command Load command

Backup of application DUAP LOAP
A total RAM backup of data base and PC program. DUmp Application Programs LOad Application Programs
The backup also includes DIMDB, DIMPC information.
Redimensioning and temporary backup of the data base. DUTDB LOTDB

The backup also includes DIMDB information which is DUmp Total Data Base LOad Total Data Base
deleted at redimensioning.
Redimensioning and temporary backup of the PC DUTPT LOTPT

program (object code). DUmp Total Program Table LOad Total Program Table
The backup also includes DIMPC information which is
deleted at redimensioning.
Source code of data base (1) DUDBS TRDBS

DUmp Data Base Source TRanslate Data Base Source
Source code of PC program DUPCS TRPCS

See text below (2) DUmp PC Source TRanslate PC Source
(1) DUTDB/LOTDB is sometimes a faster alternative than source code handling (source code is always possible). The compatibility code
for the data base of the system software decides.
Possible causes of non-compatibility (and need of source code) are: new release, revision, changed mix of optional program modules.
(2) PC program source code is transferable between different Advant Controllers provided that the PC elements exist in the system in
which the dump is to be loaded.
3BSE 002 414R601 Rev B 2-57

Certain events and handling of the controller system result in clearing the RAM (set to zero).
A total RAM backup (DUAP/LOAP) is needed to restore the memory. Or a backup of the
application on flash memory card can be used. The latter feature was introduced by product
release 1.2. Table 2-15 shows the situations which result i clearing the RAM.
NOTE
The listed situations in Table 2-15, besides clearing the RAM, automatically:
1. Boot the system.

2. Load system software from the system program card (backup).
3. Alternatively
a. Set the controller in working mode CONFIGURATION, ready for application
program load, LOAP, from an engineering station.
b. Or, if an optional application program card (backup) is available, load the application
software ending up in the working mode prevailing when the backup was created.
For example working mode OPERATION.
Table 2-15. Situations which Cause Clearing of the RAM
Event Start mode selector position

Power-up CLEAR
Command RECONFIG Any position
Pushing ENTER button on processor module front CLEAR
Fatal error in central units(1) Any position
(1) A remaining fatal error of course will prevent loading and restart
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. Please refer to the reference manual AMPL Configuration Advant Controller 400
Series, for complete information.
1. Power up
Set start mode to CLEAR on processor module
Set power switch on
For indications which verify a successful power-up, see Section 2.4.2.1, Power-up.
2. Working mode CONFIGURATION
Automatically enter the working mode CONFIGURATION at power-up
Then set start mode selector in position AUTO. No ENTER
Processor module indicates P2 (working mode CONFIGURATION).
3. Controller system configuration
2-58 3BSE 002 414R601 Rev B

a. Dimensioning of data base, DIMDB

b. Creating the data base, CRDB
c. Data entry of data base, MDB
d. Dumping and loading (compress) the data base, DUTDB/LOTDB
e. Dimensioning of PC program tables, DIMPC.
4. Configuration/application building
a. Populating the data base, MDB
b. Entering and editing PC program, miscellaneous commands
c. Dumping and loading PC programs, DUTPT/LOTPT.
5. Backup of the entire RAM, DUAP.
6. Disabling working mode CONFIGURATION, DICONFIG.
In addition to those indications obtained at power-up:
– All red LED F (Fault) on S100 I/O board fronts are switched off.
– The processor module changes over and indicates P1 (working mode OPERATION).
The system is now started and ready for operation.
Perform the final stages, which include start of application program execution, successively and
relate to the product verification. One PC program at a time.
WARNING
When the application program is started, the process to be controlled is
influenced.
Significant engineering tool commands to use are:

1. DIsable Build Mode, DIBM PCx
2. DeBLock, DBL
Indications of an operating system with a started application:
• Analog inputs
A/D conversion in progress, LED C flashes (not all board types).
• Analog outputs
Output signals are produced by the executing PC program.
• Digital inputs
The LEDs on I/O board fronts show the process status regardless of whether or not the PC
program is executing.
• Digital outputs
Output signals are produced by the executing PC program.
Indicated by LEDs on I/O board fronts.
3BSE 002 414R601 Rev B 2-59

2.4.2.8 Installation of Battery for Backup of Memory

The battery is mounted inside the cabinet on the right-hand side.
When the controller is started, connect the battery. Disconnectible connectors are found close to
the battery unit.
You know that the battery backup is functioning when you see the following indications:
• On the Backup Power Supply SB171
– by green LED CHARGE.
• On the Processor Module PM150 front
– by green LED BC (backup voltage for RAM connected).
When you plan to disconnect power for a period of time exceeding four hours, disconnect the
battery. This avoids total discharge of the battery.
Use the disconnectible contacts on the battery unit.
2.4.3 Peripheral Equipment

Only the printer is treated below.
For a description of the terminal MasterView 320, see the manual MasterView 320 User’s
Guide.
2.4.3.1 Printer
Power-up
Turn on the power to the printer.
Configuration, Printer
Check that all programmable parameters on the printer are set according to the tables below.
To check the parameters, please refer to the user’s manual of the printer in question.
The basic settings correspond to the settings of the unit when delivered by ABB Automation
Products AB. The language parameter is pre-set for English printout.
Table 2-16. Printer Programmable Parameters
Parameter Basic setting

Font DRAFT
CPI 12 CPI
LPI 6 LPI
Country E-US ASCII
Emulate Epson FX-850
CharSet Extended
CG-Tab Graphic
Sl. Zero Off
Auto-CR Off
2-60 3BSE 002 414R601 Rev B

Section 2.4.3 Peripheral Equipment
Table 2-16. Printer Programmable Parameters (Continued)
Parameter Basic setting

Auto-LF Off
Skip 0.5 Inch
AutoTear ViewTear=Off
Bidir On
Width 13.6 Inch
Formlen 12.0 Inch
PapOpt No
Paper Form Adj. 0/72 inch
Interf. Serial
Serial Baud 9600
Format 8 Bit No 1 Stop
Protocol XON/XOFF
Configuration, Advant Controller 410

With an engineering station, you can implement a printer communication in the Advant
Controller 410 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.
This setting remains valid for as long as the power remains turned on, or until the RECONFIG
command is given.
Verification of the Start

You can obtain a verification of correct hardware configuration with the data base element
PRINT. Status flags subordinated to the attribute ERR give detailed information. See the
description in the DB Element manual.
You can obtain a test printout by running a PC program including the PC elements PRINT and
TEXT to generate a report printout.
Please note that the data base elements CI531 and PRINT are needed to define the printer
communication.
For a detailed description of the PRINT and TEXT PC elements and how to use them, see the
reference manual PC Elements Advant Controller 400 Series, and the manual AMPL
Configuration Advant Controller 400 Series, Reference Manual.
3BSE 002 414R601 Rev B 2-61

2.5 Product Verification

Since the test requirements vary considerably among different installations, the designer is
responsible for determining the function requirements, the limits within which the function
requirements are to apply and other parameters which apply in the installation.
Necessary Outfit
• Universal instrument, for example, digital multimeter.
• Specific documentation enclosed at delivery, drawings, and so on.
In more complex installations, which include closed loop control, some additional test
equipment may be necessary/practical at tuning:
• Recorder with at least two channels
• Access to an operator station facilitating object display trim curves and trend curves.

DANGER
2.5.2 Servicing Tool

Installation of an engineering station, the main servicing tool, is described in Section 2.4.2.3,
Connection of Engineering Station. Detailed information for its use is given in separate
documentation.
2-62 3BSE 002 414R601 Rev B

Section 2.5.3 Commissioning
2.5.3 Commissioning
2.5.3.1 General
For a general description of how to set the controller in operation and start the execution of an
application program, see Section 2.4.2.7, Summary of the Controller Start-up and Verification
of the Start.
Below, you can find general information on some function tests which you can perform to verify
the product. Short notes on adequate facilities provided by the engineering station are also
listed.
For a more detailed description, see the AMPL Configuration Advant Controller 400 Series,
Reference Manual.
2.5.3.2 Procedure
The application program is normally checked, one executing unit at a time. This is done by
deblocking the complete PC program (DIBM command) and successively deblocking the
execution units, one after the other. You can, for example, check that a flow valve functions and
then verify the start sequence for a pump motor, and so on.
After each sub-function is tested, a comprehensive function control is performed to verify that
all execution units function together.
Finally, a full scale check of the complete installation is performed to verify that the program is
in accordance with the plant specification.
2.5.3.3 Modify Permission

Executing units such as control module headers, see Figure 2-23, 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.
“Modify Permission” is activated/deactivated via the engineering unit with the commands EMP
(Enable Modify Permission) and DIMP (Disable Modify Permission). You can obtain a list of
the status of all control modules in a PC program, with respect to “Modify Permission,” with the
command LMP (List Modify Permission).
When each individual control module has been tested and found to be correct, the “Modify
Permission” conditions of the module can be deactivated as an acknowledgment that the module
is verified and to avoid unintentional change of its contents. Blockings can still be set and
operational parameters changed if required.
CONTRM
(C1,C2,C3)
1 ON RUN 5
2 >SINGLE
3 R MODP 6
Modify permission
Figure 2-23. “Modify Permission” in a Control Module
3BSE 002 414R601 Rev B 2-63

2.5.3.4 Blocking and Deblocking of the PC Program

During a test of the application program, you can prevent the control system from affecting the
process in two ways:
• By opening terminal switches on the connection units (or likely locations) to physically
isolate output signals from the process.
• By blocking the updating of the data base with the help of certain commands.
Blocking commands and their use are listed below:
• BL Blocking of individual or all executing units in one or more PC programs.
• BL,DB Blocking of output to data base from individual or all executing units in
one or more PC programs.
• BLRS Blocking and resetting of individual or all executing units in one or more
PC programs.
• DBL Deblocking of individual or all executing units in one or more PC programs.
The blocking of a complete PC program gives the same result as blocking of all individual
executing units in a PC program (the command BL after the conclusion of entry of a PC
program blocks the program). The executing units can therefore be deblocked in succession
during commissioning. In this way, each program function can be verified sequentially and
program error or process error can be corrected before an attempt is made to test run the
complete PC program for the process.
2.5.3.5 List of some Test Facilities provided by the Engineering Station

For a detailed list and detailed descriptions, see the reference manual AMPL Configuration
Advant Controller 400 Series.
Presentation of Values in Data Base and PC Program

You can show a dynamic updating of several data base values on an engineering station display
with the help of the command GETAB.
Use the command MDB to present a data base value.
The following example shows a digital input signal and how it is dynamically updated:
• MDB DI 1.1 (Modify Data Base)
• GVD (Get Values Dynamically)
• Interrupted with <SHIFT> <BREAK>.
Use the command GEPCD to present all values on a single PC element dynamically updated.
The presentation is made in the graphical element symbol.
Further commands to use to read the values allocated to operational parameters, PC variables
and constants are: MV (Modify Value), LV (List Variable).
Changing of Data in the Data Base

You can make changes in the data base with the commands MDB (Modify Data Base) or
MV (Modify Variable).
2-64 3BSE 002 414R601 Rev B

Parameter Change in PC Program

Read and change the values of the operational parameters during program execution with the
command MV (Modify Value).
Change of SCAN Time

Change the scanning time for an input signal with the command MDB through a change of the
corresponding SCANT (SCAN Time) in the data base.
Change of Periodicity and Place in the Cycle Time Table

The periodicity (cycle time) for an execution unit is determined by the call parameter C1.
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 410
A(ms) B(ms) C(ms)

10 50 250
20 100 500
40 200 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.
NOTE
All PC elements within a control module have the same periodicity.
The order in which several executing units with the same periodicity are executed is controlled
by the call parameter C2. If no value is specified for C2, the system places this executing unit in
the first vacant space in the cycle time table which specifies the order of execution.
Use the command MV to change the value of C2 to move an execution unit in the execution
sequence, for example, MV PC1.1:C2.
Change of Execution Sequence for PC Elements

The PC program elements within an executing unit are always executed in the order in which
they are listed in the PC list. To change the order, select the build mode with the help of the
engineering station (command EBM). Use the command DS (Delete Statement) to remove the
element to be moved. You can then insert (IS) the element in another place in the PC list.
The above change can be made during operation by authorized personnel. An alternative to
rebuilding the PC program is to dump the PC program as source code, then edit and reload the
source code. This is effective when there are considerable changes.
3BSE 002 414R601 Rev B 2-65

2.5.3.6 Tuning of Feedback Control Loops

When feedback control functions are used in the Advant Controller system, select the optimum
sampling time for the process concerned and set other feedback control parameters so that the
feedback control becomes stable under varying loading conditions, and so on. This is described
in separate documentation.
2.5.3.7 Use of PC Programming During Operation when Commissioning

You can follow the value of signals by using the engineering station command insert (IS) PC
elements and connect (C) these during operation:
• Insert an SR element to permit the study of fast pulses.
• Insert an SW element and connect several interesting signals to this. Present these signals
dynamically with GEPCD.
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.
• If an executing unit is blocked.
• If the output from an executing unit to the data base is blocked.
• If a PC program is locked.
2.5.3.9 Check of Process Input/Output System
General
As mentioned in the setup instructions for process I/O, it is advantageous to make an integrated
check of process equipment and wiring and the corresponding control function. You make this
check in a circuit-by-circuit procedure. The data base is then used as one checkpoint.
An engineering station reads status/values and simulates control signals to the process objects.
When an operator station is included in the system, it is most effective to maintain the check
from the automatically generated process I/O object displays.
You may need to simulate digital and analog input signals which are normally generated by the
process. Suitable methods to do this follow:
• Digital inputs: Activate the input by connecting a voltage which corresponds to the
nominal value of the input. The “1” and “0” status is simulated by opening and closing the
terminal switches. Activate the input as close to the process transducer as possible to test
the process wiring as far as possible.
Manual operation of transducers, for example, limit switches can also give the required
change for the input signals.
• Analog input signals: Use a signal generator for analog signals.
Use a simple test coupling as a voltage generator. This consists of a potentiometer coupled
over a suitable voltage source which gives ± voltage.
A current source which can give sufficient current, 20 mA, is required for current signals.
Enter analog test signals as close to the ordinary signal generator as possible to test the
process wiring.
2-66 3BSE 002 414R601 Rev B

Digital and analog output signals are obtained by setting the required values in the data base via
the engineering station. This means entry of values from the keyboard for the data base elements
concerned (property VALUE).
The system designer provides test specifications with the limits permitted.
As each channel is tested and approved, you can set a test flag “TESTED” in the data base with
the help of MDB. This is not essential, however, for the program function since you can use
simpler methods such as marking the channels on the connection diagram to register the test
procedure.
Input Signals
Figure 2-24 shows in principle where to check an input signal in an S100 I/O application.
DI boards provide X90 connector and DI channel LEDs.
AI boards provide X90 connector, a test terminal X3 and a common-to-all-channels A/D
conversion indicating LED.
See separate documentation for detailed information.
Engineering station
DB elements
Board
TYPE Signal
ERR
Operator station NAME
VALUE
- Object display ERR
- Trend curve
Process S100 I/O hw interface AC 410 sw interface
Connection
unit
Process Input Data base PC program
object board
X3
X90 AI
DI ch. (A/D)
Figure 2-24. Principal Block Diagram of S100 I/O Input Channel, Test Points
3BSE 002 414R601 Rev B 2-67

• Digital Input Signals

Figure 2-24 shows where you can check a digital input signal in an input channel.
Proceed as follows:
– Use the command MDB (Modify Data Base) to present the data base element.
Use GETAB as an alternative.
– Ensure that the connections of the data base element are filled in correctly for the
signal to be examined. See the data sheet for the data base element.
– Simulate the digital input signal as close to the process transducer as possible or
activate the transducer itself.
– Check that the corresponding yellow LED on the input board concerned illuminates
and that the change is registered by the property VALUE on the display screen in the
engineering station. For MDB, use GVD for dynamic updating of the values on the
display screen.
– Change the input signal to a low level. Check that the yellow LED on the input board
extinguishes and that the property VALUE is changed.
• Analog Input Signals
Figure 2-24 shows where you can check an analog input signal in an input channel.
Proceed as follows to check an analog input channel:
– Check first that all data base connections are filled in correctly for the signals to be
checked, also that solder straps for voltage signals are removed or clipped.
– Simulate the analog input signal as close to the process transducer as possible.
– Use the command MDB to present the element. GVD gives dynamic updating.
Use the command GETAB, which gives dynamic updating, as an alternative.
– Check that the simulated signal is available at the screw terminal of the
corresponding connection and at test terminal X3.
– Check that the value read on the display screen (property VALUE) is the same as the
simulated value set. Check the complete signal range.
For a description of the adjustment of analog input signals, see Chapter 5, Maintenance.
Output Signals
Figure 2-25 shows in principle where you can check an output signal in an S100 I/O application.
DO boards provide X90 connector and DO channel LEDs.
AO boards provide X90 connector.
For detailed information, see separate documentation.
2-68 3BSE 002 414R601 Rev B

Engineering station
DB elements
Board
TYPE Signal
ERR
NAME Operator station
VALUE
ERR - Object display
- Trend curve
AC 410 sw interface S100 I/O hw interface Process
Connection
unit
PC program Data base Output Process
board object
DO ch. X90
Figure 2-25. Principal Block Diagram of S100 I/O Output Channel, Test Points
• Digital Output Signals

Figure 2-25 shows typical digital output channels and where you can test the signals.
Digital output signals in a specific plant are shown in the connection diagrams for the
plant.
Proceed as follows to check digital channels:
– Use the blocking command (BL) to block any PC programs already entered.
– Ensure that the data base connections for the output signals concerned are correct.
– Use the command MDB on the engineering unit to present the element in the data
base, set the VALUE and check that the corresponding output shows this value.
Then measure the value on the screw terminal block of the corresponding connection
unit end and, if practically possible, at the process as well.
– Check that the corresponding yellow LED on the digital output board concerned
illuminates.
When you are checking analog output signals, use a multimeter to test that an output signal is
obtained over the complete signal range.
3BSE 002 414R601 Rev B 2-69

• Analog Output Signals

Figure 2-25 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.
Proceed as follows to check analog channels:
– Use the blocking command (BL) to block any PC programs already entered.
– Ensure that the data base connections for the output signals concerned are correct.
– Use the command MDB on the engineering unit to present the element in the data
base, set the VALUE and check that the corresponding output shows this value.
Then measure the value on the screw terminal block of the corresponding connection
unit end and, if practical, at the process as well.
– When you are checking analog output signals, use a multimeter to test that an output
signal is obtained over the complete signal range.
For a description of adjustment of analog output signals, see Chapter 5, Maintenance.
Readjustment of Analog Output Signals
AO boards are factory adjusted for voltage output signals. If current signal is
desired/jumpered, you must readjust for maximum accuracy. Please follow the instructions
in Section 5.4.12, Channel Adjustment on AO Board.
2.5.3.10 Listing of PC Program and Data Base

When the PC program is entered, you can obtain a printout from the printer connected to the
engineering tool for editing or documentation purposes. Two different types of printout are
available:
• Printout as a graphic diagram with LPCD (List PC Diagram). See Figure 2-26.
• Printout as program list with LPCL (List PC List). Use this to your advantage when you
need rapid listing of a PC program on a printer or screen and when listing on a printer
without graphic mode. See Figure 2-27.
Use the command LDBD (List Data Base Diagram) to print the data base.
All procedures are described in the manual AMPL Configuration AC 400 Series.
2-70 3BSE 002 414R601 Rev B

COMMON IDENTITY: ABB INDUSTRIAL SYSTEMS 1993-02-01/18:04:15
PCPGM (20,1)
D=1 1 ON RUN 5
D=0 2 R
CONTRM (20,2,0)
D=1 1 ON RUN 5
D=0 2 >SINGLE MODP 6
D=0 3 R
OSC-SIN
1-PC1.1:RUN 1 EN O 5 P
D=1.0 2 TC ERR 6 P
D=2.000 3 AMP
.1
PC1
Figure 2-26. Graphic Diagram
ABB INDUSTRIAL SYSTEMS PCD PAGE: 1
IDENTITY NAME TYPE SOURCE UNIT PAGE NOTES
PC1 PCPGM (20,1)

:1 ON IB D=1
:2 R IB D=0
:5 RUN OB
PC1.1 CONTRM (20,2)
:1 ON IB D=1
:2 SINGLE IB D=0
:3 R IB D=0 1 PC1.1.1:1
:5 RUN OB
:6 MODP OB
PC1.1.1 OSC-SIN
:1 EN IB PC1.1:5 1
:2 TC ITR D=1.0
:3 AMP IR D=2.000
:5 O OR =AO1.1 =AO1.1 P
:6 ERR OB =DO1.1 =DO1.1 P
Figure 2-27. Program List
3BSE 002 414R601 Rev B 2-71

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.
• Check that all terminal screws on connection units are properly tightened and that all
grounding is effective.
• Check that all ribbon cable connectors are properly mated.
• Check that all cable bushings are installed properly to avoid cable wear.
• Check that no tools or debris from cable installation remain in the cabinet. Clean the
cabinet.
• Use the command LSS to check the status of the executing units so that no unit remains
blocked unintentionally.
• Make a final listing of the data base and PC programs to obtain correct documentation of
the system, including all tuning parameters.
• Make a copy of the final PC programs and data base using DUAP. You can reload the
dump using the command LOAP. For a description of the commands, see the manual
AMPL Configuration Advant Controller 400 Series.
2.6 Implementation of Functions in Systems Already Operating

Enlargement of the system with additional functions differs from a “from-scratch installation.”
The main reason they differ is that the system is or has been in operation, which means that
on-line/off-line aspects are important. The influence on the application program is also
important. From these viewpoints, among other things, the most common additional functions
are treated below.
Necessary Outfit
The following kit is normally a minimum requirement:
• Universal instrument, for example, digital multimeter.
• Specific documentation enclosed at delivery.
In more complex installations, which include closed loop control, some additional test
equipment may be necessary/practical at tuning:
• Recorder with at least two channels.
• Access to an operator station facilitating object display trim curves and trend curves.
2-72 3BSE 002 414R601 Rev B

Section 2.6.1 Servicing Tool
2.6.1 Servicing Tool

See 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.

DANGER
2.6.3 General Guidelines

Naturally, all design considerations given in Section 3.1, Design Considerations are also
relevant to installation in a system already in operation. Among other things, you may want to
reflect upon:
• Hardware, types and location.
• Restrictions in function combinations.
• Software (program modules) needed to produce the total application you desire, for
example, MasterBus 300, aimed at central operator station communication, which
requires, in addition to the communication equipment, the central operator station software
option.
• Interface to application program to be used.
• CPU load.
• Power supply requirement.
• Heat dissipation.
In Table 2-18, you can find information about whether or not a function can be implemented
on-line.
On-Line/Off-Line
On-line means that all work can be carried out while the controller is in full operation.
Because of the risk of making manual mistakes in such handling, and the possible severe
consequences to the process controlled, it is recommended that you use this on-line facility
restrictively.
The best method of working:
The system is stopped and the voltage supply is disconnected when a new function is
installed.
3BSE 002 414R601 Rev B 2-73

Disconnection of the mains supply may have impact on dynamic information stored in the
application program. For example counter/register content, integrator content and so on, will be
lost if not secured by special considerations in the application program design. However this is
general design considerations. The controller should manage “normal” mains supply
interruptions.
Data Base Dimensioning

Table 2-18 notes the requirement of data base dimensioning.
Sometimes an on-line implementation presupposes that the data base is dimensioned for the
additional function in advance, that is, at the original setup and start-up of the system, it is
recommended that you plan for future enlargement. This is especially true for I/O boards, whose
numbers are commonly enlarged during the commissioning.
When planning for future additional functions, for example, communication, also reflect upon
the need of application functions attached, and the corresponding need for spares in the data
base, for example, DAT, Data Set, MVI Set. These application requirements are not included in
the statement of Yes or No concerning dimensioning of data base in Table 2-18.
Do not overstress reserving spares. You can always redimension the data base. You must do it,
however, off-line.
See below for a brief description of how to perform the dimensioning/redimensioning (look
under the heading Dump of Application Program).
See the manual AMPL Configuration AC 400 Series for detailed instructions.
Dump of Application Program

If dimensioning of the data base is prescribed and no spare is left or if you need to implement
new system software, the following guidelines apply.
Before installing a new additional function, dump the data base and PC program.
Use the dump command DUTDB for the data base.
Use the dump command DUTPT for the PC program.
When loading (LOTDB and LOTPT, respectively), you can select, among other things,
REDIMENSIONING.
When the new function includes software (on a new program card), then the data base is
dumped as object code. Use the command DUTDB. The PC program is dumped as source code.
Use the command DUPCS.
You need only dump the data base as source code in one case - when the compatibility code for
the data base is changed. This is normally performed with new releases and not with revisions.
2-74 3BSE 002 414R601 Rev B

Section 2.6.4 Additional I/O Boards
Summary of Aspects
Table 2-18. Implementation of Functions in Systems Already Operating
Enlargement/Addition Dimensioning
Function/Equipment Comments
On-Line Off-Line of Data Base
System software X Yes
I/O module (S100, S800 I/O) X Yes
I/O unit (S400 I/O) X Yes
Redundant regulator 5 V X No
MasterBus 300 (all types) X No
GCOM X No
MasterFieldbus X (Yes) (1)
Advant Fieldbus X Yes
PROFIBUS-DP X Yes
LONWORKS Network X Yes
EXCOM X No
Printer X No
MV 320 X Yes
RCOM X No
MVI X No
Free-programmable X No
Communication
(1) Braked (Yes) means that the requirement for dimensioning depends on the planned use of the equipment.
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.
For a detailed description of the connection and use of an engineering station and different
dump/load commands, see separate documentation, AMPL Configuration Advant
Controller 400 Series.
Preparation and Setup

I/O boards are normally grouped by type, so place the new boards with boards of the same type,
if possible. This also applies to the connection unit. Note, however, that you must consider the
power requirement and heat dissipation.
3BSE 002 414R601 Rev B 2-75

Route cables in accordance with the guidelines set forth in Section 2.2.6, Cable Routing in
Cabinets.
Mount I/O functions in the following way:
1. Make a plan for the work to be done.
– Read the General Guidelines above and apply the information.
– Check for available spares in the data base. Use the commands DIMDB (check is
possible, redimensioning is not possible on-line) or LDBD.
– Determine I/O address to be used. Use the documentation of the data base or the
delivery documentation, if applicable.
2. If no spares are available, make a dump of the controller system configuration and the
application program. Engineering station dump command DUTDB and DUTPT.
3. Switch off the supply voltage to the control system (recommendation).
NOTE
Remember that the control function of the system ceases and the process being
controlled is affected.
4. Screw the connection unit to the mounting bar at the rear wall of the cabinet. Ensure that
the screws make contact with the tinned surface of the earth plane of the circuit board for
effective grounding.
It is also of the utmost importance that you tighten the screws properly to give a reliable
earth connection. See Figure 2-28.
5. Screw the board connector with connection cable to the desired slot in the subrack and
connect to the connection unit in the opposite end. See illustration in Figure 2-29.
6. Ensure that there is no tension in the wiring, especially if it may be necessary to swing the
hinged subframe for the I/O subrack.
7. Set the I/O address and other functional jumpering on the board.
Addressing and functional measures like jumpering are described in the reference manual
S100 I/O Hardware.
8. Provide access to the desired position in the subrack by loosen the locking bar in front of
the boards.
9. Insert the I/O board carefully in the subrack without reaching the rear plane contacts.
Ensure that the board slides in the guides in the subrack.
CAUTION
At insertion, use the grounded wristband.
10. Push in the new board quickly and decisively
11. Ensure that the board contacts mate properly with the contacts in the rear plane. Screw the
locking bar in place.
12. Connect the process cables to the connection unit. Reflect upon all installation rules
regarding cable routing and grounding.
2-76 3BSE 002 414R601 Rev B

Section 2.6.4 Additional I/O Boards
As an alternative, first make a functional verification when the process is not connected.
Then connect.
Eventual
grounding Grounding
of signal Thread-cutting
M6x10 screw
Cable duct
Connection unit
Cable
Grounding Mounting rail
Self-tapping ST 3.5x9.5
screw (B6x9.5)
Figure 2-28. Grounding of Connection Units
Mounting bar for

connection units
Connection to the process
Connection cable
Backplane for parallel
communication bus
Plug-in units
Figure 2-29. I/O Subrack
3BSE 002 414R601 Rev B 2-77

Start-up
The start-up is carried out in different ways, depending on the main working mode, on-line or
off-line.
If a board is added on-line, the different I/O channels are put into operation as the adequate data
base is created and the application functions are built and started (deblocked).
You can, of course, switch off the power supply during the installation work.
Then switch on the power supply, keeping the start mode selector on the processor module in
the AUTO position. The system is restarted and in full operation apart from the additional
board. The different I/O channels are put into operation as the adequate data base is created and
the application functions are built and started (deblocked).
If the board is added off-line because REDIMENSION of the data base was necessary (no
spares available), the following start-up sequence is applicable.
A data base dump DUTDB and a PC program dump DUTPT are presupposed.
1. Follow the general instructions in Section 2.6.6, Power-up Ahead of Program Loading.
2. Perform the controller system configuration:
a. Load the data base dump, LOTDB and REDIMENSION.
b. Create the additional data base, DIMDB.
c. Perform data entry of additional data base, MDB.
d. Dump and load (compress) the data base, DUTDB/LOTDB.
e. Load the PC program dump, LOTPT, and REDIMENSION PC program tables,
if necessary.
3. Configuration/application building:
a. Populate the additional data base, MDB.
b. Enter and edit PC program, if relevant.
c. Dump and load PC programs, DUTPT/LOTPT.
4. Back up the entire RAM, DUAP.
5. Disable working mode CONFIGURATION, DICONFIG.
6. The processor module changes over and indicates P1 (working mode OPERATION).
Perform the final stages, which include start of executing application programs, successively,
especially those application programs which are affected by the additional I/O board. Do one
PC program at a time.
WARNING
When the application program is started, the process to be controlled is
influenced.
2-78 3BSE 002 414R601 Rev B

Section 2.6.5 Enlargement of the System Software
The significant engineering tool commands you use are:

2. DeBLock, DBL.
Verification
Make functional tests, including process functions, applicable.
2.6.5 Enlargement of the System Software

Below you can find instructions on how to change a program card with the system software to a
variant with another assembly of program modules, that is another functional assembly.
Revision of system software is dealt with in the same way.
An exchange procedure is assumed. After reception of a new program card, the used one is
returned to the sender.
For a detailed description of the connection and use of an engineering station and different
dump/load commands, see separate documentation, AMPL Configuration Advant
Preparation and Setup

1. The new SW is ordered.
A new program card is delivered, including the desired assembly of program modules.
2. Enclosed at delivery, you will find a release identification with a compatibility code.
(See Section 1.7.1.1, Version Designation.) The compatibility code determines whether
you must use data base source code to re-create the application with new system software
or if other alternatives exist.
3. Check the system software compatibility code in the running system.
This is visible on the engineering station display screen when you log in on the target
system, or it is displayed with the help of the command SHTARG.
4. 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).
– If there is a change in the system software compatibility code, make a source code
dump (DUDBS).
Source code is always an option, but it is more time-consuming.
5. Shut down the controller (and thereby the entire process control) by switching the power
supply off. Use the circuit breaker S1 on the power switch unit(s) for mains A and
mains B. Do not disconnect mains C.
6. Extract the program card on the Processor Module PM150. Use the release push button.
3BSE 002 414R601 Rev B 2-79

CAUTION
Do not forget the general rule: Reflect on the danger of ESD. Use the grounded
wristband.
7. Insert the new program card.
CAUTION
At insertion, use the grounded wristband.
Start-up
Suitable data base and PC program dumps, per point 4 in the setup instructions above,
are presupposed.
The following instructions do not include any utilization of the new software functionality,
but only aim at restoring the “old” application. Enlargement of the application may require
redimensioning of the data base and the PC program tables as well. For relevant information on
these topics, look elsewhere in this manual or see separate documentation.
1. Follow the general instructions given in Section 2.6.6, Power-up Ahead of Program
Loading.
2. Perform the controller system configuration:
a. Load the data base dump, LOTDB or TRDBS, as applicable.
3. Perform configuration/application building:
a. Load the PC program dump, TRPCS.
4. Back up the entire RAM, DUAP.
5. Disable working mode CONFIGURATION, DICONFIG.
6. The processor module changes over and indicates P1 (working mode 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.
Significant engineering tool commands to use are:

2. DeBLock, DBL.
Verification
Make functional tests, including process functions, applicable.
2-80 3BSE 002 414R601 Rev B

Section 2.6.6 Power-up Ahead of Program Loading
2.6.6 Power-up Ahead of Program Loading

1. Set the mode selector on Processor Module PM150 in CLEAR position.
2. Switch on the circuit breaker S1 on the power switch unit(s) in any order.
(If this circuit breaker has been used to switch off the power supply to the system.)
Several power switch and distribution units can exist in the controller cabinet or in
adjacent I/O cabinets.
3. Check for the following positive indications of a successful power-up:
– Distribution Unit SX554 green LED LIVE (24 V)
– Regulator SR170 (redundancy applied) green LED LIVE
(Regulator SR 122 has no indications)
– Battery Charger SB171 green LED CHARGE
– Processor module PM150 green LED RUN
display ind. P2
(Indicating working mode CONFIGURATION)
See Figure 2-21.
There are also some negative indications, for example:
– S100 I/O boards red LED F (Fault)
(Indicating that the boards are not implemented) -
4. If a LAN communication module CS513 or CI547 exists, it gives the following
indications:
– Communication module CS513 or CI547 green LED RUN
ylw LED TX/LAN (flash)
ylw LED RX (flash)
(Indicating a successful automatic configuration of the LAN communication.)
5. The target system is now ready for configuration or program load by connecting the
engineering station directly to the processor module. Configuration is also possible via the
network if applicable and desirable.
6. Finally, set the mode selector on Processor Module PM150 in AUTO position.
NOTE
Do not push the ENTER button!
The controller remains in working mode CONFIGURATION.
If correct indications fail to appear, trace the fault in accordance with instructions in Section 5.4,
Fault Finding and User Repair.
3BSE 002 414R601 Rev B 2-81

2-82 3BSE 002 414R601 Rev B

Section 3.1 Design Considerations
Chapter 3 Configuration/Application Building
3.1 Design Considerations

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.
• Appropriate Hardware and Software
What is necessary to achieve a function.
• Interface to Application Program
• Guidelines
Typical information:
– Location of hardware
– Recommendations
– Limitations.
For information on the possible number of instances, please see Section 3.2, Technical
Data Including Capacity & Performance.
3.1.1 Product Structure

The product structure deals primarily with general functional modularization. In that context,
questions regarding number of supported functions, possible combinations of functions, and so
on, are relevant. For the answers to such questions, see Section 3.2, Technical Data Including
Capacity & Performance.
Regarding the realization of functions, please note that the hardware structure and the software
structure of the product differ. A functional option may require extra hardware, but the software
is included in the basic program module. Or an optional program module may support several
functional options (each with a dedicated hardware).
Appropriate Hardware and Software

Most functions and equipment described as General System Utilities are included in the basic
unit of a controller (smallest unit to be ordered) loaded with the basic system program. You can
enlarge this platform further with alternatives and options.
3BSE 002 414R601 Rev B 3-1

3.1.2.1 System Clock

No extra hardware or software is needed.
To achieve external synchronization, the “minute pulse” is connected to the Backup Power
Supply SB171, see Figure 3-1.
Synchronization input electrical data is given in Section 3.2.1.3, System Clock.
SB171
SYNC+
X2:3
SYNC-
X2:4
Configuration: DB element Clock Sync
Figure 3-1. External Synchronization of System Clock
3.1.2.2 Run/Alarm Relay

The Backup Power Supply SB171 is used according to Figure 3-2.
Contact data: see the module description in Appendix A, Hardware Modules.
SB171
RUN-COM
External X2:6
equipment
RUN-NO
X2:5 RUN (PM150)
“normal closed”
Figure 3-2. Run/Alarm Relay Connection
3-2 3BSE 002 414R601 Rev B

3.1.2.3 Additional Supervisory Inputs

The Backup Power Supply SB171 is used according to Figure 3-3.
Electrical data: see the module description in Appendix A, Hardware Modules.
SB171 System status

display in
F1+ operator station
Free disposition X2:1
within cabinets F1- F1
X2:2
Configuration: DB element AC410
Figure 3-3. Connection of Additional Supervisory Inputs
3.1.2.4 Backup of Application Program
Table 3-1. Backup of Application Program, Hardware and Software
Program
Function Submodule Peripheral Comments
module
Backup of application MB510 QC01-BAS11 A PCMCIA card
program (Option) of suitable
memory size
must also be
ordered
Guidelines
• No restrictions in location of submodule in controller slot 1-4.
• Advant Station 130 Engineering Station and AdvaBuild On-line Builder supports the
preparation of flash cards (PCMCIA) with application dumps.
• AdvaBuild On-line Builder User’s Guide describes the work procedures in detail.
• You can find an overview regarding work procedures in Section 5.6.2, Backup of
Application.
3BSE 002 414R601 Rev B 3-3

3.1.3 Free-Programmable Module
Table 3-2. Free-Programmable Module, Hardware and Software
Program
Function Submodule Peripheral Comments
module
Free-Programmable Module PU535 QC01-BAS11
(Basic)
Interface to Application Program

You use an HP 9000/700 workstation to write, download and test application programs.
The PU535 communicates with the application program via the following PC elements:
FPM-COM, FPM-I, FPM-IA, FPM-O and FPM-OA.
Guidelines
• PU535 can be located in any of the submodule slots in the Processor Module PM150.
3.1.4 Power Supply

Appropriate Hardware
Alternative power supply systems are available. When you order, you can select a suitable
alternative. Do not be concerned with the number of included parts, that is, normally you do not
have to deal with current consumption calculations.
There are, however, occasions with special requirements, special designs, and so on, when
detailed information regarding current consumption is valuable. Please find a description under
the heading Guidelines, below.
Guidelines
• For a summary of the main requirements of the plant supply from a planning viewpoint,
see Section 2.1, Site Planning Environment.
• Auxiliary equipment in the controlled system is normally powered separately from the
control system power supply.
• Heavy current on/off loads are always powered separately.
• An exception to the second point above is analog outputs, for example 0-10 V, 4-20 mA,
which are powered by the system power supply. Please note, galvanically isolated analog
outputs are powered separately.
• You can use the system power supply for transducers provided that:
– the need for current is small
– there is idle capacity in the available power supply units (see Current
Consumption)
– the transducer is grounded directly in the control system chassis.
3-4 3BSE 002 414R601 Rev B

Current Consumption
As a rule, an SA168 (25 A d.c.) supply unit is sufficient for supply of a controller and I/O (one
subrack). Please note that the supply unit types given are for 230 V a.c. mains supply.
Corresponding types for 120 V a.c. mains supply are available.
The current consumption with 24 V is obtained in the following way:
I tot = I 24V + 0.37 × I 5V
where I24V = current consumption 24 V, obtained from Table E-1...E-3 in

Appendix E, Current Consumption and Heat Dissipation
I5V = current consumption 5 V, obtained from Table E-1.E-3 in
Appendix E, Current Consumption and Heat Dissipation
0.37= conversion factor
This current is used as output current for analog outputs in addition to supplying the internal
electronics.
See Table E-1...E-3 in Appendix E, Current Consumption and Heat Dissipation for information
about the current consumption of the available units in Advant Controller 410. These tables hold
typical data relevant for the actual type of calculation. It also holds power dissipation data to be
used in calculating the heat generated in a cabinet. You can use the tables as a form when you
make your own calculation.
The total static and dynamic loads may under no circumstances exceed 100% of the capacity of
the supply unit. As all current consumption information is typical and not an “absolute
maximum,” it is recommended that you not load the supply unit beyond 90% of its capacity,
including all static and dynamic loads.
When calculating the current supplied to SA162/168 units, use 0.85 as the efficiency factor of
the units.
Fusing in Distribution Board
The system is protected with adequate internal fusing. In addition to fusing distributed to
different apparatus, there are common miniature circuit breakers in the power switch and
distribution units in the cabinets (see the terminal diagram form for the actual power supply
system).
The superior distribution board fusing protects the equipment with respect to:
• Internal fusing in the Advant Controller
• Rated current of connected equipment
• In-rush current at power switch-on
• Need to protect the power supply cables to the equipment installed.
For a guide to dimensioning the fusing, see below.
When necessary, you can make a more accurate current consumption calculation to obtain exact
data for fusing. This calculation should focus on the actual number and type of circuit boards in
the different subracks.
3BSE 002 414R601 Rev B 3-5

a.c. Network A/B
Table 3-3. Distribution Board Fusing, a.c.
Distribution board fusing

(Recommended)
No. of power supply units (SA16X)
connected to the same line 230 V a.c. 120 V a.c.
Fusable Fusable
MCB MCB
link link
1 16 A K16A 20 A K25A
2 16 A K16A 20 A K25A
3 16 A K25A 25 A K32A
4 20 A K32A 35 A K50A
The in-rush current at power switch-on must be considered at the fuse dimensioning.
Consequently, you must include redundant power supply units (connected to the same line) in
the calculation of number of units. Normally, redundant power supply units are connected to
separate lines.
a.c. Network C
To reflect the in-rush current and the current rating for the applied power switch and distribution
unit (SV54x), the distribution board fusing should be in the range 10 - 20 A.
d.c. Network A/B
Considering distribution board fusing at d.c. supply, an almost “worst case” view is, out of
necessity, taken. See Table 3-4 below.
The fuse dimensioning current in the table is settled with respect to:
• lowest supply voltage (19 V/38 V)
• efficiency factor of power supply unit SD150 (ca 0.7)
• margin (1.25 x calculated load current).
The minimum fuse value is determined by the miniature circuit breakers in the actual power
switch and distribution units.
At 24 V d.c., the minimum value is normally 50 A. At 48 V d.c., the minimum value is 25 A.
.
Table 3-4. Distribution Board Fusing, d.c.
Fuse dimensioning current)

Item (Recommended)
24 V d.c. 48 V d.c.
I/O subrack with controller 18 A 9A
(1) (1)
Field equipment
(1) If a power supply unit for field equipment, type DSSA 150, is included, please use a formula to
calculate the Fuse Dimensioning Current (FDC).
3-6 3BSE 002 414R601 Rev B

Fuse Dimensioning Current (FDC)

General:
FDC = Load effect ⋅ 1/Efficiency factor ⋅ 1/Lowest supply voltage ⋅ Margin
At 24 V d.c mains supply:
FDC = Load effect ⋅ 1/0.7 ⋅ 1/19 ⋅ 1.25
At 48 V d.c. mains supply:
FDC = Load effect ⋅ 1/0.7 ⋅ 1/38 ⋅ 1.25
In addition, these formulas are also applicable when a detailed current consumption (and thus
the load effect) for a subrack is available and when it should be transformed into fuse
dimensioning current. The figures in Table 3-4 are almost “worst case.”
The in-rush current at redundant power supply units DSSA 150 connected to the same line is
normally no problem and, consequently, you should not consider it when dimensioning the
distribution board fusing. In continuous operation, they will share the load.
A more practical installation of redundancy uses duplicated line voltages. Then identical fusing
according to the above table and rules is realized.
Some application examples for the d.c. mains supply are given in Figure 3-4.
a) 24 V/48 V Advant Controller 410

Distribution board
Power switch and
distribution unit Power supply I/O subrack with
50A/25 A (min. value) controller
50/25A d.c
50/25A d.c
b ) 24 V/48 V
Distribution board
Power switch and I/O subrack with
distribution unit Power supply controller
50A/25 A (min. value)
50/25A d.c
50/25A d.c
Power supply
d.c Field
d.c equipment,
e.g., load effect 240 W
Figure 3-4. Examples of Distribution Board Fusing, d.c.
3BSE 002 414R601 Rev B 3-7

Uninterrupted Power Supply, UPS

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 are backed up by a battery package.
To prevent shut down, you can feed the controller by a UPS.
In addition, make the actual load (VA, W) considerations with respect to information given in
Table 3-5 and Table 3-6 when a UPS is dimensioned. First half period peak values given are
close approximations at 0.2 ohm net impedance, 230 V, 50 Hz. Corresponding figures at
0.1 ohm net impedance, 115 V, 60 Hz are obtained by multiplying with a factor 1.5.
Table 3-5. Requirement on UPS from Voltage Supply Unit SA162
Data Value
First half period peak value at switching on 60 - 80 A
cos ϕ >0.7
Crest factor (peak current / RMS current) <2.6
Table 3-6. Requirement on UPS from Voltage Supply Unit SA168
Value
Data Number of units
1 2 4
First half period peak value at switching on 25 A typical 45 A typ. 80 A typ.
120 A worst case 160 A wc 200 A wc
cos ϕ >0.7
Crest factor (peak current / RMS current) <2.0

No extra software is needed, the basic system QC01-BAS11 is sufficient.
No extra hardware is needed besides the desired I/O board/unit if:
– Spare slot in the I/O subrack is available (S100 I/O)
– MasterFieldbus communication is available (S400 I/O)
– Advant Fieldbus 100 and an S800 I/O station is available (S800 I/O).
Supported I/O boards (S100 I/O), I/O units (S400 I/O) and I/O modules (S800 I/O) are listed in
Section 1.7, Product Overview. Besides the board/unit type designation, you can also find
information about suitable connection units and internal cables in that section. Further
guidelines are given below.
3-8 3BSE 002 414R601 Rev B


Each board/unit/module is normally represented by a data base element. The same applies to
the individual channels of the board/unit/module, For a digital input board in the S100 I/O,
there is a superior DI board element and 32 Digital Input (channel) elements.
For an S400 I/O unit or S800 I/O module, there is a corresponding superior element defining the
unit (AX unit, DX unit) or module. Comparing the different I/O system S100 I/O, S400 I/O and
S800 I/O the individual channel elements are almost identical.
The board elements are created by the user/configurer. As a result, the relevant individual
channel elements appear automatically.
Some board types listed below have one or several PC elements as the interface to the
application program.
Pulse Counter and Frequency Measurement Module DP820:
Data Base Element DP820 is used to configure the module.
The following PC elements are used for communication with the module:
– DP820-I Read values from one channel
– DP820-O Issues commands for one channel and Initializes the DP820
module.
Positioning Board DSDP 140A.
The following PC element are used for communication with the board:
– Pos -A Positioning - Analog control
– Pos -L Positioning - Length
– Pos -O Positioning - On/off.
Pulse Counter and Frequency Measurement Board DSDP 150:
Three different PC elements, COUNT-DP, FREQ-SP, and FREQ-MP, are used for varying
applications together with the board DSDP 150.
Pulse Counting and Frequency Measuring Board DSDP 170:
The following PC elements are used for communication with the board.
– PCU-COM Starts and supervises DSDP 170
– PCU-I Reads values from channels
– PCU-O Sets parameters and issues commands
– PCU-SS Gathers data from several channels simultaneously for up to
five boards.
Weighing boards DSXW 110 and DSXW 111:
The following PC elements are used for communication with the boards.
– SCALE Provides the logical interfacing between PC programs and the local
weighing function on the weighing board
– SCALEDOS Provides the logical interfacing between PC programs and the local
dosing function on the weighing board.
3BSE 002 414R601 Rev B 3-9

With the given DB element, PC element and board type as a reference, you can find functional
and hardware descriptions in:
• Data Base Elements Advant Controller 400 Series, Reference Manual
• PC Elements Advant Controller 400 Series, Reference Manual
• S100 I/O Hardware, Reference Manual.
Guidelines
The following sections, Section 3.1.5.1, S100 I/O System and Section 3.1.5.2, S400 I/O System,
guide you in selecting suitable I/O for an application and some design rules.
By way of introduction, the question of centralized I/O or distributed I/O is discussed.
A combination of centralized I/O and distributed I/O can often be an appropriate solution.
Centralized I/O
The traditional method of building control equipment with a central assembly of all electronics
in the control or equipment room is still the most common. There are several reasons for this:
• Not all processes are suitable for distribution of I/O functions. In some cases, safety or
environmental requirements with respect to equipment and maintenance personnel may
make a process unsuitable.
• The geographical spread of the process is often limited.
• It may be necessary to supplement a central operator’s function (including a display
screen) with a conventional panel function independent of the control system.
For example, a panel instrument in a current loop showing a process measured value
which is to be placed in the central control room.
• The control system interacts closely with central switch gear for control of the motor
supply.
Distributed I/O
Cables and wiring represent a large part of the costs of a control system. It is, therefore,
an obvious advantage if a communication bus can transport a large number of signals between
an Advant Controller 410 and a distributed I/O unit and have separate signal leads only between
the I/O unit and the process. The wider the process is dispersed geographically, the more
profitable distributed I/O becomes.
The option to supplement the distributed I/O function with independent small controllers for
fast logic control makes this type of system configuration even more attractive economically.
The control in the distributed controller can, in addition, be integrated with the Advant OCS.
In connection to a revamp, you can locate distributed I/O units in an existing marshalling area as
interface between an old installation and a new control system.
3-10 3BSE 002 414R601 Rev B

3.1.5.1 S100 I/O System
Guidelines - General
There are certain restrictions in number of I/O subracks, number of I/O boards and number of
signals of different categories. Please see Section 3.2, Technical Data Including Capacity &
Performance.
There are no restrictions on location and mixing of boards of different categories in an I/O
subrack. There are, however, some production rules to facilitate ordering and rapid delivery.
See Section 2.1.4, Standard Layout and Disposition of Cabinets.
When you design a control system, it is desirable to leave some spare capacity. You can add new
I/O boards on-line. It is practical to have approximately 10% to 20% of the channels as spares.
The same recommendation is valid for spare space in subracks.
You can add new I/O boards on-line provided there are spare items in the data base. Reflect the
need when you make the data base dimensioning.
Guidelines - Analog Inputs

General
With current signals and series coupling of loads, the total resistance may not exceed the
resistance through which the sensor output can be driven.
The referred type designations below are valid to circuit board, connection unit and internal
cable, respectively.
DSAI 130
DSTA 131, DSTK 221L3
DSAI 130A
Differential inputs for applications with considerable accuracy requirement. Common Mode
Voltage up to 100 V (50 V DSAI 130A) is acceptable. These are used when it is necessary to
ground measurement circuits at different places in the system. This means you can use
transducers which require grounding of the signal zero. Fusing occurs in groups at six fuses
which can be used for an optional number of channels.
DSAI 130
DSTA133, DSTK 221L3
DSAI 130A
16 differential wit individually power limit transducer power supply for applications with
considerable accuracy requirements. Common Mode Voltage up to 100V (50V DSAI 130A) is
acceptable.
DSAI 133
2x DSTA 002A, DSTK 222L3
DSAI 133A
2x DSTA 002B, DSTK 222L3
3BSE 002 414R601 Rev B 3-11

32 single ended and unipolar current inputs, which means that the transducers or their power
supply can be grounded only within a geographically limited area, where the ground potential is
the same as the system ground.
NOTE
There are two connection units due to the number of input channels.
In a redundant configuration two DSAI 133 can be connected to the same connection units.
The redundant inputs are handled by the application programmer in the same way as the other
analog inputs.
DSAI 146
DSTA 145, DSTK 229SL3
A design for three-wire connected Pt 100 transducers, which compensates for the length of lead,
provided that the lead resistance is the same for the cable conductors.
A conductor break in a transducer does not affect other measurement channels.
DSAI 155A
DSTA 156, DSTK 225SL3
DSAI 155A
DSTA 156B, DSTK 225SL3
Used for grounded and non-grounded thermo elements. Earth channels to which transducers
are not connected.
DSTA 155, DSTA 155P
Placed out in the process to minimize the length of expensive compensation cable from
thermoelements. The unit measures the temperature at the cold junction. Locate it at a place
with small temperature variations and, naturally, at a place conveniently located with respect to
all of the transducers connected to the board concerned.
DSTA 155P has pluggable screw terminals.
Guidelines - Combined Analog Inputs and Outputs

DSAX 110
DSTA 001A, DSTK 223L3
DSAX 110A
DSTA 001B, DSTK 223L3
Eight single ended, unipolar current inputs and eight supervised current outputs, which means
that transducers or their power supply can be grounded only within a geographically limited
area, where the ground potential is the same as the system ground.
In a redundant configuration two DSAX 110 can be connected to the same connection unit.
The redundant inputs and outputs are handled by the application programmer in the same way
as the other analog inputs and outputs.
Guidelines - Analog Outputs

DSAO 110
3-12 3BSE 002 414R601 Rev B

Used when considerable accuracy and galvanic isolation between control system and load,
channel by channel, are required. The load resistance may be a maximum of 500 Ω with 20 mA
and 1000 Ω with 10 mA.
DSAO 120
Used when considerable accuracy is required. You can ground the load provided that the
potential difference between the ground of the load and the ground in the controller is low.
The equivalent resistance caused by the ground voltage drop and the load resistance together is
not to exceed 500 Ω with a current signal.
DSAO 120A
Used when considerable accurancy and galvanic isolation between control system and load,
channel by channel, are required. The load resistance may be a maximum of 600 Ω for current
and minimum 1000 Ω for voltage output.
DSAO 130
Used with moderate demands for accuracy (inaccuracy 0.4%). Do not ground the load. The load
resistance may be a maximum of 1 kΩ with 20 mA and 2 kΩ with 10 mA, @ U24 ≥ 25 V.
DSAO 130A
Used when considerable accurancy is required. You can ground the load provided that the
potential difference between the ground of the load and the ground in the controller is low.
The equivalent resistance caused by the ground voltage drop and the load resistance together is
not to exceed 850Ω with a current signal.
DSTY 101
With DSTY 101 (insulation amplifier), you can obtain insulation at individual input and output
channels. The insulation is obtained between primary and secondary sides and to the supply.
Guidelines - Digital Inputs

You can choose between scanned or interrupt-controlled inputs when you select the digital input
board. The different methods of reading inputs are as follows:
• Scanned inputs
The software scans the digital input boards and updates the data base in
the Advant Controller 410 at regular intervals. This causes the load in the controller to
remain constant, irrespective of the frequency of change at the inputs.
• Interrupt-controlled inputs
The data base in Advant Controller 410 is only updated when the values at the inputs are
changed. This gives a more exact time-tagging with event handling of the inputs. Interrupt-
controlled inputs also mean a lower load with low to moderate frequency of change.
DSDI 110A
DSTD 150A / DSTD 190, DSTK 221L3
DSDI 110AV1
DSTD 150A/DSTD 190V1
DSTK221L3
3BSE 002 414R601 Rev B 3-13

Scanned or interrupt-controlled 24 V d.c. inputs. You can configure the inputs for pulse
catching, that is, with filter times of 100 ms at switch-on and 2 s at switch-off. This function is
especially well suited for setting keys (push buttons).
In the connection unit, the current supply is divided into two groups of 16 channels each.
Each group has a common 0 V. This does not prevent external voltage supply and fusing for
smaller groups of channels but naturally requires that the 0 V sides can be connected. The two
groups are galvanically isolated from the internal electronics.
DSDI 110A
DSTK 226L3
DSDI 110AV1
DSTK 226L3
32 scanned or interrupt-controlled digital inputs. You can configure the inputs for pulse
catching, that is, with filter times of 100 ms at switch-on and 2 s at switch-off. This function is
especially well suited for setting keys (push buttons). You can connect up to four of the
connection units listed below to this board and cable. Division between the different connection
units is a free choice. The properties of the inputs are decided by the selected connection units.
Each connection unit contains eight inputs.
DSTD 195 (replacing DSTD W110)
A connection unit with eight inputs for 24 V d.c. All channels are galvanically isolated.
DSTD 196P
A connection unit with eight inputs for 24 V d.c. The inputs have common 0V and bias of -24 V,
which means that there is 48 V over the connection. DSTD 196P has pluggable screw terminals.
A connection unit with inputs for 100 V - 120 V a.c./d.c. The connection unit contains eight
independent channels. The inputs are galvanically isolated from the electronics.
With connection distances greater than approximately 200 m, with an a.c. supply, the capacitive
cross-talk can result in malfunctioning. Consider the technical data of the cable type concerned
in relation to the input impedance of the board and switch-over levels. The connection unit is
supplied with an external 24 V voltage.

A connection unit with inputs for 230 V a.c. The connection unit contains eight independent
channels. The inputs are galvanically isolated from the electronics. With connection distances
greater than approximately 200 m, with an a.c. supply, the capacitive cross-talk can result in
malfunctioning. Consider the technical data of the cable type concerned in relation to the input
impedance of the board and switch-over levels. The connection unit is supplied with an external
24 V voltage.
DSDI 120A
DSDI 120AV1, DSTD 150A/DSTD 190V1
DSTK 221L3
Scanned or interrupt-controlled 48 V d.c. inputs, otherwise similar to
DSDI 110A/DSDI 110AV1.
3-14 3BSE 002 414R601 Rev B

Guidelines - Digital Outputs

Advant Controller 410 can be equipped with digital outputs of static type (semiconductor) and
with a relay contact. The different output types have partially different properties.
Certain significant properties are presented below:
• Static outputs
These generally have a long service life, even with a high frequency of change.
• Relay outputs
These have a shorter service life than static outputs. When the output is frequently
changed, it is subject to wear and its service life is shortened. They can withstand
occasional higher voltage. Different system voltages can be accommodated on the same
board. A certain degree of inductive load can be accepted. Small load currents with low
voltage (<40 V) can give contact problems.
In the control of two-phase motors (with a phase-displacing capacitor between the forward and
reverse windings), a reverse voltage considerably higher than the system voltage can be induced
over the capacitor. This voltage is induced over the open control function and can result in the
maximum permitted voltage being exceeded. This can be a problem with a.c. 230 V and with
the use of DSTD 108P.
DSDO 115
4xDSTD 108/DSTD 108L, DSTK 226L3
With these connection units four times eight closing relay outputs, 24 - 250 V a.c./d.c. max 3 A
are obtained. The relay contacts have a safety circuit (RC-link) for spark suppression.
For supply and grounding purposes, 32 completely individual channels are obtained.
Each connection unit (DSTD 108) is 120 mm long. The four connection units are connected to a
DSDO 115 with a divided ribbon cable, DSTK 226L3. The minimum load on the relays is 2.5
VA but the lowest is 100 mA with 24 V.
A variant of connection unit DSTD 108L is used for low-current loads (maximum 200 mA).
DSDO 115
DSDO 115A
DSTD 110A, DSTK 221L3
/DSTD 190V1, DSTK 234L3
These give short-circuit-protected static outputs for 24 V d.c. (transistor outputs). The load
current may be a maximum of 150 mA per channel for DSDO 115 and 0.5A for DSDO 115A.
The supply is divided in the connection unit into two groups of 16 channels each. Each has a
common supply and 0V. The outputs are galvanically isolated from the internal electronics.
DSDO 115A, DSTK 226L3
32 digital outputs. You can connect up to four of the connection units listed below to this board
and cable. Division between the different connection units is a free choice. The properties of
the outputs are decided by the selected connection units. Each connection unit contains eight
outputs.
DSTD 108P
Connection unit with eight closing relay outputs, 24 - 250 V a.c./d.c. max 3 A. The relay
contacts have a safety circuit for spark suppression. For supply and grounding purposes,
32 completely individual channels are obtained. Each connection unit (DSTD 108) is 120 mm
3BSE 002 414R601 Rev B 3-15

long. The minimum load on the relays is 2.5 VA but the lowest is 100 mA with 24 V. With
pluggable screw terminals.
DSTD 108LP
Same as DSTD 108P but for maximum load current on it is 200 mA.
DSTD 109P
Connection unit with eight static outputs, 24 V 2 A with common power supply.
Each connection unit (DSTD 109P) is 120 mm long. With pluggable screw terminals.
DSDO 120
DSTD120A, 220L3.2
Static outputs for 24 V - 48 V d.c. (transistor outputs). The board is designed to withstand a load
up to 1 A per channel. The supply is divided in the connection unit into two groups of eight
channels each. Each has a common supply and 0V. The outputs are galvanically isolated from
the internal electronics.
Guidelines - Pulse Counting and Positioning Boards

DSDP 140A
DSTD 150A / DSTD 190, DSTK 225SL3
A positioning loop for positioning up to 80 kHz.
DSDP 150
DSTD 150A/DSTD 190, DSTK 225SL3
Twelve channels 5/12/24 V d.c. for pulse and frequency measurement up to a maximum of
10 kHz. Pulse or frequency measurement is selected optionally for each channel pair. To obtain
acceptable accuracy, the frequencies which the two channels in a channel pair are to measure
should be fairly similar.
DSDP 170
DSTX 170, DSTK 228L3
Four channel high-speed pulse counter board for up to 2.5 MHz. The board is primarily
intended for control of motor operation where there is a need for position/length and
speed/frequency measuring.
Guidelines - Connection of Static Converters

DSDC 111
DSTX 110, DSTK 224L3
A board to connect a thyristor converter with analog control of d.c. motor operation.
3-16 3BSE 002 414R601 Rev B

3.1.5.2 S400 I/O System
Guidelines - Analog Inputs and Outputs

With current signals and series coupling of loads, the total resistance may not exceed the
resistance through which the sensor output can be driven.
The referred type designations below are valid for S400 I/O Units.
DSAX 452
This is a combination unit for 14 analog inputs and 6 analog outputs for applications which
require considerable accuracy. You can ground the transducer and load if the difference in
potential between the load ground and the DSAX 452 ground is within the specification.
The equivalent resistance caused by the ground voltage drop and the load resistance concerned
together is not to exceed 650 Ω with a current signal, ≤ 20 mA.
Both inputs and outputs can suppress moderate CMV in the range ±10 V for voltage input and
±20 V for current input. This means, in practice, that you can ground the transducer and load
freely within a geographically limited area in which the difference in ground potential is within
the specification.
The unit has an integrated voltage source providing d.c. 24 V for transducer supply. The voltage
is fused. This supply can also be used for supply to the outputs which can then drive a current
signal through a load of 650 Ω. Additionally the outputs can be supplied from an external supply
unit. You can increase the load resistance for the current signal towards 1000 Ω.
Guidelines - Digital Inputs and Outputs

DSDI 452
DSDI 451 (expansion unit)
Thirty-two scanned inputs for 24 V. All channels have a common signal return. Transducer
supply is obtained from a common fused source. External voltage supply and fusing for groups
less than 32 channels are possible, but the return sides of the different voltage sources must be
capable of being connected. The 32 channels are galvanically isolated from the internal
electronics in the unit.
DSDI 454
DSDI 453 (expansion unit)
Thirty-two scanned inputs for 48 V. For further properties, see DSDI 452.
DSDX 452(L)
DSDX 451(L) (expansion unit)
Combination unit for 20 digital 24 V inputs and 12 digital outputs. The inputs have the same
qualities as the inputs on DSDI 452. The outputs are completely separated relay contacts for
24 V - 240 V a.c./d.c. The recommended minimum load on the contacts is 2.5 VA but a
minimum of 100 mA with 24 V d.c. Units with an additional letter L are equipped with low-
voltage relay contacts. Maximum load on the contacts is 200 mA. The recommended minimum
load on the contacts is 5 mA or 0.05 VA.
DSDX 454(L)
DSDX 453(L) (expansion unit)
3BSE 002 414R601 Rev B 3-17

Combination unit for 20 digital inputs (48 V) and 12 digital outputs. The inputs have the same
qualities as the inputs on DSDI 454. The outputs are completely separated relay contacts for
24 V - 240 V a.c./d.c. The recommended minimum load on the contacts is 2.5 VA but a
minimum of 100 mA with 24 V d.c. Units with an additional letter L are equipped with low-
voltage relay contacts. Maximum load on the contacts is 200 mA. The recommended minimum
load on the contacts is 5 mA or 0.05 VA.
3.1.5.3 S800 I/O System

The general information given by way of introduction in Section 3.1.5, Process Interface is
adequate for an S800 I/O system. Otherwise you are referred to the S800 I/O User’s Guide.
3.1.6 Communication

From the hardware viewpoint, the concept of submodule and submodule carrier is used to build
a function. Please refer to Section 1.8.11.3 Submodule Carrier and Submodules for a
description.
Information given is valid to the controller end of the communication.
Table 3-7. Link Types, Hardware and Software
Program
Link type Submodule Peripheral Comments
module
(1) (2)
MasterBus 300 CS513 QC01-BAS11 See separate ,
executed in main CPU (Basic) documentation
(1) (2)
MasterBus 300E ,
executed in main CPU
(1) (2)
MasterBus 300 exe- CI547 ,
cuted in slave CPU incl.
on the submodule.
(1) (2)
MasterBus 300E exe- ,
cuted in slave CPU incl.
on the submodule.
GCOM CI543
3-18 3BSE 002 414R601 Rev B

Table 3-7. Link Types, Hardware and Software (Continued)
Program
Link type Submodule Peripheral Comments
module
Bus extension to QC01-BAS11 See separate Internal
S100 I/O (Basic) documentation
(3)
MasterFieldbus CI570 + TC570
Advant Fieldbus 100 CI522 + TCxxx
PROFIBUS-DP CI541V1
LONWORKS Network CI572
(3)
EXCOM CI531
V.24/RS-232-C
RCOM CI532Vxx or Protocol
CI534Vxx(4) variant xx.
See below
MultiVendor Interface
(Standard protocol)
MVI Free-programma- CI535, CI538
ble communication
(1) MasterBus 300 or MasterBus 300E is selected with a switch on the submodule CS513 or CI547.
(2) Selection of “executed in main CPU”/”executed in slave CPU” is made by selecting slave number on CS513 or
CI547. Numbers 1-6 mean slave CPU while 7-8 mean main CPU. For CI547 slave number 1-2 is valid.
The latter numbers, 7-8 “executed in main CPU,” are the only relevant settings for CI513 in
Advant Controller 410. See the separate manual MasterNet.
(3) A range of modems and connection units are available for the different communication media. See respective
communication User’s Guide.
(4) Depending on protocol
Guidelines - Communication in General

Communication among different computers gives rise to a load divided among the
communication link itself and the main CPU of the involved computers. This must be
considered when you design a distributed control system.
A basic rule, always relevant, is to limit the frequency of the information transfer to what is
really needed by the application. Event-controlled transfer (if possible to execute in a secure
way) is preferred to cyclic transfer.
The main CPU is always loaded by a communication. The significance depends on the actual
design. For the MasterBus 300, there is only one implementation in Advant Controller 410.
It utilizes the main CPU on the Processor Module PM150. The same information applies to
MasterBus 300E.
3BSE 002 414R601 Rev B 3-19

Guidelines - Location and Exploitation of Hardware

• No restrictions in location of submodules in slots 1..4 on the Processor Module PM150.
Guidelines - EXCOM
• Communication interface CI531 has two ports V.24/RS-232-C. Each port can be used for
EXCOM or MasterView 320 or a combination of these.
Guidelines - V.24/RS-232-C
• Use the basic V.24/RS-232-C interface for printer and MasterView 320 communication.
• You can connect one printer and one MasterView 320 directly to the Processor Module
PM150 via a front connector. No extra hardware needed.
• Communication interface CI531 has two ports V.24/RS-232-C. Each port can be used for
EXCOM or additional MasterView 320 or a combination of these.
Guidelines - RCOM
• Communication interface CI532V01 has two ports. Both ports have the same protocol.
Guidelines - MultiVendor Interface (Standard Protocol)

• Communication interface CI532Vxx or CI534Vxx has two ports. Both ports have the same
protocol.
• CI532Vxx and CI534Vxx is delivered with a standard protocol, for example, RCOM,
Modbus, Siemens, and so on.
Different protocols are sold as different articles: CI532V01, CI534V02, and so on.
“V” stands for variant.
• Combining CI532Vxx, CI534Vxx and CI535 is restricted, see Section 3.2.4.1, Provided
Link Types.
Guidelines - MVI Free-programmable Communication

• The Free-Programmable MVI Module CI535/CI538 have two ports. Both ports have the
same protocol.
• CI535 and CI538 are delivered without protocol. The user defines the protocol.
• Combining CI532Vxx, CI534Vxx, CI535 and CI538 is restricted, see Section 3.2.4.1,
Provided Link Types.
3-20 3BSE 002 414R601 Rev B

Table 3-8. Applied Communication, Used Links and Interface to Application Program
Software interface (1)

Equipment Used link(s) Link Application
DB elements DB/PC elements
Advant Controller 410/450 MasterBus 300/300E CS513 or CI547 (2) DS, DAT
(RCOM is an alternative)
Advant Station 500 Series OS MasterBus 300/300E CS513 or CI547 (2) Subscription, Command,
Events
Advant Station 500 Series IMS MasterBus 300/300E CS513 or CI547 (2) Subscription, Command,
Events
Advant Station 500 Series ES MasterBus 300/300E CS513 or CI547 (2) Set of commands
Configuration data
(2)
MasterPiece 200/1 MasterBus 300/300E, RCOM CS513 or CI547 DS, DAT
(2)
MasterView 800/1 MasterBus 300/300E CS513 or CI547 Subscription, Command,
Events
MasterBatch 200/1 MasterBus 300/300E CS513 or CI547 (2) GENUSD (3 ref. types)
PC: defined by the progr.
module QC01-BAT11
MasterGate 230/1 MasterBus 300/300E CS513 or CI547 (2) ---
Advant Station 100 Series IMS GCOM CI543 Subscription, Command,
Events
S100 I/O Internal Bus Extension to Not needed I/O element
S100 I/O
S100 I/O Internal Bus Extension to Not needed I/O element
S100 I/O
S400 I/O MasterFieldbus CI570 I/O element
S800 I/O Advant Fieldbus 100 CI522, CI810A/CI820 I/O Element
Advant Controller 70 Advant Fieldbus 100 CI522, AC70 DSP (Data Set Periph.)
DAT, EVS(R)
MasterPiece 51 MasterFieldbus CI570, PX PC: COM-MP51
TYRAK L, SAMI, and so on MasterFieldbus CI570, CV PC: COM-CVI01,
COM-CVO01
AdvaSoft for Windows GCOM CI543
MasterPiece 90 MasterFieldbus CI570, PX MBF-IN, MBF-OUT
Advant Controller 110 Advant Fieldbus 100 CI522A, AC110 DSP (Data Set Periph.),
(RCOM is an alternative) DAT, EVS(R)
3BSE 002 414R601 Rev B 3-21

Table 3-8. Applied Communication, Used Links and Interface to Application Program (Continued)
Software interface (1)
Equipment Used link(s) Link Application

DB elements DB/PC elements
ACV 700, DCV700 Converter Advant Fieldbus 100 CI522A DSP (Data Set Periph.),
DAT
Advant Station 100 Series ES Internal bus --- Set of commands
Config. data
ABB Prologger, DCS Tuner EXCOM CI531, CAPXCOM DS, DAT,
Read DI, DO, AI, AO
Printer V.24/RS-232-C CAPPRI PC: TEXT, PRINT
MasterView 320 V.24/RS-232-C TERMPAR TERMGEN, TERMDYN,
(CI531 when CI531 TERMDIS, TERMREF,
hardware is used) TERMSTR
Advant Controller 55 RCOM CI532 MS, DAT
ABB Active Mimic Controller RCOM CI532
Other manufacturers’ equipment PROFIBUS-DP CI541 PC: PB-S, PB-R,
PB-DIAG
DB: PBS, PBSD
LONWORKS Network LON,LONCHAN PC: LON-R, LON-S
DB: LONDEV,
LONNVI, LONNVO,
LONMNVI, LONEVTR,
LONMREF
MultiVendor Interface CI532 MS, DAT
- MODBUS (via CI532V02)
- Siemens 3964R
MultiVendor Interface MVIMOD MVB, DAT
- MODBUS (via CI534V02) MVICHAN
- Allen-Bradley DF1 MVINODE
MVI Free-programmable
communication
- via CI535 CI535 MS, DAT
- via CI538 MVIMOD MVB, DT
MVICHAN
MVINODE
(1) Generally data base elements are given for establishing the link and the interface to the application program. PC: denotes PC element.
(2) The user “straps” network, node, slave number and protocol on dip-switches on the communication interface board CS513 or CI547.
From the network communication viewpoint, the system is then automatically configured at power-up. See strapping information in the
manual MasterNet. In addition to the data base element CS513 also handles the CI547 submodule, which shows basic communication
parameters, further parameters are found in the elements NETWL, TL, TU, BM, NM. Those latter elements are meant for advanced
users.
3-22 3BSE 002 414R601 Rev B

Guidelines - Data Set Communication

Designation of Data Sets
Data Sets (DS) are used with signal exchange between, for example, controllers. A Data Set is
defined by a data base element which states if it is a transmitting or receiving Data Set, the cycle
time and from where the information is received or to where it is transmitted. The data base
element for a Data Set also refers to a number of DAT elements. These DAT elements contain,
in turn, the values which are to be transmitted/received.
When a DS and associated DAT elements are allocated names, it is important to be able to trace
the origin of the data, that is, where the data originates. One way is to give a Data Set a name in
accordance with DS “from node number” - “to node number”. If a Data Set is transmitted from
node 12 to node 11, it is given the name DS12-11. Associated DAT elements can be given the
name DS12-11.R1 (which is obtained automatically if a real DAT element is created with the
help of DS).
As an alternative, you can give DAT elements function-describing names (of up to 12
characters).
Performance Considerations
Information given in Section 3.2, Technical Data Including Capacity & Performance shows that
receiving Data Sets generate more load than transmitting Data Sets. To minimize the load, you
can create data base elements for receiving Data Sets in an Advant Controller 410 before
transmitting. Place data base elements for the Data Set which receives data most frequently at
the beginning. If, despite the above actions, there are load problems in the controller or on the
bus, you can transmit data event-controlled. Use the PC element SENDREQ for this. You can
use the “VALID” flag on the data base element for a receiving Data Set and the DAT element as
a “Fresh data available” flag.

For the available general function block library included in the basic system program and
different additional system programs, see Section 1.7, Product Overview.
You are also referred to information regarding necessary hardware and software given in other
sections of this chapter. These sections are more focused on concrete functions.

The controller data base is the normal interface to the application program.
For example, there are different data base elements representing process interface such as
analog input, digital output, and so on.
General Guidelines
See Section 3.1.7.1, Application Building with AMPL.
3BSE 002 414R601 Rev B 3-23

3.1.7.1 Application Building with AMPL

This section is not intended to be a formal guide to application programming but rather a
collection of suggestions and ideas for program design and structuring. The following are
general rules for program design:
• Structure the application program (see below).
• Write programs that are as readily understandable as possible.
• Avoid “smart” programming unless absolutely necessary to achieve the necessary
performance.
• Prepare a draft PC diagram in which the required function is built up with the help of PC
elements.
• Use the largest elements possible.
• Use the most powerful elements possible.
• Use the principles of typical solutions (type circuits).
Structuring of the Application Program

When structuring the application program, you must satisfy these three requirements:
• Structuring in accordance with the structure of the plant and the process.
• Structuring in accordance with execution time.
• Function orientation from the typical solution aspect.
The structure elements primarily used are PCPGM, CONTRM and FUNCM. SEQ and STEP
are also used with sequential control.
The elements PCPGM, CONTRM and SEQ are execution-controlling. You can activate and
deactivate these elements from outside—do this when high performance is required. The
elements are only activated when execution of the subsidiary program (-section) is necessary.
Place the execution control in its own module with a short cycle time. Note, however, that there
may be occasions such as at start, stop and emergencies when you must run all programs (-parts)
simultaneously. If there are such occasions, they determine how hard the process station can be
utilized.
Use the following as rules of thumb when structuring:
• Do not place the whole application in just one PC program.
• It is preferable that you place independent parts of the application program which have no
data exchange or a limited data exchange in different PC programs.
• A control module (CONTRM) delimits a function to which a special cycle time is applied.
• A function module (FUNCM) delimits a function consisting of several control modules or
divides a control module into subfunctions.
• Use more than three levels with structure elements only in exceptional cases.
• Use BLOCK elements to close part of a control module when reducing the load on the
controller.
3-24 3BSE 002 414R601 Rev B

NOTE
Writing to the data base continues while the blocking is active.
Use a simple pin diagram when you are structuring the application program.
Signal Exchange between PC Programs

The main purpose of the division of the application program into PC programs is to divide the
application into independent parts which have no signal exchange with each other. It can,
however, be practical to divide the application into PC programs despite a limited signal
exchange between the parts. The signals are then exchanged through a DAT element in the data
base.
Use a consistent designation philosophy and a booking list. In certain cases, you can justify the
use of a binary DAT element for only one binary value in order to make it possible to allocate a
relevant plain language name to the element/signal.
3.1.8.1 Local Operator

Communication with a local operator’s station Masterview 320 is an application of
V.24/RS-232-C. For further information, see Section 3.1.6, Communication. In that section you
will also find an overview of the application interface used and some guidelines for the link
implementation.
In other respects, Masterview 320 and its application are described separately.
Software supporting the operator function is included in an optional program module
QC01-LOS11.
3.1.8.2 Central Operator

Communication with a central operator’s station, Masterview 800/1, Advant Station 500 Series
Operator Station or Advant Station 500 Series IMS Station, is an application of
MasterBus 300. See Section 3.1.6, Communication. In that section, you will also find an
overview of the application interface used and some guidelines for the link implementation.
In other respects, the named operator station products and their application are described
separately.
Software supporting the operator function is included in an optional program module
QC01-OPF11.
3BSE 002 414R601 Rev B 3-25

3.1.9 Availability and Security
General Guidelines
Control system availability is often discussed in relation to industrial processes, power
generation systems, machines, and so on. Redundancy is one instrument to reach high system
reliability and availability.
The advantages of such redundancy include:
• Improved personnel safety
• Less risk of machine damage
• Reduction of expensive production loss
• Less demand for shift work by highly paid, qualified maintenance personnel.
Processes and machines are seldom identical and it is often necessary to adapt the solution of
the redundancy problem to the application concerned. It may be sufficient to equip particularly
sensitive process sections or functional parts with control system redundancy. The level of
redundancy considered necessary varies and can be, for example:
• 100% availability necessary - Hot stand by
• Stop for some seconds acceptable
• Stop for some minutes acceptable
• The possibility of a controlled manual stopping of the process required.
When studying an operational malfunction in a production unit, it is often found that the fault is
in a motor, a contactor, a valve, or field-mounted instrumentation. It can thus, in theory, appear
more appropriate to duplicate an important measuring sensor or valve than to duplicate the
control system, but errors in the controller have more serious consequences.
When considering whether redundancy of the control system really is the best configuration,
study the question broadly. Base the result on the construction and requirements of the process
and the total function. “A chain is no stronger than its weakest link.”
By taking into consideration the risk of malfunction when designing a specific control system,
you can obtain a high degree of availability at minimum cost.
The distribution of sensitive I/O channels to different circuit boards is a form of risk-spreading.
You can divide application programs into an independent basic function and a more advanced,
perhaps optimization, auxiliary function, dependent on sensitive measurement functions.
This means that production need not be stopped when parts, both within the control system and
externally, do not function correctly.
Other means of increasing system availability, irrespective of the configuration selected,
are maintenance resources such as spare parts and the availability of trained personnel.
3-26 3BSE 002 414R601 Rev B

Duplication for Security
DANGER - CAUTION
Duplication of control system functions is one way to ensure that all tasks are performed
correctly. It is, however, very important to emphasize that the security in a process control
system, when it comes to personnel safety, must never be based on duplication of system
functions alone. You must always check other measures as well.
In the most critical applications, a special design of the Advant OCS, the Advant Safety System,
is then applicable.
3.1.9.1 Redundancy

Redundancy is achieved by duplication of actual hardware modules.
Options for redundancy in Advant Controller 410 are described in Section 1.7.10.2,
Redundancy.
It is not necessary to order extra software to support a duplication of hardware.
From the configuration viewpoint, a redundant pair of I/O modules is kept together by a
common data base element. Normally, the element used in a single application has the extra
parameters needed for a redundant application.
Guidelines
• Always base your investment in redundancy on a relevant reliability and availability
analysis. Reflect on, for example:
– Not only the control system itself but also field instrumentation and other production
equipment.
– Costs of production stop vs. increased costs for a system with high availability.
– Vulnerability, price and performance with different alternatives.
• Be aware of the increased need for maintenance and spare parts to keep a high level of
availability.
3.1.10 Mechanics
See Chapter 2, Installation in this manual, Section 2.1, Site Planning Environment in particular.
3BSE 002 414R601 Rev B 3-27

3.1.11 Heat Dissipation
3.1.11.1 Cabinet Ventilation

To avoid overheating, when ambient temperatures are high, take into consideration the heat
dissipated in the electronics cabinet. This is particularly important with sealed cabinets (IP54) or
tropicalized cabinets (IP41) with considerable circuit board equipment and ambient
temperatures at levels approaching 40°C.
The frequency of faults is estimated to be doubled for each 20°C increase in temperature.
It is, therefore, important to maintain as low a temperature as possible where the equipment is
installed.
The different hardware modules in the controller and the I/O system have different outputs of
heat. Accurate calculation of the heat produced by the system requires knowledge of the
modules and the work cycle.
3.1.11.2 Heat Dissipation Permitted in Cabinets

The maximum permitted temperature above the subracks in the cabinet is 55°C.
The permissible amount of heat generated depends on the type of cabinet and its location.
Appendix B, RM500 Cabinet - Data Sheet indicates the heat generated to give a 15°C
temperature rise and a 30°C temperature rise in the cabinets. The figures are valid for cabinet
type RM500.
Please note that there is normally no requirement for fans in an Advant Controller 410
installation.
The standard design and assembly of cabinets aim to give a maximum of 15°C temperature rise
within the cabinet, which results in a maximum permitted ambient temperature of 40°C
(55°C - 15°C).
In critical applications with subracks fully equipped and cabinets arranged in groups, you may
need to make a calculation of the actual power dissipation and an estimation of the temperature
rise within the cabinet. Calculation is recommended at system enlargement too.
Some data to be used in calculations is given below. Power dissipation for different hardware
modules are collected in Appendix E, Current Consumption and Heat Dissipation.
Cabinets including a single subrack normally have no temperature rise higher than 15°C,
irrespective of the disposition of the subrack, cabinet type and location of the cabinet.
3-28 3BSE 002 414R601 Rev B

Section 3.1.11 Heat Dissipation
3.1.11.3 Cabinets in Groups

When cabinets are installed in groups, reduce the permitted power dissipation in accordance
with Figure 3-5. The permitted power dissipation in a particular cabinet is the power specified
in Appendix B, RM500 Cabinet - Data Sheet multiplied by a factor from Figure 3-5.
0.95 0.95
2 Cabinets
0.9 0.9
0.95 0.9 0.9 0.95

4 Cabinets
0.9 0.8 0.8 0.9
0.9 0.85 0.85 0.9

0.85 0.75 0.75 0.85
8 Cabinets
0.9 0.85 0.85 0.9
0.85 0.75 0.75 0.85
Reduction factor for ventilated

cabinet and tropicalized cabinet
0.95 Reduction factor for

0.9 sealed cabinet
Figure 3-5. Reduction Factors for Cabinets Installed in Groups
3.1.11.4 Calculation of Heat Generated in a Cabinet

When you are calculating the heat generated in a cabinet, add up the heat generated by the
different circuit boards. To this sum, add the heat generated by the power supply units and other
equipment such as an extra modem, extra unit for supply of power to transmitters and so on.
See Appendix E, Current Consumption and Heat Dissipation for the power dissipated as heat by
hardware modules in Advant Controller 410 and the available I/O system. It is assumed that
70% of the channels of an I/O module are active simultaneously.
A power supply unit located beneath the subracks contributes to the total power dissipation with
100 W. Do not include redundant power supply units in the calculation of number of units
because of the load shedding.
The total power dissipated in the cabinet can be written as follows:
P Total = ( ∑ PC – module ) + ( ∑ P IO – board ) + ( ∑ P Voltagesupplyunit ) + ( ∑ P Sundry )
3BSE 002 414R601 Rev B 3-29

3.1.12 Maintenance and Repair

From the maintenance viewpoint, use as few module types as possible in the hardware
disposition of a control system. This is most relevant with the process I/O design.
Standardization of I/O signal types and other electrical qualities is important to minimize the
spare part stock.
If possible, do not use “smart programming” when you make an application program.
Your solutions must make sense to the maintenance people in the event of disturbances and
following trouble-shooting.
3.1.13 Expansion Possibilities and Spare Considerations
Expansion Possibilities
You can connect a new Advant Controller 410 to an existing control network
(MasterBus 300) without affecting other stations and controllers. The new controller is
automatically incorporated in the communication system.
You can expand the controller step by step, that is the system can be enlarged and made more
complex in different ways. Examples of such areas are:
• Process I/O
• Communication with external computers and other systems
• Operator functions
• Application program
• Redundancy.
Of course, there are some limitations such as maximum number of possible instances and
functionality offered by the available library. You can, however, exchange program modules if
certain optional functions are required.
For limitations, see Section 3.2, Technical Data Including Capacity & Performance.
If desirable, you can carry out most expansions and operations on-line.
Some preparations are necessary when you are dimensioning the system since the dimensioning
commands DIMDB and DIMPC are only available off-line. Practically, this is not a problem.
A number of spare instances in the data base and spare PC program structures should always be
defined for future limited expansions.
Extensive reconfiguration and enlargement of the system is normally linked to revamping the
plant. Shut-down of the system and off-line work is then advisable.
Spare Considerations
In addition to what is said above regarding spare instances in the data base and spare space for
additional application programs, there is a simple rule of thumb for the hardware design:
You can add new I/O modules on-line. It is practical to have approximately 10% to 20% of the
channels spare. The same recommendation is valid for spare space in subracks.
3-30 3BSE 002 414R601 Rev B

Section 3.1.14 Memory Calculation
3.1.14 Memory Calculation

Advant Controller 410 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, several hundred I/O points and a large number of logs with the shortest
possible log interval requires a lot of RAM. In such cases, you are advised to make a memory
estimation as soon as possible in the preliminary design work.
Empirical formulae are necessary for you to make a quick estimation of the memory
requirement. Table 3-9 for memory requirement calculation is presented below.
Forms for you to use in practice are given in Appendix G, Memory Calculation.
An explanation of the memory requirements of the different functions follows. You can assume
that the items listed include sufficient memory for common applications of a PC element. If the
application concerned has a special requirement in one or more respects, for example, the PC
program can be very complex, it may be necessary to adjust the memory requirements for this.
See the PC element manual for information regarding the memory requirements of individual
PC elements.
When discussing the memory, please note that there is a limit. The local data area available for
each PC program is limited to 32 kbytes.
If the application program is well structured, and divided into several PC programs, this limit
normally has no relevance.
Structuring of the application is strongly recommended for other reasons as well. It is the basis
of easily interpreted documentation (for example circuit diagram), effective maintenance and
simple future system enlargement.
Explanation of Memory Requirement

AI/AO: An application with two four-input ADD elements (or other typical elements) is
assumed for each channel.
DI/DO: An application with two four-input AND gates (or other typical gates) is assumed for
each channel.
PIDCON: The feedback control loop consists of a PIDCON PC element with all size
parameters set to 1 and one PIDCON data base element.
MANSTN: The manual station consists of one MANSTN PC element with all size parameters
set to 1 and one MANSTN data base element.
RATIOSTN: A RATIOSTN PC element with all size parameters set to 1 and one RATIOSTN
data base element.
GENCON, GENBIN, GENUSD: An application corresponding to that in the manual for
functional units is assumed for each functional unit.
VALVECON: The valve control consists of a VALVECON PC element with all size parameters
set to 1 and one VALVECON data base element.
MOTCON: The motor control consists of a MOTCON PC element with all size parameters set
to 1 and one MOTCON data base element.
GROUP: The group start consists of an application corresponding to that in the manual for the
functional unit GROUP. The group start contains eight steps. The logic for control and
3BSE 002 414R601 Rev B 3-31

presentation contains around 70 PC elements. Subordinated functional units of the type

MOTCON are not included in this figure.
SEQ: The sequence is assumed to consist of a sequence head, 10 steps and one data base
element SEQ.
TEXT: Consists of one data base element TEXT.
Table handling: The figures are calculated for one table with 10 rows and 100 values per row.
MasterView 320: The displays are assumed to have 40 text strings with 20 characters and 30
dynamic values. The event list is assumed to accommodate 100 events.
Central operator station: The numbers for logs are based on a log with 10 variables with 240
stored values. Each value takes approximately 5 bytes.
Each group member in the group alarm function is assumed to be included in three group alarm
objects.
MasterBatch 200/1: The number for PROCESSES is based on 50 storage vessels, four sections
and 20 operations with six recipe variables each.
Space for storage of User Diskette content: Included only if you choose the user diskette as a
backup option in Advant Controller 410. The memory space can be dimensioned.
100 kbytes is a space suitable for most requirements.
Spare RAM area: Reserve RAM capacity is required because information about memory
requirements of the different functions is generalized and inherently uncertain. This RAM
compensates for minor departures from the data constituting the basis of the memory
requirement presented. Extra memory is also required when commissioning to permit smaller
adjustments of the application program.
Total RAM requirement: Must be less than the RAM size of the processor module.
Table 3-9. Calculation of RAM Requirement
Factor Appr. RAM

Object type Remark Total
(kbytes) req. (kbytes)
AI/AO S100 I/O x 0.30
S400 I/O (MP 51 not included) x 0.30
S800 I/O x 0.27
DI/DO S100 I/O x 0.26
S800 I/O x 0.14
Calculated signals For presentation and event handling in x 0.30
Advant Station 500 Series Operator Sta-
tions (including signals via
Advant Fieldbus 100)
S800 I/O No. of S800 I/O stations on fieldbus x 0.40
3-32 3BSE 002 414R601 Rev B

Section 3.1.14 Memory Calculation
Table 3-9. Calculation of RAM Requirement (Continued)
Factor Appr. RAM

PIDCON Excl. I/O x 1.50
MANSTN Excl. I/O x 0.80
RATIOSTN Excl. I/O x 1.00
GENCON Excl. I/O x 0.50
GENBIN Excl. I/O x 0.50
GENUSD Excl. I/O x 0.50
VALVECON Excl. I/O x 0.60
MOTCON Excl. I/O x 0.80
GROUP Excl. I/O 1 x 3.00
SEQ Excl. I/O x 1.00
DAT No. of DB elements x 0.02
TEXT No. of DB elements x 0.14
Table handling No. of tables x 4.90
MasterView 320 Basic requirements for QC01-LOS11 1 x 231.00
No. of displays x 2.00
No. of MV 320 with event lists x 9.00
Advant Station 500 Series Basic requirement for QC01-OPF11 1 x 836.00
Operator Station and IMS
No. of trend data storage logs x 12.00
Station or MasterView 800/1
Group alarm, No. of group objects x 0.13
No. of group members x 0.09
MasterBatch 200/1 Basic requirement for QC01-BAT11 1 x 411.00
No. of SECCON x 1.7 + OPCON x 6.0 + x 1.00
TANKCON x 1.8
No. of processes x 25.00
PROFIBUS DP No. of PROFIBUSES x 1.20
Number of PROFIBUS slaves x 0.80
3BSE 002 414R601 Rev B 3-33

Table 3-9. Calculation of RAM Requirement (Continued)
Factor Appr. RAM

LONWORKS No. of LONWORKS Communication mod- x 65
Network ules CI572
No. of LONWORKS devices x 0.2
No. of LONWORKS variables x0.06
(input and outputs)
No. of LONWORKS multiple network vari- x 0.33
able
No. of LONWORKS Event Treat x 0.14
No. of MasterBus 300/300E, RCOM/RCOM+, GCOM and MultiVendor x 10.00
Interfaces
User Defined PC Elements Basic requirements for QC01-UDP11 1 x 132.00
Storage of user defined PC elements 1 x 150.00
Space for storage of User Diskette content x 100.00
Basic requirements for QC01-LIB11 1 x 31.00
Basic requirement for QC01-BAS11 1 x 1904.00
Spare RAM area 1 x 40.00 40.00
Total RAM requirement
3.1.15 CPU-optimization, Load Calculation

This section deals with the program execution capacity of an Advant Controller 410. It provides
answers to questions such as, “What can I expect the load generated by my application to be?”
It also provides a survey of how the software functions in an Advant Controller 410. In
conclusion, you can find recommendations for the reduction of system load.
What is the CPU to do?

The different functions in an Advant Controller 410 are allocated different priorities.
This means that a function with a higher priority takes precedence over a function with a lower
priority if both functions are activated simultaneously. A schematic presentation of the priority
system follows.
3-34 3BSE 002 414R601 Rev B

Section 3.1.15 CPU-optimization, Load Calculation
Advant Controller 410 Priority System

Priority
- Clock (Timer task) 100 ms STALL
High
- PC and I/O with cycle times, 10, 20, 40 ms
- Interrupt-controlled DI
- PC and I/O with cycle times 50, 100, 200 ms

and 250, 500 ms, 1 sec, 2 secs
5 secs. STALL
- AI-channels with cycle times 5, 10, 30, 60, 300 and 600 secs
- Order handling from operator stations type AS 500 OS, MV 800/1
- MasterBus 300
- System status
- Data Set-communication
- Trend data logging
- Event handling to operator stations type AS 500 OS, MV800/1

- Printer
- Handling of values for presentation on AS 500 OS, MV800/1
- EXCOM
- Engineering tool handling
Low - MasterView 320

30 minutes WARNING
Figure 3-6. Advant Controller 410 Priority System
There is a “stall level” between the different levels. This means that the system must execute all
functions, including all PC-control operations, at least each fifth second for the system to
continue operation. If an operator station or an engineering tool is connected to the controller,
a warning consisting of a system message is presented on the display screen if all functions are
not executed within a 30-minute period. This protection is provided to guarantee that all
functions in an Advant Controller 410 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.
3BSE 002 414R601 Rev B 3-35

CPU Load Calculation

With certain heavy load situations in an Advant Controller 410, or if you want to determine if
one controller is sufficient for a particular application/load, it may be valuable to perform a CPU
load calculation.
In the development of standard solutions, including type circuits of different scales, other
working methods are strongly recommended. The best result will be obtained by load
measurement in an actual target system. For CPU load measurement, see Chapter 5,
Maintenance.
Load calculation is not intended to give absolute values, but rather to indicate the magnitude of
the load generated by the different parts. The calculation also provides an excellent basis for
determination of where optimization would be most effective if it is necessary to lower the CPU
load.
Two calculation methods are presented below. The main differences between the methods are
the accuracy obtained and the work required. Approximations, of course, provide less accuracy
but rapid results.
The equation for calculating the total CPU load for several similar functions is:
CPU load = NF × T × 100 ⁄ (TS) [%]
where NF = number of functions (for example feedback control loops)

T = execution time for the function (ms)
TS = cycle time for the function in PC (ms)
The equation is generalized for load calculation in Advant Controller 410.
When the load is to be calculated or estimated, concentrate on those circuits which are frequent.
You can disregard some quite advanced single circuits from a PC program load viewpoint.
Just include the relevant I/O in the calculation/estimation. Sometimes complexity necessitates a
detailed study of a certain part of an application. Then it is practical to combine an “accurate
method” with a “shortcut method.”
The structures of the two calculation methods are illustrated in Figure 3-7.
When calculating, include only relevant items.
3-36 3BSE 002 414R601 Rev B

Section 3.1.15 CPU-optimization, Load Calculation
Accurate method Shortcut method
Approx. 8 % + 3) Approx. 8 % + 3)
Base load
PC and Process I/O Detailed analysis and calculation Use of EAF load data 1)
(Application)
Subscription, Detailed analysis Typical 4% 2)
Command, Events
Detailed analysis Typical 4% 2)
Data Set, EXCOM
Master View 320 Detailed analysis Typical 3% 2)
Logging Detailed analysis Typical 2% 2)
Detailed analysis Typical 1% 2)

Others
Try to obtain Try to obtain
Reserve at least 15-20% at least 15-20%
∑ 100 % ∑ 100 %
1) EAF is the abbreviation for
Estimated Application Function
2) Same figures as for AC 450, however

the utilized capacity is reduced some 50%
3) Add 0.8 % for each node on the network
Figure 3-7. CPU Load Calculation Methods
The method commonly used when accuracy is desirable is based on an analysis of

I/O, PC, Communication, and so on, part by part, to obtain load figures for each part and the
complete system.
Another shortcut method to analyze the CPU load is to work with estimated application
functions of varying complexity.
Forms to be used in your own practice are given in Appendix F, Load Calculation.
For execution times to use in analyses and estimations of CPU load, see Section 3.2, Technical
Data Including Capacity & Performance. See the manual PC Element for detailed information
regarding execution times for the individual PC elements.
How can an excessive CPU load be reduced?

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.
3BSE 002 414R601 Rev B 3-37

Recommendations for optimization in these three areas are given below.

I/O
• If many interrupt-controlled DIs with high frequency of change are used, it can be optimal
to go over to cyclically scanned DI, if this is permissible from the time-tagging viewpoint.
The form for “Calculations of CPU-load from inputs” can indicate if this is optimal with
interrupt-controlled or scanned DI.
• Are I/O signals scanned with an unnecessarily short cycle time? I/O signals normally need
not be scanned more often than the cycle time of the execution unit in the PC in which they
are used. Note that it may be necessary to scan AI quickly because of the frequency
content of the input signal. The signal can be low pass-filtered in AI software,
thus providing frequency components with lower frequency in the signal which the
application program uses. This means that the application program can be run more slowly
than the corresponding AI is scanned.
• Select as large dead-band for the AI channel as possible. Of course the accuracy
requirement must be considered.
PC
Check that no execution unit is executed with an unnecessarily short cycle time.
• If possible, break out parts of an execution unit or execution units and allocate to these a
longer cycle time.
• Utilize the option to block execution units when they need not be executed. It is also
possible to introduce a BLOCK element here when only parts of an execution unit can be
blocked.
Communication
• You can transmit Data Sets event-controlled on a MasterBus 300 with the help of the PC
element SENDREQ. Use the VALID flag in the receiving DS as an acknowledgment that
the signal is received.
• Always present digital signals on the operator station screen with event-controlled update
in combination with 9 sec cyclic update, to get fast updating on changes while minimizing
the load.
3-38 3BSE 002 414R601 Rev B

Section 3.2 Technical Data Including Capacity & Performance
3.2 Technical Data Including Capacity & Performance

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.
Technical data about communication links is given in separate documentation for the specific
link.
The primary structure outlined in Section 1.8 Product Overview is the basis of the presentation.
The following subordinated headings are used when relevant:
• General Technical Data, Capacity
Typical information given is maximum number of instances, magnitudes, distances, and so
on.
• Performance
Typical information is accuracy, CPU load, and so on.
3.2.1.1 CPU
General Technical Data, Capacity
Table 3-10. Technical Data of CPU and Memory
Data AC 410
CPU type MC68020
Clock frequency 25 MHz
RAM (total) 4 alt 8 MByte
RAM (for application) Calculate from
Table 3-9
Performance - General
The load caused by different subsystems in the controller is reported below. To start with, you
will find an overview. The following headings cover details to respective subsystems, apart
from individual PC element load data, which is included in the PC element manual.
All performance data is based on actual measurements in Advant OCS configurations.
For instructions on how to make calculations, see Section 3.1.15, CPU-optimization, Load
Calculation.
3BSE 002 414R601 Rev B 3-39

The load from cyclic functions in Advant Controller 410 is built up as shown in Figure 3-8.
Base load fix 8 %

(variable see below)
PC and Process I/O

(Application)
Subscription, Command
and Event Handling
Data Set and EXCOM
Master View 320
Logging
Others
Reserve
Recommended min 15-20 %
Figure 3-8. Load from Cyclic Functions, Overview
Performance - Base Load

The fix base load 8% of a controller can be further subdivided as follows:
• General load 3%
including basic network communication load (MasterBus 300)
irrespective of number of links and redundancy.
• PC and Process I/O related load 5%
This latter load does not exist in working mode CONFIGURATION.
A variable base load exist. Each additional node on the network will increase the load 0.8 %.
3-40 3BSE 002 414R601 Rev B

Performance - PC and Process I/O (Application)

Process I/O Handling
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.
Table 3-11. Load from Process I/O Handling
Channel type Basic time Addition on change (1)

[each execution] [VALUE changed)
AI 0.23 0.16
DI scanned 0.26/board 0.08
DI interrupt -- 1.0
AO 0.02 0.20
DO 0.01 0.15
AIC 0.005 0.18
DIC 0.005 0.10
AOC 0.005 0.10
DOC 0.005 0.07
(1) Channels with NORMAL_TREAT = 1 (event handling selected) will give rise to
increased load when the event occurs, which means VALUE changed (DI) or
LIMIT exceeded (AI) this is not included in the table. However this is taken care
of by having the stipulated reserve capacity.
PC System
In addition to the base load of the PC interpreters (included in base load given above), the CPU
load generated by the PC system is composed of the following parts:
• PC element execution. The PC element manual contains information on the load from each
PC element.
• Reading and writing of data to/from the data base. Each time a value is read from the data
base to a PC element, or written to the data base from a PC element, 6 microsecs are spent.
When a process output channel is written, add the time for I/O handling.
3BSE 002 414R601 Rev B 3-41

Estimated Application Functions

Use the following execution times and load figures when the shortcut method of CPU load
calculation is applied:
• One feedback control loop takes approximately 1.9 ms.
Thirty feedback control loops with the cycle time 1000 ms thus give approximately 5.7%
load. (Complexity: 1- PIDCON, 1- AI, 1- AO and several calculation and logic elements.)
• One feedback control loop for a three-position actuator takes approximately 2.3 ms.
Four such loops with the cycle time 2000 ms give approximately 0.5% load.
Complexity: 1- PIDCON, 1- CON-PU1, 2- AI, 2- DO and some calculation and logic
elements.
• When cascade-coupled regulators are applied, consider approximately each loop in the
cascade as a single loop. Use the figures above.
• A simple feedback control loop takes approximately 0.9 ms.
Complexity: 1- PI element, 1- AI, 1- AO and 5 simple arithmetic and/or logic elements.
• One ratio station or manual station takes approximately 1.0 ms.
Complexity: 1- RATIOSTN alt. MANSTN, 1- AI, some arithmetic and logic elements.
• One AI or AO takes approximately 0.3 ms.
The load figure is valid to different AI signal types: standard signal, Pt 100 and
thermocouple signal.
Fifty AI with cycle time 1000 ms give approximately 1.5% load.
Complexity: 1- AI alt. 1- AO.
• One measuring circuit, for example mass flow measuring, max/min selector, application
adapted linearization, etc., takes approximately 0.7 ms.
Complexity: 1- AI, some 5 arithmetic elements and logic elements.
• A motor drive takes approximately 1.3 ms.
Fifty motor drives with cycle time 1000 ms give approximately 6.5% load.
Complexity: 1- MOTCON, 1- AI, 5- DI (interrupt), 1- DO, some logic elements.
• An on/off valve control takes approximately 0.5 ms.
Fifty valve controls with cycle time 1000 ms give approximately 2.5% load.
Complexity: 1- VALVECON, 2- DI (interrupt), 1- DO, some logic elements.
• The execution time of a digital signal DI or DO with attached logic, for example,
interlocking logic depends of certain conditions. Table 3-12 gives you some alternative
applications.
3-42 3BSE 002 414R601 Rev B

Table 3-12. Estimated Execution Times of Digital Signals
Load example
(100 signals, PC
Signal type Change frequency
element cyclic
condition
time: 250 ms)
DI 0.02 Hz (50 s) 0.8%

Interrupt, low change frequency 0.1 Hz (10 s) 1.6%
DI 0.5 Hz (2 s) 5.6%
Interrupt, high change frequency 1 Hz (1 s) 10.6%
(This design should be avoided)
DI 0.02 Hz (50 s) 0.9%
Cyclic, low change frequency 0.1 Hz (10 s) 1.0%
DI 0.5Hz (2 s) 1.3%
Cyclic, high change frequency 1 Hz (1 s) 1.7%
DO 0.02 Hz (50 s) 1.0%
Low change frequency 0.1 Hz (10 s) 1.2%
DO 0.5Hz (2 s) 1.7%
High change frequency 1 Hz (1 s) 2.5%
Table 3-12 includes some technical terms which require explanation:

• Interrupt means that the execution of the input signal software (the DB function) is
initialized by the process signal change of state.
• Cyclic means that the input is scanned cyclically. Normally, the scan rate configured is the
same scan rate used for the PC program scan rate.
• Low/high change frequency relates to the actual PC program scan rate. That is low means
that the time between changes is much longer than the time between PC element
executions (determined by the PC program scan rate). High means that the time between
changes has the same magnitude as the time between PC element executions.
Complexity: 2 - 4-input AND gates per digital signal.
3BSE 002 414R601 Rev B 3-43

Performance - Subscription, Command and Event Handling

Subscription
The load in an Advant Controller 410 caused by a central operator station or information
management station subscription is a linear function of the number of “objects” (for example
AI, DI, PIDCON, and so on) subscribed for and of the update frequency. That is the load only
comes up when a subscription is utilized.
NOTE
The capacity of the communication bus must also be considered in the
performance calculation. See separate documentation attached the used bus.
Load data is given by a diagram, Figure 3-9. By extrapolation you may obtain the load figure
for an extended number of objects.
First an example and some general comments:
A display with 100 objects from one Advant Controller 410, with an update cycle of 3 sec,
generates a load of approximately 5% in the controller. Use of 10 different object types is
presupposed.
Always present digital signals with event-controlled update in combination with 9 sec cyclic
update, to get fast updating on changes while minimizing the load.
The total load in the controller from subscriptions for displays should normally not exceed
20 %.
3-44 3BSE 002 414R601 Rev B

1 s update
Load (%) time
5
4
4 object types
3
3s
2
1 9s
10 20 30 40 50 60 70 80 90 100 110 Number

of objects
1 s update
Load (%) time
6 3s
10 object types
4
9s
2
10 20 30 40 50 60 70 80 90 100 110 Number

of objects
Figure 3-9. Load Caused by Subscription
3BSE 002 414R601 Rev B 3-45

Command
The load in a controller caused by a command from an operator station or an information
management station is non-recurrent and relatively small. It can be disregarded.
Event Handling
I/O signals (including calculated variants) with NORMAL_TREAT = 1 (event handling
selected) will give rise to increased load when the event occurs, which means VALUE changed
(DI) or LIMIT exceeded (AI). However this is taken care of by having the stipulated reserve
capacity.
Performance - Data Set with MasterBus 300

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 410.
Figure 3-10, sending data sets and Figure 3-11, receiving data sets show the additional load
from these applications. The CPU load caused by the basic network communication between
two nodes is included in the CPU base load figures given.
Load (%)
4 8 12 16 18 Number of
DS / sec.
Figure 3-10. Load Caused by Sending Data Set
3-46 3BSE 002 414R601 Rev B

Load (%)
4 8 12 16 18 Number of
DS / sec.
Figure 3-11. Load Caused by Receiving Data Set
Performance - Master View 320

The resulting CPU load in Advant Controller 410 from MasterView 320 is given in Figure 3-12.
Load [%]
16
2,3
r minal
12 Te
8 See text
al 1
Termin
4
10 20 30 40 50 Number of
max. 48 variables/sec
Figure 3-12. Load Caused by a MasterView 320
3BSE 002 414R601 Rev B 3-47

On the X-axis you can find the update requirement from a display, which is presented on the
screen. Note that the load caused by, for example, 20 variables updated every second is the
same as the load from 40 variables updated every other second. If several MasterView 320 is
used at the same time (with a display on screen) you have to add the load figures from each
terminal.
Performance - Logging
The load caused by each individual log can be estimated from the diagrams and models below.
Finally make an addition.
The lowest configured value of sampling interval or log interval for an actual log is used when
entering the diagrams. In that way the different load caused by a momentary log and a mean
value log is practically considered.
A primary and a secondary log is treated in the same way when analyzing the CPU load.
The secondary log normally gets its data from a primary log. This means that the load data from
the primary log and the secondary log must be added up.
Short Log Intervals, 1 s - 10 s
Load (%) 1s
log interval
(sampling interval
at mean value log)
8
2s
6
4 5s
10 s
2
6 12 18 24 30 Number of
variables
in the log
Figure 3-13. Load Caused by a Log (Short Intervals)
3-48 3BSE 002 414R601 Rev B

Medium Log Intervals, 12 s - 30 s
Load (%) log interval

(sampling interval
at mean value log)
4
12 s
3 20 s
30 s
2
20 40 60 80 100 Number of
variables
in the log
Figure 3-14. Load Caused by a Log (Medium Intervals)
Long Log Intervals, ≥1 minute

A typical load caused by a single long interval log including 100 variables can be set to 1.5%.
Performance - Others
General
A number of applications of communication links are dealt with below. The communication link
itself will give rise to a small controller CPU load. This load is specified for each application
and should be finally added when the individual sending/receiving is considered.
NOTE
The capacity of the communication link must also be considered in a performance
calculation. See separate documentation attached the used link.
Data Set Peripheral with Advant Fieldbus 100

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 410 CPU load from data set peripheral communication can be estimated
from the curves given in Figure 3-15 and Figure 3-16.
3BSE 002 414R601 Rev B 3-49

R = Receiving
Load (%) S = Sending
12
10 R
S
8
50 100 150 200 250 300 No. of DSP/ sec
Figure 3-15. Load caused by DSP with Advant Fieldbus 100, basic cycle time 32 ms
The basic cycle time for the DSP scan task is set to 32 ms with the APP command.
Add the basic link load = 0.4% (no sending/receiving).
R = Receiving
Load (%) S = Sending
12
10
8
R
6 S
50 100 150 200 250 300 No. of DSP/ sec
Figure 3-16. Load caused by DSP with Advant Fieldbus 100, basic cycle time 512 ms
3-50 3BSE 002 414R601 Rev B

The basic cycle time for the DSP scan task is 512 ms (default value).
Add the basic link load = 0.4% (no sending/receiving).
Data Set and AI, AO, DI, DO with EXCOM
The load in an Advant Controller 410 caused by a communication with an external computer
using EXCOM is approximately the same irrespective of if the actual controller is a transit node
or a slave node in the communication. The computer is always master.
Reflect the following when you read the load data at different transmission rates (bus) given in
figures below.
• The load algorithm is quite complex and the straight lines in the figures are practical
approximations only.
• Limit values for maximum number of messages (with a given number of signals in the
message) is given.
• A limit value within parenthesis is estimated.
• You should consider the individual signals included in a data set package in the same way
as AI-, AO-, DI-, DO-signals.
• To minimize the CPU load and to get high communication through-put you should apply
several signals in each message.
A 2 signals / message
B 4 signals / message
C 8 signals / message
Load (%) (30) 43
B 61
1.5 C A
1.0
0.5
12 24 36 48 60 Messages / sec
Figure 3-17. Load Caused by EXCOM, 1200 bit per seconds
3BSE 002 414R601 Rev B 3-51

Load (%) 217 C 8 signals / message
A
5
3
109
2 B
1
C
(50)
50 100 150 200 250 Messages / sec
Load (%) 263 C 8 signals / message
A
7
4
139
3 B
(60)
2 C
50 100 150 200 250 300 Messages / sec
Performance - Reserve
This is a matter of the disposition of the total CPU load. A reserve of 15% to 20% is
recommended. See Section 3.1.15, CPU-optimization, Load Calculation.
3-52 3BSE 002 414R601 Rev B

3.2.1.2 Memory

System Software and Application Program
Read write memory RAM total 4 alt. 8 Mbyte
(Residing on processor module)
Battery Backup Time (after 20 h of recharging) min. 4 hours
(after ≥100 h of recharging) min. 8 hours
System Software Backup
Program card with flash PROM (PCMCIA)
Number of program cards (min. 1) max. n1 (n1 + n2 ≤4)
One program card is located in a dedicated slot in the Processor Module PM150.
Additional program card utilizes Program Card Interface MB510 and an ordinary
submodule slot.
Application Program Backup
Optional program card with flash PROM (PCMCIA).
Various memory sizes available.
Cannot be mixed with System Software Backup
in a single program card.
Number of program cards. max. n2 (n1 + n2 ≤4)
Memory card utilizes Program Card Interface MB510 and an ordinary submodule slot.
Memory Requirement
Empirical formulae are used to permit practical estimation of the memory requirement of the
different application functions. Please refer to Section 3.1.14, Memory Calculation. For detailed
information regarding the memory requirements of different PC elements, see the PC element
manual PC Elements Advant Controller 400 Series.
3.2.1.3 System Clock
General Technical Data of the System Clock

Inaccuracy expressed as drift in time max. 0.1 ms/s
(stand-alone system)
When a controller is included in a control network, the clock is
synchronized to a master clock, for example the clock in an operator station
or a dedicated controller.
The accuracy is then related to the master clock accuracy.
Relative error in time when synchronized via network max. 10 ms
You can synchronize one or several controllers via external minute
pulse signal. The aim is to synchronize to an accurate external clock
and, in the case of several controllers, to keep the relative error
in time low.
Relative error in time when synchronized
via external minute pulse signal max. 2 ms
3BSE 002 414R601 Rev B 3-53

Relative time error with time-tagged events, see Section 3.2.3, Process Interface.
The external synchronization input is, from an electrical viewpoint, compliant with PC
standards. For data, see Table 3-13 below.
Table 3-13. Clock Synchronization, Electrical Data for Minute Pulse
Data Value
Input signal “0” = -50 to + 2 V
(opto-coupled input type) “1” = +12 to + 60 V
Filter time constant ≤1 ms
Pulse length >10 ms
Triggers at positive flank
Battery Backup Time (after 20 h of recharging) min. 4 hours

(after ≥100 h of recharging) min. 8 hours
3.2.1.4 Free-Programmable Module

Number of modules PU535 no software limit
3.2.2 Power Supply

Current consumption is a complex matter when it comes to a flexible control system concept.
For rules for calculation of current consumption and dimensioning of distribution board fusing,
see Section 3.1.4, Power Supply.
A quick guide to power consumption to use in a very preliminary phase of work on a project or
anytime you need estimated figures for planning purposes follows.
Note that average figures are given. That means:
• Average equipped subrack
• Most common mixture of modules.
In other respects, such as technical data and so on, please refer to separate documentation:
Individual power supply units Data sheets included in Appendix A, Hardware Modules
Voltage regulator units S100 I/O Hardware, Reference Manual
Table 3-14. Estimated System Power Consumption
Power consumption
Controller with S100 I/O
cos ϕ >0.7 (at a.c.)
1 180 W
Power Supply Interruption

≤10 ms 1 Unaffected operation
>10 ms 1
Safety shutdown.
At battery supply, the Advant Controller is equipped with an energy reservoir to comply
with this specification.
1. The time limit is valid at lowest permitted supply voltage, 19.2 V, and maximum load (worst
case).
3-54 3BSE 002 414R601 Rev B


Event Handling
For each object type, there is a buffer in the controller for event bursts. These buffers have the
following capacity:
Table 3-15. Size of Buffer for Event Burst
Object type Buffer size

DI 200 events
AI 40 events
PIDCON 90 events
GENOBJ 70 events
MANSTN 30 events
RATIOSTN 30 events
SEQ 30 events
MOTCON, VALVECON, 350 events
GROUP, MMCX
If an event burst exceeds the capacity of a buffer, the “lost events” are marked in the data base
file and sent to the operator station with time marked “uncertain” when the load decreases.
These events will not be missing in the event and alarm lists if MasterBus 300 is used.
The maximum steady state rate is 2 events/sec.
Momentary event bursts with higher frequency are handled
as described above.
Relative time error with time-tagged events:
• Events handled within a controller utilizing S100 I/O
or S800 I/O with SOE functionality <2 ms
• Events handled within a controller utilizing S400 I/O 10-100 ms
(The event is time tagged when the signal arrives at the controller.
Time error depends on scanning selected.)
• Events handled within a subordinated autonomous
controller (for example Advant Controller 110) <1 ms
(Events locally time tagged.)
• Events handled within separate controllers
Advant Controller 450, Advant Controller 410,
Advant Controller 110 (not S400 I/O)
– With external time synch. 1 <4 ms
– No external time synch. <5 ms
1. “Minute pulse” connected to the actual controllers.
3BSE 002 414R601 Rev B 3-55

• For S800 I/O without SOE functionality, the relative time error between events
(DI signals) in one controller can be evaluated from the expression:
Relative time error = a + b + c
a = scan cycle time of the Fieldbus Communication Interface (5 - 100 ms)
b = Data Set Peripheral cycle time of Advant Fieldbus 100 (set by the user)
c = scan cycle time of the process data communication in Advant Controller 410
(set by the user, terminal SCANT)
• It is also possible to receive events from Advant Controller 70/110 using Advant
Fieldbus 100, or from Advant Controller 55/110 using RCOM/RCOM+. The relative time
error between events for different configurations are given in Table 3-16. A condition for
the table is that all events are connected to one Advant Controller 410/450.
Table 3-16. Relative Time Errors between Events (DI Signals)
Events generated by Relative time

Bus Advant error
Module/Calc. (ms)
Controller
Advant Fieldbus 100 110 DI650 <2
110 Calculated in AMPL <2 + Sct (1)
70 Calculated in AMPL <2 + Sct (1)
RCOM/RCOM+ 110 DI650 <50 (2)
110 Calculated in AMPL <50 + Sct (1) (2)
55 Calculated in AMPL <50 + Sct (1) (2)
(1) Sct means Scan cycle time of reading I/O signals in the Advant Controller 55, 70 or 110
(2) This value is valid for a fixed RCOM connection where there is a continuous clock synchronization over the
bus (at least once per minute). If dial-up phone lines are used the error is also dependent of the elapsed time
since the previous call (clock synchronization).
• Event received from via LONWORKS interface module CI572 from an INSUM Motor
Controller: approx. 100 ms.
The system clock accuracy, see Section 3.2.1.3, System Clock.
3-56 3BSE 002 414R601 Rev B

3.2.3.1 S100 I/O

Please note that you must consider practical limits when the data below is applied, for example:
• Space in the used cabinet
• CPU load
• Integrity aspects
• Availability aspects.
Table 3-17. Capacity S100 I/O
Data Value
No. of buses (bus extension) 0
No. of I/O subracks max. 1
No. of I/O boards in the subrack max. 15
No. of DI boards 15
DI signals (1) max. 2300
No. of DO boards 15
(1)
DO signals max .1489
No. of AI boards 15
(1) (2)
AI signals max. 910
No. of AO boards 15
(1)
AO signals max . 963
No. of other board types
DSAI 133 (3), DSAI 133A (3) 15
DSAX110, DSAX 110A 15
DSDP 150 15
DSDP 170 15
DSDC 111 (4) 15
DSDP 140A (4) (5) 15
(1) This total includes S100 I/O signals, S400 I/O signals and calculated
signals.
(2) When any combination of the following analog input boards is used, the
total number of analog input channels on these boards is limited to 400:
DSAI 146 with 31 channels.
DSAI 151 with 14 channels.
DSAI 155A with 14 channels.
(3) Only when DSAI 133 is used in redundant configuration. When used in
single configuration,
DSAI 133 is to be considered an analog input board.
(4) DSDC 111 and DSDP 140A occupy two I/O addresses.
(5) The maximum recommended number of DSDP 140A boards is 10.
3BSE 002 414R601 Rev B 3-57

3.2.3.2 S400 I/O

• Space aspects
• CPU load
Data Value
No. of buses max. 4
(1)
No. of I/O units per bus max. 16
(2)
No. of DI signals max. 2300
(2)
No. of DO signals max. 1489
(2)
No. of AI signals max. 910
(2)
No. of AO signals max. 963
(1) Including products like MasterPiece 51, TYRAK L, SAMI, etc.
(2) This total includes S100 I/O signals, S400 I/O signals, S800 I/O signals
and calculated signals of the category. The grand total of all kinds of
analog and digital signals may not exceed 2500.
3.2.3.3 S800 I/O

• Space aspects
• CPU load
Data Value
No. of AF100 buses max. 4
No. of I/O stations/bus max. 79/32 (1) (2)
No. of I/O modules per station max. 24
No. of cluster per station 8 (3)
No. of I/O modules per cluster 12 (3)
No. of DI signals (4) max. 2300
(4)
No. of DO signals max. 1489
(4)
No. of AI signals max. 910
3-58 3BSE 002 414R601 Rev B

Table 3-19. Capacity S800 I/O (Continued)
Data Value
(4)
No. of AO signals max. 963
No. of DP820 Pulse Counter channels ca. 1700 (5)
(1) 32 is valid for a twisted pair communication media within a segment.
(2) If other stations than S800 I/O stations are used on the same Advant Fieldbus 100, the
maximum number of S800 I/O stations must be reduced with corresponding number of stations.
(3) Note that the total number of I/O modules cannot exceed 24.
(4) This total includes S100 I/O signals, S400 I/O signals, S800 I/O signals and calculated signals.
(5) The practical limit depends on number of other PC-elements and there’s memory size. Se PC
Element Advant Controller 400 Series Reference manual.
3.2.4 Communication
Table 3-20. Provided Link Types, Capacity
Link type Number of instances

MasterBus 300 (executed in main CPU) max. 2 buses Tot. max. 2
MasterBus300E (executed in main CPU) max. 2 buses
Bus Extension to S100 I/O 1 internal link only
MasterFieldbus max. 4 buses
max. 16 units per bus
Advant Fieldbus 100 max. 4 buses Tot. max. 4
PROFIBUS - DP max. 4 buses
LONWORKS Network max. 4buses (1)
EXCOM max. 2 links
V.24/RS-232-C (application of basic physical layer) max. 1 printer,
(2)
max. 3 MasterView 320
RCOM max. 4 links Tot. max. 4
(3)
MVI (available protocol) max. 4 links
MVI (free-programmable facility) max. 4 links
GCOM max. 2 links
(1) Max number of CI572 communication modules is two.
(2) Please note that EXCOM, RCOM and MVI also utilize V.24/RS-232-C at the physical layer (electrical interface).
(3) RCOM and MVI (available protocol) use the same type of communication interface CI532Vxx or CI534Vxx.
MVI (free-programmable facility) uses communication interface CI535 and GCOM uses CI543.
CI532Vxx, CI534Vxx and CI535 have two physical channels each.
The following restrictions are valid:
- No. of CI532Vxx + CI534Vxx + CI535 + CI538 + CI543 ≤2.
- Max. number of physical channels is four (limit in software).
3BSE 002 414R601 Rev B 3-59


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 410, you can find information in
Section 3.2.4.1, Provided Link Types above. For further technical data such as load data,
performance, maximum lengths, and so on, for the different links, see separate documentation.
Data Set Peripheral (DSP) with Advant Fieldbus 100

A data set peripheral can hold 1 to 8 DAT values. Each DAT value represents 32 Boolean, or
1 integer (16 or 32 bit), or 1 real number.
Advant Controller 450 can accommodate max 4000 data set peripheral for communication on
Advant Fieldbus 100.
Data set peripherals are cyclically transmitted to their respective destinations, with a cycle time
selectable in the range 32 ms to 4096 ms.

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. The main key data are listed below.
Table 3-21. Key Data, Process Control
Key data Maximum number

I/O signals See Section 3.2.3,
Process Interface
PC programs 99
Levels in structure 9 (practical limit is 4-5)
Control modules for structuring and See Figure 3-20,
execution control Structuring Limits
3-60 3BSE 002 414R601 Rev B

Table 3-21. Key Data, Process Control (Continued)
Key data Maximum number

Functional Units and Group alarm:
SEQ 173
GENOBJ (GENUSD+GENBIN+GENCON) 528 (in total)
MOTCON+MOTCONI+VALVECON+
GROUP+MMCX 595 (in total)
PIDCON 234
MANSTN 420
RATIOSTN 330
GRPALARM 151
GRPMEMB 2978
Data transfer and Communication:
DAT 32000
TEXT 32000
PCPGM
max. 99 Max. deep is nine levels
(practically four to five)
Structuring element
max . 999
or
Structuring element Block/PC element
max. 999 max. 256
Note: Structuring/execution element CONTRM, SEQ, MASTER

Structuring/function element FUNCM, STEP, SLAVE
Figure 3-20. Structuring Limits
3BSE 002 414R601 Rev B 3-61

3.2.5.1 Logging
The following table shows the logging capacity of Advant Controller 410. Note, however,
that the CPU load and the RAM requirement must also be considered.
Table 3-22. Data Logging Capabilities
Aspect Limit/Value
Max. no. of logs 15
Max. no. of variables/log 127
Max. no. of storable values/variable 32767
(common to all variables in the log) (The free amount of RAM usually sets a
lower limit)
Log sampling intervals 1, 2, 3, 4, 5, 6, 10, 12, 15, 20, 30 s
(in discrete steps) 1, 2, 3, 4, 5, 6, 10, 12, 15, 20, 30, min
1, 2, 3, 4, 5, 6, 12, 24 h
1 week
3.2.6.1 Local Operator Station

The number of local operator stations MasterView 320 is limited to 3.
You can connect one MasterView 320 directly to the Processor Module PM150. No extra
hardware is needed.
3.2.6.2 Central Operator Station

The number of operator stations of the types Advant Station 500 Series and MasterView 800/1
is limited to 16.
3.2.6.3 Printer
You can connect one printer directly to the Processor Module PM150. No extra hardware is
needed.
3-62 3BSE 002 414R601 Rev B

You can use printers that satisfy the following requirements with Advant Controller 410.
Table 3-23. Printer Data which must be fulfilled
Data Value
Character code Standard 7 bits ASCII
Parity None
Number of stop bits 1
Data word length 8 bits
Type of interface RS-232-C
Baud rate 9600 bits/s
Protocol XON /XOFF
No. of characters per line 72
Printer speed 160 characters/s
Limit for Xoff / Busy Min. 226 bytes
Signals used and pinning in the communication port for RS-232-C on Processor Module PM150
are shown in Table 3-24.
Table 3-24. Printer Signals, RS-232-C
Pin Short Description

1 DCD Data Carrier Detect
2 RD Receive Data
3 TD Transmit Data
4 DTR Data Terminal Ready
5 GND Ground
6 DSR Data Set Ready
7 RTS Request To send
8 CTS Clear To Send
9 (RI) (Ring Indicator)
3BSE 002 414R601 Rev B 3-63

3.2.7 Availability
The reliability and availability of an Advant Controller 410 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.
3.2.8 Mechanics
General Technical Data
Measurements, weight and space required for a door or hinged frame - Appendix B, RM500
Cabinet - Data Sheet refers.
Electro Magnetic Compatibility, EMC

Advant Controller 410 meets the requirement specified in the EMC Directive 89/336/EEC and
in Low Voltage Directive 73/23/EEC provided appropriate cabinetry is used.
CE-marking can be obtained for all cabinet versions.
Compliance is verified by the application of the following standards:
EN 50081-2 EMC, Emission in industrial environment
EN 50082-2 EMC, Immunity in industrial environment
EN 60950, EN 61010-1, EN 60439-1 Electrical safety
The resistance to interference for equipment not CE-marked, sold outside the EU, is verified in
accordance with national and international standards for industrial equipment. Refer to
Environmental Immunity for ABB Advant OCS Products.
Subrack Dimensions
Most of the controller components are installed in an I/O subrack:
Table 3-25. S100 I/O Subrack Dimensions
Data Value
Width 19 inches (482.6 mm)
Depth 335 mm (13.2 inch.) (including DSSR 122)
345 mm (13.5 inch.) (including DSSR 170)
Height 347 mm (13.6 inch), 8 U (including cable duct)
3-64 3BSE 002 414R601 Rev B

Section 3.3 Application Start-up
Sub-
position
2 3 4
Position: 1 6 7..... .20 21
The subpositions within the processor module are the item designations
in the computer infrastructure. Position referred addressing is not used in S100 I/O.
Figure 3-21. S100 I/O Subrack, Slot Disposition
3.3 Application Start-up

Not applicable. See Chapter 2, Installation.
3.4 Tutorial
The aim of this section is to give those who are inexperienced in this area a short guide through
the different phases of a controller design project. There are methods and tools developed to
make such project work effective in a variety of aspects. No references are made to methods and
tools in this section because that is beyond the scope of this product manual.
Whenever possible, concrete references are made to suitable sections in this manual or to other
documentation. The novice reader will preferably read the Introduction (Chapter 1) and Section
3.1, Design Considerations in this manual completely before starting the design work.
3.4.1 Introduction to the Design

The realization of a control system is normally based on a range of different documents.
On the highest level, there are Plant Descriptions which give basic and general requirements
like:
• Function
• Operation
• Security
• Availability
• Maintenance.
3BSE 002 414R601 Rev B 3-65

Individual requirements on particular supporting processes like electric, instrument air, cooling,
and particular subplants and sections are given in the Plant Design Documents. Here you can
also find documents which are the basis of the control system design. Examples of such
documents commonly used are:
• Function Descriptions (detailed)
• P&I diagram
• Instrument lists
• Motor lists
• I/O lists
• Applicable standards (plant, domestic, international).
3.4.2 Design Procedures

The following four main stages can be identified in the control system design procedure:
• System Definition
Based on process control application analyses, a definition of the equipment required must
be made.
The system definition phase is supported by this manual, especially Chapter 1, which gives
an overall introduction from the functional and available resources viewpoints and, of
course, Section 3.1, Design Considerations. In addition, Section 3.2, Technical Data
Including Capacity & Performance gives some important information.
The Advant OCS Product Guide gives you an overview of the available product
alternatives and possible options. Not “every combination” is either practical or offered.
• Controller System Configuration
The controller system configuration is the practical work required to create the
infrastructure of the controller, that is, the computer resources to maintain the application
functions.
You can regard this phase, more or less, as an installation activity. See Section 2.4.2.4,
Controller System Configuration.
• Configuration/Application Building
This phase is, to a certain extent, supported by the same chapters as the system definition
phase. However, most information is available in separate reference documents as follows:
– Configuration and Programming
– PC Programming
– PC Elements
– DB Elements
– Functional Unit descriptions (adequate parts)
– Application Examples: Measuring, Feedback Control.
Please refer to Section 1.5 for further document information.
• Installation
This is not really a design procedure. However, during the design there are certain
installation considerations to take care of, for example the connection to the process. It is
mentioned here as a reminder.
3-66 3BSE 002 414R601 Rev B

Section 3.4.2 Design Procedures
3.4.2.1 System Definition

System definition in the actual context is a definition of the equipment required.
As a basis of the system definition, it is assumed that superior design stages have resulted in an
overall rough application-functional identification. It is further assumed that a scheme of the
functional distribution is available. Thus, a rough allocation of functions to different controllers
is available.
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.
– CPU performance
– Capacity requirements
– Dependability questions like Availability, Integrity
– Need for communication (Need for physical interface).
• Type of I/O system
Centralized or distributed location of I/O is normally determined at prior and superior
design stages reflecting such questions as Maintenance, Environment, Economy (cable
savings).
• I/O board assortment. Limitation in number of different types is often desirable.
• Physical interface to the process. Terminal blocks, Marshalling, Hazardous applications.
• Application of redundancy.
• Environmental questions. Special requirement of cabinetry.
• Mechanical design. Cabinet lay-out.
When the design work reaches this stage, the hardware and the system software for the
controller have been determined. Sufficient information should also be available to permit a
controller system configuration. The information should include a rough estimation of
application functions needed thus facilitating a dimensioning and disposition of the RAM.
3.4.2.2 Configuration/Application Building

The next step is to make a detailed function identification and to design the application program
based on AMPL. Finally, you implement the program.
To sum up, the main activities are:
• Circuit identification with respect to
– Standard type circuits (typical solutions)
– User-defined type circuits
– User-defined circuits
– User-defined PC element.
3BSE 002 414R601 Rev B 3-67

• Structuring
• Definition of functional interface to other system
• Execution control work-through
• Configuration/Implementation
This is mostly an interactive session using an engineering station.
Some of these activities, subactivities and other similar subjects of interest are dealt with below.
Naming
All global objects are identified (and accessed) by unique names which you define within an
application project. Certain objects are given default names by the system, which you can
change later. From the system’s point of view, the name structure is flat. However, since a name
is a visible ASCII string, you can implement any kind of structure in naming objects.
Names are introduced in a controller via data base elements representing the actual object.
In general, the designation (connection NAME) on the data base element must be unique in the
controller. Designations referred to from an operator station via a Control Network must also be
unique in the total process control system connected to that network.
When defining signals, it is important that the signals be given names which are well considered
and which will not have to be changed at some later stage.
With auto-generation of a PC-diagram, the signal names are printed in the diagram. This is the
reason for providing the signals with plain language names, even with a stand-alone controller.
The philosophy behind the naming of the signals is to also be applicable to calculated signals.
As an example, the values provided by two level transducers are averaged to give a calculated
signal. The physical signals are named LT 104A and LT 104B and the calculated signal is
named LT 104.
The designation philosophy for objects in the process control system must be established when
the signals are named. (Following relevant standards.) The designations should preferably be
hierarchic so that objects and signals are given associative names.
A feedback control loop for level control named LICA 104 (LICA = Level Indication Control
Alarm) is an example.
The PID controller object is assigned the name LICA 104 while the actual value (the feedback
signal) is suitably designated LT 104 (LT = Level Transmitter) and the controller output value
3-68 3BSE 002 414R601 Rev B

Section 3.4.2 Design Procedures
LV 104 (LV = Level Valve). These names are obtained from one of the standards for
designations in process industries, ISO 3511.
Advant Controller 410 Process
Feedback control loop LICA 104
LV 104 Control
valve
PID controller
LICA 104 AO LV 104
LT 104 Level
transmitter
AI LT 104
Figure 3-22. Example of Designations in a Feedback Control Loop
Type Circuits
Type circuit building is a very important aid in the configuration procedure. A type circuit is the
largest common collection of PC elements which occurs at several places in the application
program.
A type circuit can be, for example, a certain type of feedback control loop or a panel control unit
with push buttons and lamps. An advantage obtained by working with type circuits is that the
work in designing the application program is reduced.
Instead of designing X program parts, one part is designed and used X times at different places,
perhaps with the addition of a minor PC element for adaptation in certain cases.
When the function of a type circuit is thoroughly verified in one application, the commissioning
of the remainder is much simpler. Another advantage is that the operator’s functions based on
type circuits become standardized.
Application Building with AMPL

This phase is carefully supported by separate documentation as mentioned earlier. Some general
notes and rules regarding application building and structuring are also given in Section 3.1.7.1,
Application Building with AMPL, where the subject is dealt with from other vantage points.
3BSE 002 414R601 Rev B 3-69

Configuration/Implementation
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, AMPL
A recommended procedure is “cut” from that document:
1. Make a copy of the original user diskette. The original is supplied together with the
engineering station.
2. Activate those MasterBus 300, RCOM, GCOM and MultiVendor Interface that are to be
included in the system.
3. Dimension the data base.
4. Populate the data base.
5. Dump the data base.
6. Restart the controller for configuration and load the data base dump.
7. Dimension the space for the PC program.
8. Build the PC program. (In this context, the input of the program.)
9. Make a backup of the entire system.
NOTE
The command files that control the menu handling functions in the engineering
station are stored on the user diskette.
3.5 Application Procedures

For information on how to achieve an application function from a configuration viewpoint,
please see separate manuals. A summary of available documentation is given in Section 1.4,
Related Documentation.
3.6 Configuration/Application Building Menus

Please refer to the separate reference manual, AMPL Configuration Advant Controller 400
Series.
3-70 3BSE 002 414R601 Rev B

Section 4.1 Product Operation
Chapter 4 Runtime Operation
4.1 Product Operation
4.1.1 Working Modes

Advant Controller 410/450 has four working modes:
OPERATION, CONFIGURATION, STOPPED and OFFLINE.
The LED display on the processor module front indicates the working mode with the codes
P1, P2, -3 and -4, respectively.
P1, working mode OPERATION:
The processor module executes the application program. This is the normal status of an
Advant Controller. The system can then perform control tasks and control the process
outputs.
P2, working mode CONFIGURATION:
The processor module does not execute the application program.
You can configure the controller system and the application program.
-3, working mode STOPPED:
The processor module does not execute at all.
The main CPU performs self-tests to check some basic controller functions.
The process outputs have defined states (zero).
-4, working mode OFFLINE:
The processor module executes low-level fault-tracing commands only.
Usually performed by ABB personnel.
The process outputs have defined states (zero).
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.
4.1.2 Ordering Working Modes

You order working modes in either of the following ways:
• Use a start mode.
• Use Advant Station 100 Series ES commands.
Please see the following sections.
3BSE 002 414R601 Rev B 4-1

4.1.3 Start Modes

The Processor Module PM150 has a start mode selector with four positions:
AUTO
STOP
CLEAR
OFFLINE
Figure 4-1. Start Mode Selector
The controller reads and utilizes the start mode selector position at the following occasions:
• When you press the ENTER button on the processor module front.
• At power-up.
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.
STOP:
Go to working mode STOPPED.
CLEAR:
Cold start, that is clear RAM (controller system configuration and application program are
erased).
The controller goes to the working mode CONFIGURATION.
OFFLINE:
Go to the working mode OFFLINE.
4.1.4 Primary and Backup Processor Module

Not relevant in the Advant Controller 410.
4-2 3BSE 002 414R601 Rev B

Section 4.1.5 Relations between Start Modes and Working Modes
4.1.5 Relations between Start Modes and Working Modes

The relation between start modes and working modes is described in figures as follows:
• First power-up (the system has never been configured), see Figure 4-2.
• Power-up of controller which contains application, see Figure 4-3.
4.1.5.1 First Power-up
Starting-point: Uninitialized controller,

e.g., newly delivered controller, or controller without memory backup voltage.
Event : Power- up
AUTO
Start mode selector: STOP
CLEAR
OFFLINE
(Compulsory
setting)
Actions executed -Install system

by the controller SW
-Clear applic.
area
Resulting
working mode OPERATION CONFIG. STOPPED OFFLINE
P1 P2 -3 -4
Figure 4-2. First Power-up
3BSE 002 414R601 Rev B 4-3

4.1.5.2 Power-up and Initialization of Controller which Contains Application
Starting-point: Controller containing an application,

in working mode OPERATION or CONFIGURATION.
Event : --Power fail/power disconnection and subsequent power-up

--User presses ENTER button
AUTO
CLEAR
OFFLINE
Starting CON
point:
OP
Actions executed - Initialize and - Install system

by the controller start SW
application - Erase
application
Resulting
P1 P2 -3 -4
Figure 4-3. Power-up of Controller which Contains Application
4-4 3BSE 002 414R601 Rev B

Section 4.1.6 Relations between Engineering Station Commands and Working Modes
4.1.6 Relations between Engineering Station Commands and Working

Modes
The following AS 100ES commands order working mode transitions.
DICONFIG - Disable working mode CONFIGURATION:
Orders the controller from working mode CONFIGURATION to working mode
OPERATION.
See Figure 4-4.
ECONFIG - Enable working mode CONFIGURATION:
Orders the controller from working mode OPERATION to working mode
CONFIGURATION.
See Figure 4-5.
RECONFIG - Reconfigure the controller:
Clears the RAM, that is erases the whole application, and orders the controller to
working mode CONFIGURATION. (Also called COLD START.)
See Figure 4-6.
3BSE 002 414R601 Rev B 4-5

4.1.6.1 DICONFIG
Starting-point: Controller executing in working mode

CONFIGURATION
Event : User enters engineering station

command DICONFIG
(Compulsory
setting)
AUTO
CLEAR
OFFLINE
Actions executed Initialize and

by the controller start
application
Resulting
P1 P2 -3 -4
Figure 4-4. Working Mode Caused by DICONFIG
4-6 3BSE 002 414R601 Rev B

Section 4.1.6 Relations between Engineering Station Commands and Working Modes
4.1.6.2 ECONFIG

OPERATION

command ECONFIG
(Compulsory
setting)
AUTO
CLEAR
OFFLINE
Actions executed Stop

by the controller
application
Resulting
P1 P2 -3 -4
Figure 4-5. Working Mode Caused by ECONFIG
3BSE 002 414R601 Rev B 4-7

4.1.6.3 RECONFIG

CONFIGURATION

command RECONFIG
(Compulsory
setting)
AUTO
CLEAR
OFFLINE
Actions executed -Install

by the controller system SW
-Erase
application
Resulting
P1 P2 -3 -4
Figure 4-6. Working Mode Caused by RECONFIG
4-8 3BSE 002 414R601 Rev B

Section 4.1.7 Programmed Start
4.1.7 Programmed Start

In Advant Controller 410, 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. In the PC program, you can define how the process is to
start (by controlling the inputs on the execution units which control the process). Start module
and time limits and start method for the restart alternative are defined in the data base element.
For a detailed description of the start-up function, see the reference manual AMPL
See the overview of the start functions below.
Figure 4-7 is an overview of programmed start at power-fail - power-up.
Figure 4-8 describes programmed start at AUTO - ENTER (when you push the ENTER button
while the start mode selector on processor module front is in the AUTO position).
Figure 4-9 describes programmed start at DICONFIG.
3BSE 002 414R601 Rev B 4-9

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
setting)
AUTO
CLEAR
OFFLINE
Starting
point: CON S
OP
C
Actions executed - Install
by the controller Programmed start
system SW
- Erase
Initialize and application
start application
R A
Resulting
P1 P2 -3 -4
R Programmed start, option RESTART
A AUTO
C CLEAR
S STOP
Figure 4-7. Programmed Start at Power-fail - Power-up
4-10 3BSE 002 414R601 Rev B

Section 4.1.7 Programmed Start
Programmed Start at AUTO - ENTER

OPERATION
Event : User presses ENTER button

(Recommended
setting)
AUTO
CLEAR
OFFLINE
Actions executed Programmed start - Install

by the controller system SW
- Erase
Initialize and start application
application
A
Resulting
P1 P2 -3 -4
A Programmed start, option AUTO
Figure 4-8. Programmed Start at AUTO - ENTER
3BSE 002 414R601 Rev B 4-11

Programmed Start at DICONFIG

CONFIGURATION

command DICONFIG
(Conpulsory
setting)
AUTO
CLEAR
OFFLINE
Actions executed Programmed start

by the controller
Initialize and start
application
A
Resulting
P1 P2 -3 -4
A Programmed start, option AUTO
Figure 4-9. Programmed Start at DICONFIG
4-12 3BSE 002 414R601 Rev B

Section 4.1.8 System Program
4.1.8 System Program

You can divide the software in an Advant Controller 410 into system programs and application
programs (PC programs). The system program provides internal program functions and links
together the application program with the system hardware.
Figure 4-10 presents broadly the interrelation between application programs, system programs
and the hardware. The application programs are built up and edited with an engineering station
with the support of a special program in the Advant Controller.
The execution of the PC program modules in the application program is organized by the
interpreter which also handles certain program amendments, primarily those performed during
execution.
Process I/O data is exchanged with the data base via the software for process communication,
which works in turn directly with the S100 I/O boards and with the communication units on the
MasterFieldbus, Advant Fieldbus 100, and so on.
Pulse counting/frequency measurement, positioning, weighing, free-programmable board,
connection of thyristor converter with analog speed control and communication with
“intelligent” transducers are implemented as direct interaction between PC elements and the
different circuit boards. MasterView 320 mainly works with the data base but receives, for event
printout, information directly from PC elements.
Transverse communication on MasterBus 300 works with the data base and the communication
units. The programs for central operator stations (MasterView 800/1, Advant Station 500 Series,
and so on) work principally with the data base, but can also receive events and data from PC
programs and the process communication.
The printer function receives data directly from the PC element PRINT but can also receive
information from another node via the communication software.
Information Management Stations interact, via GCOM, with the data base and can also receive
data via Data Set. Trend data logs are transmitted cyclically from the controller.
EXCOM works with the data base and can exchange information with another node via,
for example MasterBus 300.
Long-distance communication RCOM and communication via MultiVendor Interface interact
with the data base and the communication units. The protocol from the communication named
above is implemented on the different boards.
3BSE 002 414R601 Rev B 4-13

4-14

CI531 MasterBus CI535/538 CI532Vxx
CI543 CI532V01
free-pr. CI534Vxx
RS-232-C 300 GCOM RCOM MVI
comm.
Printer MV 320
System
Program
EXCOM
Figure 4-10. Advant Controller 410 - Survey of Software System

Printer MV 320 Handlers
RS-232-C
Applic.
1 Program Data Set
comm.
Data Base
Engineering Dialog
Station Consol Pres.,TTD
comm. Data Area COS
for S100 I/O
PC program 2 3
DSA__
Process
Interpreter comm.
PC program DSD__
Master
PC element Fieldbus Master
execution Fieldbus
code Advant Advant CI570
Fieldbus Fieldbus
100 100
CI522A
3BSE 002 414R601 Rev B
LONWORKS
CI572
CI541V1
1 Events PROFIBUS-DP
DSXW 110 DSDP 140A DS__ PU535
2 Events, Alarm Misc. Free-prog. CI541V1
Weighing Positioning
3 Alarm Module
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. It is also
responsible for that part of the data exchange between the different program modules which is
not performed in the data base.
The kernel also organizes interrupts at regular intervals for the cyclic execution, for example,
from DI and communication boards and from the interval clock to activate, for example, the
interpreter.
Hardware
Memory Processor Calendar Interval Power Supply

68020 clock clock system
Kernel DI
Interrupt MB300
handling EXCOM
Start-up Etc.
MB 300, etc.
Process comm.
Interpreter
MB 300, etc.
Process comm.
Interpreter
Figure 4-11. Survey of Processor Module and Operating System
4.1.8.2 Process Communication

An Advant Controller 410 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. A PC program
normally utilizes the actual value of the signal.
3BSE 002 414R601 Rev B 4-15

Reading data in and out, between process and data base, is performed by the module for process
communication. For the most important types of input and output boards, this is performed in
accordance with the following:
DI:
Each digital input board (this applies to most types) monitors the channels for changes in
value. If there is any change, an interrupt signal is transmitted to the processor and the
kernel starts the program for reading in the new measured value for storage in the data
base.
Digital input boards can also be read cyclically. All channels on the board are then read
and the new values are stored in the data base.
AI:
Each channel on an analog input board is read cyclically. The cycle time, which can be set
individually, is stored in the data base. For temperature measurement boards (Pt100 and
thermocouple boards), the conversion is started cyclically. When the conversion is
completed, the board generates an interrupt. The inputs are handled so that the
measurement signal is filtered and converted to process-related units. The limits are
checked and then stored in the data base. The reading is normally performed synchronous
with the execution of PC modules with the same cycle time.
DO:
Each time an execution unit in a PC program is executed, the value at the output is stored
in the data base. If a change has occurred since the preceding execution, a read-out
program for read-out to the digital output board is started.
AO:
Analog outputs are processed in the same way as digital outputs. Process-related units
must first, however, be converted to digital values within the range of the D/A-convertor.
You can select either current or voltage with solder straps on the connection unit. In the
case of boards with expanded supervision (DSAX 110), the analog output value is read
back to permit a comparison with the database value.
4.1.8.3 Diagnostics for the System Program

When an engineering station is connected to an Advant Controller, you can analyze the reason
for the stoppage, the status of the internal communication channels, and so on. You can also use
the engineering station for fault-tracing in the application program. For a detailed description of
the different commands used for this purpose, see the reference manual AMPL Configuration
4.1.9 Application Program

You can divide the software in an Advant Controller 410 into system programs and application
programs. The application program is written in a high-level language AMPL. A user normally
only comes in contact with AMPL and definition of parameters for data base elements.
The application program consist of one or more PC programs and the data base.
4-16 3BSE 002 414R601 Rev B

Section 4.1.9 Application Program
4.1.9.1 Data Base

The data base in an Advant Controller 410 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.
The data base is used, above all, for process I/O and functional units and is handled as DB
elements.
The data base contains data for, for example, the following functions.
• Input and output boards:
– Analog input boards (AI)
For standard current and voltage signals.
For temperature measurement.
– Analog output boards (AO)
– Digital input boards (DI)
– Digital output boards (DO)
– Pulse counter boards.
• Parameters for MasterFieldbus, Advant Fieldbus100, MasterBus 300, printers, EXCOM
and GCOM.
• Data and text exchange between PC programs within an installation or between PC
programs in several installations.
• Description of the data to be transmitted on MasterBus 300 and to external computers via
EXCOM, RCOM and MultiVendor Interface.
• Data for displays on MasterView 320.
• Data for the different objects and functional units, which can be shown in a central
operator station (Advant Station 500 Series OS or MasterView 800/1).
– Sequences
– Process controllers
– Manual control stations
– Ratio stations
– General objects
– Motor-, valve- and group start object.
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
3BSE 002 414R601 Rev B 4-17

accordance with the requirement of different cycle times in the process. A PC program can
accordingly be divided into function modules and several execution units, which in turn consist
of PC elements.
Each execution unit can be given its own periodicity and its own execution conditions for
connection and disconnection.
PC elements are the smallest “building blocks” in a PC program. They are described in detail in
the manual PC Elements. As an example, Figure 4-12 shows the graphical symbol for the PC
element FUNG-1V, a function generator. The figure also gives a rough outline of the supporting
elements for the break-points of the desired function (curve).
Figure 4-13 shows the desired application function.
FUNG-1V
(C1)
1 X Y 10
REG-G 2 BAL ERR 11
3 BALREF BALREFO 12
4 XTAB
5 YTAB
REG-G
Figure 4-12. Example of PC Element: FUNG-1V
Y C1
Y K+1
Y
YK
Y2
Y1
X1 X2 XK X X K+1 X C1
Interpolation is performed in accordance with the equation below:
X – XK
Y = Y K + ------------------------- × ( Y K+1 + Y K )
XK+1 – X K
Figure 4-13. Example of Function Performed by FUNG-1V
4-18 3BSE 002 414R601 Rev B

Section 4.1.10 Execution
4.1.10 Execution
The execution is organized by the interpreter which, in accordance with the PC program, calls
the correct code for the PC element concerned from the library of PC elements.
4.1.10.1 Interpreter
The interpreter is a system program which organizes the execution of the different program
modules with the periodicity required. The interpreter also checks if any unit is blocked, if the
RESET of any unit is activated, etc. In an Advant Controller 410, there is a large difference
between the shortest and the longest possible cycle times.
Cycle times of 5 ms and 32 s can be used in one and the same system. Normally, with no
reconfiguration, the cycle times are between 10 ms and 2 s. An internal allocation of priorities is
therefore necessary. The system has three interpreters designated A, B and C.
A has the highest priority and C the lowest (see Figure 4-14 below).
The standard cycle times obtained are given in the figure. For a more detailed description of the
configuration of cycle times, see the manual Configuration and Programming.
Interpreter Interpreter Interpreter

A B C
10ms 20ms 40ms 50ms 100ms 200ms 250ms 500ms 1000ms 2000ms
Cycle time
Figure 4-14. Interpreters
The allocation of priorities to the interpreters means that the execution of PC elements with
cycle times associated with interpreter C can be interrupted for the execution of PC elements
with cycle times associated with the interpreters A and B. The execution of PC elements with
cycle times associated with interpreter B can, however, only be interrupted by the execution of
PC elements with cycle times associated with interpreter A. The execution of PC elements
which are associated with interpreter A cannot be interrupted by the execution of other PC
elements.
3BSE 002 414R601 Rev B 4-19

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.
To get close synchronization between I/O scanning and PC execution, a common
interpreter is used. See Section 4.1.10.7, Scanning of Process Inputs.
• The program codes of the PC element within the execution unit are executed.
• Data from the local data area is read out to the data base for the output variables which
store their values in the data base.
4.1.10.3 Sequence of Execution of Execution Units

In certain applications, the order in which execution units are executed is of interest. Assume
that a function is divided into execution units which exchange data with each other and that
these units have the same cycle time, see Figure 4-15.
It is also assumed that execution unit 1 is required to be executed before unit 2.
Execution unit 1 Execution unit 2
CONTRM CONTRM
50 ms 50 ms
Data
Figure 4-15. Function consisting of Two Execution Units
When the conditions for an execution unit are defined, it is possible, with the call parameter
“Place in the cycle table,” to specify a place number between 1 and 255. This place number
specifies the order in which the execution units are executed during the same cycle time.
If, in the example, the place number 1 is specified for the execution unit 1 and the place number
2 is specified for unit 2, the required function is obtained.
The different execution units may well belong to different PC programs, but they must all have
the same cycle time. For units with different cycle times, there is no defined sequence.
A required start sequence can, however, be obtained by controlling the start conditions for the
execution units included.
4-20 3BSE 002 414R601 Rev B

Section 4.1.10 Execution
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.
1
& 20
2
The AND function
Address to data
for input 1
Memory map
Address to data
for input 2
Address to data
for output 20
Figure 4-16. Order of Execution for PC Elements, AND Gate with two Inputs
The order of execution is:

• The interpreter reads function type, in this case AND, and selects the program code for the
function AND from the element library.
• Current values at the storage places pointed out by inputs 1 and 2 are read and the logical
AND-condition is formed with the help of the program code AND.
• The result is stored at the storage place specified for output 20.
The interpreter then resumes control and searches for the next PC element to be executed.
3BSE 002 414R601 Rev B 4-21

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.
In the following example, which is a printout from the command LTREE, the elements are
executed in accordance with the arrows. See Figure 4-17.
PC 1 PCPGM
.1 CONTRM
.1 FUNCM
.1 AND (2)
.2 OR (4)
.4 DIV
.3 ADD
.10 OR (4)
.3 FUNCM
.1 ADD (3)
.2 OR (4)
.3 AND (2)
Figure 4-17. Printout from the Command LTREE
Note that the item designations of the individual PC elements have no effect on the order of
execution. The PC element DIV with item designation PC1.1.1.4 is thus executed before the PC
element ADD, PC1.1.1.3.
4.1.10.6 Resetting Execution

Resetting or RESET-execution is performed when a RESET input on an execution unit is
activated. This means that all variables in the local data area adopt an original status which,
for most variables, is the zero value. With RESET-execution, the zero values are read-out to the
data base.
4-22 3BSE 002 414R601 Rev B

Section 4.1.11 Data Transport
4.1.10.7 Scanning of Process Inputs

All analog and digital process inputs are scanned cyclically with a periodicity which can be
selected with a parameter (SCANT) in the data base element. As an alternative, for S100 I/O,
you can select interrupt-controlled scanning of digital inputs by selecting the parameter SCANT
to INTERRUPT. You can select different values of SCANT in the range 10 ms to 600 s. See the
reference manual Data Base Element for available standard scanning times.
Inputs scanned at intervals of 10 ms - 2 s are scanned under the corresponding PC interpreter to
obtain close synchronization between scanning and PC execution. The synchronization
functions if the scanning time and the cycle time for the PC belong to the same interpreter.
There is no scanning if the PC program is not dimensioned. Scanning of inputs with the
standard times 5 - 600 s is not synchronized.
4.1.11 Data Transport
4.1.11.1 Reading-in Phase

Each execution of an execution unit begins with a reading-in phase. This means that all PC
elements in the execution unit have input data which is read on the same occasion. The weight
of associated data during the complete execution is illustrated with the example in Figure 4-18.
CONTRM
(50ms)
Digital input
board
.20
ON MOTOR ON
S
OFF
R
.21
MOTOR OFF
S
Figure 4-18. Example of Reading-in Phase
Assume that execution of element .20 is followed by an interrupt caused by the digital input
signal changing status from 1 to 0. When the execution is resumed with element .21, the signals
MOTOR ON and MOTOR OFF are active simultaneously. The system automatically introduces
a reading-in element (an “invisible” GET element) which reads the value of the input signals at
the beginning of the execution of the unit and stores them in the local data area to prevent such
faults.
3BSE 002 414R601 Rev B 4-23

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.
The following example illustrates the requirements for reading-out elements. Assume two
execution units with the cycle times 500 ms and 50 ms, respectively, see Figure 4-19.
Execution unit 1 Execution unit 2

CONTRM CONTRM
500 ms 50 ms
.11 .2
COMP
Limit Value > limit
ACT
.10 Analog
output
max
Value
Figure 4-19. Example, Reading-out Phase
A value is calculated in the execution unit with the cycle time 500 ms and a limit check is
performed on the calculated value. These values (VALUE and VALUE > LIMIT) are connected
to an execution unit with cycle time 50 ms where the logical signal VALUE > LIMIT controls
an analog output with a fixed value MAX or with the calculated signal VALUE. Assume that
when element .10 has been executed (but not .11), an interrupt signal with cycle time 50 ms is
received from the execution unit. The PC element in this unit works with the values of the
signals VALUE > LIMIT and VALUE, which are not associated with one another. To prevent
this, the system automatically introduces a reading-out element (an “invisible” PUT element).
The purpose of the reading-out element is to ensure that the output signals from an execution
unit only become legible for PC elements within other execution units when all PC elements
within the unit have been executed.
If output signals from an execution unit are to be stored in the data base, all data base points are
updated when all PC elements within the unit have been executed.
4-24 3BSE 002 414R601 Rev B

Section 4.1.11 Data Transport
4.1.11.3 Data Transport between Execution Units

Figure 4-20 shows how data is exchanged among different executing units.
PC 1
PCPGM
(20,1)
Control module executed PUT element for
under interpreter A .1 data to
data base
CONTRM
(40,2)
DB= G X P DB=
GET element for

data from
data base
Control module executed .2

under interpreter B
CONTRM
(100,4)
DB= G X P DB=
GET element for G

data from module
with higher priority P
PUT element for
data to modules
with higher priority
Control module executed

under interpreter C .3
CONTRM
(500,10)
DB= G X P DB=
G
GET element for G P
data from module
with higher priority
Figure 4-20. Data Transport
3BSE 002 414R601 Rev B 4-25

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.
• An output signal is created by a PC element with higher priority than the PC element
coupled to the output signals:
A GET element is created in the execution unit containing the receiving PC element.
• An output signal is created by a PC element with a lower priority than the PC element
coupled to the output signal:
A PUT element is created in the execution unit in which the output signal is created.
• An output signal is created by a PC element with the same priority as the PC element
coupled to the output signal:
No GET or PUT elements are created since PC elements cannot interrupt each other’s
execution.
4.1.12 Initialization of Process Communication

When the system is started, the fault-indicating red LEDs on the I/O boards illuminate. If the
system goes to the working mode CONFIGURATION, the LEDs remain active. If the mode
goes to OPERATION, the process communication starts and the following start sequence is
executed:
• Check and initialization of I/O boards.
– The internal functions on each board are checked. Analog input boards are tested by
reading-in and limit check of any reference channels.
– The parameters stored in the data base are read-out to the circuit boards.
– The fault indications extinguish if no fault is detected during the check and
initialization procedures. If, however, a fault is detected, the fault indication remains
active and an error message is sent to the programming unit connected. If the board
concerned is not defined by the user during the configuration phase, the board is not
processed and the error indication persists.
• Initialization of outputs.
– All of the outputs are deactivated in connection with the start. This is completely
controlled by the hardware.
– During the initialization procedure, a start value, stored in the data base, is issued to
the output concerned. Select either a fixed start value or the value of the signal in the
data base before the start.
4-26 3BSE 002 414R601 Rev B

Section 4.1.13 Diagnostics
4.1.13 Diagnostics
During system initialization as well as during operation, the system itself checks that the
hardware is serviceable. For a description, see Section 1.8.10 Availability and Security. In that
section, you can find information on diagnostics and process output behavior at faults and
interrupts.
4.2 Operating Overview

An Advant Controller 410 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.
Accordingly, operating instructions are spread out in this manual. See where the specific
activity is treated.
For general descriptions, see the beginning of this chapter. For concrete instructions, see
Chapter 2, Installation and Chapter 5, Maintenance.
4.3 Runtime Tutorial

See the reference made in Section 4.2, Operating Overview.
4.4 Operating Instructions

See the reference made in Section 4.2, Operating Overview.
4.5 Runtime Operation Menus

Runtime operation menus are not treated by this product documentation.
The Advant Controller 410 is maintained by an engineering station. For information in these
areas, see separate documentation attached to the actual engineering station.
3BSE 002 414R601 Rev B 4-27

4-28 3BSE 002 414R601 Rev B

Section 5.1 Preventive Maintenance
Chapter 5 Maintenance
5.1 Preventive Maintenance

This chapter describes routine maintenance, replacement and installation procedures necessary
to maintain the operation of an Advant Controller 410.

Always follow the instructions below when installing and operating an Advant Controller
system to minimize the risks of injury to personnel and damage to the equipment. Local
statutory regulations, to the degree that they are stricter than the following, take precedence.
5.1.1.1 Personnel and Process Safety
DANGER - CAUTION
Observe the following:
• Use only approved hoisting equipment when lifting cabinets. See lifting instructions
enclosed with the cabinet.
• Never switch on the voltage supply of the cabinet during installation work. However
replacement of modules in subracks can be done on line, that is while power supply is
switched on. Special instructions are given for the work with power supply units.
• Power supply units in a “live” system, that is while the mains supply is switched on, is to
be replaced by authorized service personnel only.
• Work with care when supply voltage is applied in the system. The voltage in the
cabinet can cause injury and can even kill a human being.
• Make sure that everyone working on the installation knows the location of the safety
switch and the mains power supply switch to the Advant Controller 410 equipment and
how to use it.
• When the subsections of the process are checked and a test run has been performed,
a responsible person is to check out interlocking chains, and so on.
• Inform all assembly personnel about test runs to be performed.
• Process technicians are to be present when testing and operating the process objects.
• Never press the system ENTER (initialization) if you do not know what happens in the
system with an initialization. The command RECONFIG is equivalent to an ENTER in the
CLEAR mode.
• Remember that the control system can be controlled from an engineering station connected
at another node via a MasterNet. For example it can be stopped, configured and started
remotely.
• Remember that an Advant Controller 410 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 410 by setting the START MODE selector in the STOP
position.
3BSE 002 414R601 Rev B 5-1

5.1.1.2 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.
• Use the grounded wristband installed in the cabinet when handling parts of the system.
• Handle the circuit boards carefully, particularly those which contain MOS components
which can be damaged by static electricity discharges. Note the warning label on the
circuit boards.
• Use, as far as possible, the grounded wristband when handling boards not stored in
envelopes of conductive plastic. This gives optimum protection against static electricity
discharges.
• Always store circuit boards in envelopes of conductive plastic when not installed in the
system rack.
• Always switch off the voltage before extracting a board which cannot be exchanged while
under voltage. Wait a sufficient time for the capacitors to discharge.
• Switch off voltage to the system and withdraw all boards at least 20 mm before electrical
welding is performed near the controller system.
• A warning label is fixed in the system to draw attention to possible damage by ESD
(Electro Static Discharge).
All elektronik är känslig All electronic devices are

för ESD (elektrostatisk sensitive to ESD (electro-
urladdning). För att und- static discharge) effect.
vika onödiga skador vid To avoid accidental dam-
hantering av kretskort ages while handling PC
rekommenderas använd- boards, it is recom-
ning av systemjordat mended to wear wrist
handledsband med in- strap earthed to the
byggt skyddsmotstånd chassis. Wrist strap has
samt antistatisk förva- to have built-in protective
ringspåse för korten. resistor. Antistatic bag
has to be used to store
and transport the PC
boards.
Figure 5-1. Warning Label regarding ESD
5-2 3BSE 002 414R601 Rev B

Section 5.1.2 Visual Inspection
5.1.2 Visual Inspection

Inspect the Advant Controller and I/O cabinets at regular intervals determined by environmental
factors such as vibration, high ambient temperatures, and so on.
5.1.3 Safety
Check that all screwed joints and connections within the cabinets are tightened effectively.
Ensure that wiring, circuit boards and other electrical components are undamaged.
Pay particular attention to overheating, damaged insulation or signs of wear.
5.1.4 Cleanliness
Remove dust and any other soil from the cabinet with a vacuum cleaner. Use a lint-free cloth,
dampened with methylated spirits, to remove stubborn dirt.
5.1.5 Air Filter

The cabinet RM500 contains no air filter.
5.1.6 Backup Batteries

Replace the rechargeable battery package mounted inside the controller cabinet on the right-
hand side after every three years of service.
Also replace it after each complete discharge (the memory contents are lost) which introduces
the risk of battery cell damage. See Section 5.4.10.6, Battery Exchange.
5.1.7 Forced Cooling

Fan units are normally not necessary in an Advant Controller 410 installation.
5.2 Hardware Indicators

Most of the replaceable hardware modules are equipped with LED indicators.
• A green LED indicating running.
• A red LED indicating fault.
Some modules provide additional yellow LEDs for increased maintainability, for example send
and receive information on communication modules. The general meaning of the LED
indicators can be found in the module descriptions, Appendix A, Hardware Modules. The fault
finding instructions included in this Chapter 5, Maintenance give further advice how to interpret
combinations of LED indications in different system configurations.
System halt codes are shown on the processor module character display.
You can find solid information along with the halt code/system message and fault finding
descriptions in Section 5.3, Error Messages and Section 5.4, Fault Finding and User Repair
below.
3BSE 002 414R601 Rev B 5-3

5.3 Error Messages

There are two kinds of error messages in an Advant Controller system:
• Halt codes
– on the character display on the processor module front
– more detailed information read from the memory by an engineering station.
• System messages
– accessible from an engineering station
– accessible from an operator station like Advant Station 500 Series.
5.3.1 Halt Codes

A system halt code is shown on the processor module character display but more information,
which can be read from the memory, can often be required. This method is based on the storage
of halt code and attached information, in special memory areas, by the built in diagnostics
before the system is stopped. The information can then be read by starting the system in
working mode OFFLINE.
Typical halt codes and corrective measures are listed in Appendix I, Halt Codes.
If this method does not function, the fault is probably caused by a serious CPU malfunction.
The fault must then be determined without the use of an engineering station.
5.3.1.1 Reading of Halt Codes

Detailed information attached a halt code can be read using the engineering station command
LSYSHI. Proceed as described in Section 5.3.2.1, Reading of System Messages.
5.3.2 System Messages

System messages are generated as soon as a malfunction is detected or there has been some
other important change of status in the controller. The messages are stored in a queue in the
controller memory.
Typical system messages and corrective measures are listed in Appendix J, System Messages.
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.
5-4 3BSE 002 414R601 Rev B

Section 5.4 Fault Finding and User Repair
5.3.2.1 Reading of System Messages

1. You notice that the Advant Controller has stopped the operation. The character display on
the processor module front shows a halt code (not in all situations).
2. Connect an engineering station (for example Advant Station 100 Series Engineering
Station) to the processor module service port.
If the engineering station is already connected to the processor module do the command
TSESS (terminate session).
3. Set the start mode selector on the processor module in position OFFLINE. Then depress
ENTER.
4. Set up the engineering station.
In the menu, choose:
a. Advant Controller 400
b. Post Mortem Analysis
If the engineering station prompts
! CONNECTED ERROR - CHECK CONNECTION WITH TARGET SYSTEM!
then depress in OFFLINE mode the ENTER button and try again.
5. Check that the printer is connected to the engineering station.
Enter the command HARDCOPY ON.
6. Enter the following commands one at a time and wait for the printout.
a. LSYSHI List system halt information
b. LTSL List task switch log
c. LSYSM ALL List system messages.
There are cases where it is impossible to connect the engineering station to the Advant
Controller, or impossible to use all commands. In such cases, contact ABB.
NOTE
A message is deleted from the message queue in the system as soon as it is
transmitted to the engineering station. It is important to log the information to a
printer.
5.4 Fault Finding and User Repair

In all situations when the controller has stopped you should carefully read and notes all
halt codes and system messages available before you proceed. See Section 5.3.2.1, Reading
of System Messages.
3BSE 002 414R601 Rev B 5-5

5.4.1 Introduction
Diagnostics are available in different forms for rapid localization of the source of the equipment
malfunction. Hardware error is usually corrected by replacing the faulty unit, which is returned
to ABB for repairs. The least replaceable unit is normally a circuit board or an apparatus like a
power supply unit.
Disturbances and system halt caused by software error are commonly solved by a manual
system restart. Sometimes you must load the application program, reinforcing the need for
actual backup copies. In such situations, it is strongly recommended that you take careful note
of all available stored error codes and system messages before an eventual program loading and
new initialization. Then contact ABB for further information.
External faults in process wiring and transducers can also affect the function of the controller.
However, this type of fault is not discussed in this manual.
Debugging of PC programs is described in the reference manual AMPL Configuration Advant
5.4.2 Diagnostics and Fault Announcement

Both hardware and software in an Advant Controller 410 are provided with supervision against
system fault. For a survey of the diagnostics, see Section 1.7.10.1, Diagnostics.
The following indicating facilities apply on different levels:
The Controller and I/O Cabinet

• LED indicators on circuit boards:
– Green LED, RUN, indicates normal function.
– Yellow LED indicates an active signal, for example, status of digital input (DI) or
digital output (DO).
– Red LED, FAULT, indicates malfunction.
• Character display on processor module front:
– Show working mode, error or halt code. See Section 5.3, Error Messages.
Plant Central Fault Annunciator

The Advant Controller 410 provides a collective run/alarm relay located in the Backup Power
Supply SB171. The relay contact which is normally closed, opens at system halt (processor
module halt). Use the contact function in any desired application function, for example, creating
audible alarm or interlocking of certain process objects in the event of a controller safety
shutdown.
5-6 3BSE 002 414R601 Rev B

Section 5.4.2 Diagnostics and Fault Announcement
Engineering Station
• Halt codes stored in a stopped system. Read with the command LSYSHI:
– Show error or halt code. See Section 5.3, Error Messages.
• System messages. Read with the command LSYSM ALL:
– Most information in coded form
– Give information about probable cause of malfunction.
See Section 5.3, Error Messages.
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.
• System messages:
– In plain language (edited mix for process operators).
It is possible to direct all messages intended for an engineering station and system
maintenance personnel also to an operator station. However, normally a limited
information flow in plain language is desirable.
– Give information about probable cause of malfunction.
See Section 5.4.2.1, System Status and Plain Language System Messages
• System status displays:
Showing fatal and non-fatal error in the total controller function and in individual
functions/units as well.
In many cases the system status function points out the faulty replaceable unit.
Please find information of such possibilities in Section 5.4.2.1, System Status and Plain
Language System Messages.
Process Control
Certain controller faults, for example those related to process I/O board channels, will probably
be detected indirectly when a control function goes wrong. For most I/O board types, there is
limited or no system diagnostics support on channel level.
A tank can indicate high level because of an error in the current output stage to a control valve.
An oil flow can indicate low value because of a lost measured value which in turn is caused by
an input amplifier fault, and so on.
To minimize the down-time, it is important in such cases that the operator have a good overview
and knowledge of the plant functions.
It is also essential that the control system design, in addition to the normal control functions,
include supervision of important process objects and their system inputs and outputs as well.
3BSE 002 414R601 Rev B 5-7

5.4.2.1 System Status and Plain Language System Messages

You need the following information to make use of the system status displays in a central
operator station when fault finding. The disposition is based on the displays. References for a
listed item to the controller data base and presumed faulty unit or further fault finding
instructions are given then. A reference should be seen as a “short cut” information for the
authorized maintenance personnel. The general safety regulations and principles for fault
finding and user repair must be fully clear before work starts.

The appearance in an Advant Station 500 Series operator station is shown. The lay-out of the
display is not identical in an MasterView 800/1 application. However the information can be
applied.
Controller Power Supply Controller 12 Subrack Fan Terminal

6 17
1 24 V supply A Processor module Controller fan Terminal 1
24 V supply B Terminal 2
2 Reg. redundancy 7 Program card 1.1 Terminal 3
Program card 1.2
Program card 1.3
Program card 1.4
9 Free pgm module 1 Printer
4 Batt. volt. Free pgm module 2 18 Printer 1
5 Backup Pow. Supp. Free pgm module 3
Free pgm module 4
Additional
External Comm.
F1 19 EXCom. 1
EXCom. 2
15
PCF1
16 PCF2
PCF3
PCF4
Figure 5-2. System Status Display, Advant Controller 400 applied to Advant Controller 410
5-8 3BSE 002 414R601 Rev B

Reference in Advant Controller 400 Display : 1

Presentation : 24 V supply A (or B) green Normal
red cr Fault - Lost redundancy
Function : Supervision of the 24 V power supply for the subrack containing the processor module.
(only relevant when two redundant branches A and B are installed).
Plain System Message
at fault : POW SUPP ST 24 V supply A/B faulty Net xx Nod yy
Actions at fault :
1. See Section 5.4.9.5, Check of Power Supply
Block Diagram : Hardware Software
24 V distribution DSSS 171
DSSR 170
24VA
5V System status OS
DB; AC410
Controller Power Supply
SB171 PM150
A 24VA_ERR
DIAGN. DIAGN. B
24 V supply A
24VB
24VA
Y/N

Presentation : Reg. redundancy green Normal - all regulators present and OK
red cr Fault - any regulator missing or erroneous
Function : Supervision of redundant 5V regulators in the subrack containing the processor module

at fault : POW SUPP ST Voltage Regulator faulty Net xx Nod yy
Actions at fault : 1. See Section 5.4.9.5,

5.4.9.5 Check ofCheck
PowerofSupply
Power Supply
Block Diagram :
Hardware Software
24 V distribution 3
DSSS 171 DSSR 170 2
24VA 1
5V
BB174
REGFAIL System status OS
24VB PM150 REGMISS DB; AC410
Controller Power Supply
REG_ERR
DIAGN. Reg. redundancy
Y/N REG
3BSE 002 414R601 Rev B 5-9


Presentation : Batt. volt. green Normal
red cr Fault
Function : Supervision of the battery charge and the battery condition

at fault : POW SUPP ST Backup Battery faulty Net xx Nod yy
Actions at fault : 1. Replace the Battery Unit SB 520
2. See Section 5.4.9.6, Check of Backup Power Supply

SB522
DB; AC410 System status OS

SB171
BATT_ERR
DIAGN. Batt. volt.
Y/N BPS

Presentation : Backup Pow. Supp. green Normal
red cr Fault
Function : Supervision of the backup power supply of RAM

at fault : POW SUPP ST Battery Charger faulty Net xx Nod yy
Actions at fault : 1. See 5.4.9.6 Check of Backup Power Supply
2. See Section 5.4.9.6, Check of Backup Power Supply

SB522

SB171
BPS_ERR
DIAGN. Backup Pow. Supp.
Y/N BPS
5-10 3BSE 002 414R601 Rev B


Presentation : Processor module L green filled Processor is OK
red cr Processor is erroneous
Function : Supervision of processor module.

This is a not very realistic error indication. In case of a processor module fault
the controller will be shut down and there will be no possibilities of fault
announcement on this level. However the network status display will indicate
lost communication with the actual node.

at fault : DEV ST Error in CPU Net xx Nod yy
Actions at fault : 1. See Section 5.4.9.7, Check of Processor Module
DB; PM150 System status OS

PM150
ERR
DIAGN. Processor module
Automatic
configured

Presentation : Program card green Normal
red cr Fault - wrong check sum or missing card
Function : Supervision of program card including system software (check sum)

at fault : PROGRAM CARD Memory error/Missing card/Wrong card <pos.> Net xx Nod yy
Actions at fault : 1. Install or replace program card (PCMCIA 2.0)
2. Replace processor module
PM150 DB; PM150 System status OS
⇒ Program
card
DIAGN.
ER R
Program card
Automatic
configured
3BSE 002 414R601 Rev B 5-11


Presentation : Free pgm module 1 green Normal
red cr Fault - Hardware or application program
Function : Supervision of free-programmable module PU535

at fault : MISC ST FPB board out of order A Net xx Nod yy
Actions at fault : 1. Replace PU535
2. Load application program

PM150
PC; FPM-COM
Use r
PU535 DIAGN. con nectio n
ERROR (in cl. d ata typ e conve rsion )
DIAGN.
System status OS
DB; PU535
ER R
Free pgm module 1
1/0 IMPL

Presentation : Controller fan green Normal
red cr Fault - all or any of three fans erroneous
Function : Supervision of fan unit in the subrack containing the controller (optional function)

at fault : Fan for CPU faulty Net xx Nod yy
Actions at fault : 1. Check function in cabinet
2. Check fuses in the fan unit
3. Check electrical signal
4. Replace fan unit
Block Diagram :
Hardware Software
BB174
Back plane
Fan Unit rear side PM150
Fault ⇒ 0 V FANOK FAN_ERR
DIAGN. Controller fan
X211.3
0V FAN
Y/N
5-12 3BSE 002 414R601 Rev B


Presentation : F1 or user defined text green Normal
red cr Fault
Function : Supervision of application defined function.

at fault : User defined error 1 Net xx Nod yy
Actions at fault : 1. Check application function in the cabinet

Application function DB; AC410 System status OS
SB171
X2
Fault ⇒ 0 V F1 1 F1_ERR
DIAGN. F1
0V 2 or user defined
F1
Y/N text
F1TEXT
‘text’

Presentation : PCF1 (PCF2.. PCF4) or user defined green Normal
text red cr Fault
Function : Supervision of function in application program (AMPL)

at fault : User defined error 1 Net xx Nod yy
Actions at fault : 1. Check application program
Block Diagram :
Software function only
DB; AC410 User
System status OS
PCF1 conn ection
Application PCF2 PCF 1_ERR

PCF1
program PCF3 PCF1 or user defined
Y/N text
PCF4 PCF 1TEXT
‘text’
3BSE 002 414R601 Rev B 5-13


Presentation : User defined name green Normal
For examole Terminal 1 (2..4) red cr Fault - Hardware or software
Function : Supervision of terminal MasterView 320 and its communication

at fault : RS 232 CI531 missing Net xx Nod yy
Actions at fault : 1. See the separate manual MasterView 320 User ’s Guide

DB; CI531
PM150
MasterView 320 CI531 Ńame´ NAME System status OS
DIAGN.
RS-232-C *)
DIAGN. Ńame´
1/0 IMPL
For example Terminal 1
*) N ot visible on
the element

For example Printer 1 red cr Fault - Hardware or software
Function : Supervision of printer and its communication

Actions at fault : 1. Check the communication link with respect to damage, loose connector, broken wire and so on.
2. Check the printer
3. Replace hardware modules; Modems, Printer, CI531 one at a time

DB; CI531
PM150
Printer CI531
Ńame´ NAME System status OS
DIAGN.
RS-232-C *)
DIAGN. Ńame´
IMPL
1/0 For example Printer 1
*) Not visible on
the element
5-14 3BSE 002 414R601 Rev B


E.g. EXCom. 1 red cr Fault - Hardware or software
Function : Supervision of the communication with an external computer

using V.24/RS-232-C and EXCOM protocol
Actions at fault : 1. Check the communication link with respect to damage, loose connector, broken wire etc.
2. Check the computer
3. Replace hardware modules; Modems, Computer, CI531 one at a time
4. See the separate manual EXCOM User’s Guide
DB; CI531
External PM150
computer CI531 System status OS
Ńame´ NAME
DIAGN.
RS-232-C *)
DIAGN. Ńame´
1/0 IMPL E.g. EXCom. 1
*) Not visible on
the element
DB; EXCOM
ERR
3BSE 002 414R601 Rev B 5-15

S100 I/O 1
Stat Act Name Stat Act Name Stat Act Name Stat Act Name
AI1 AO1 DI1 DO1
AI2 AO2
AI3
Figure 5-3. System Status Display, S100 I/O 1
Reference in S100 I/O 1 Display : 1 Stat (Status)

(default: DB item designation for red cr Fault - the board is erroneous
the board)
Act (Activated)
green The board is in service
yellow cr The board is out of service
Function : Status information for an S100 I/O board

at fault : PROC I/O ST XX Board error Net xx Nod yy
Actions at fault : 1. If stat indicates erroneous, the board should be replaced
See Section 5.4.10.1, Board and Subrack Mounted Unit Exchange
2. If the board is out of service, see respective data base item, terminal SERVICE
Block Diagram :
Hardware Software
DB; XX-board
XX board System status
Ńame´ NAME
Stat
ERR
D IAGN.
Ńame´
Oper. stn. Act
dialog 1/0 SERVICE
1/0 IMPL
5-16 3BSE 002 414R601 Rev B

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 1 Display : 1 Stat (Status)

(default: DB item designation for red cr Fault - the board is erroneous
the board)
Act (Activated)
green The board is in service
yellow cr The board is out of service
Function : Status information for an S100 I/O board

2. If the board is out of service, see respective data base item, terminal SERVICE
Block Diagram :
Hardware Software
DB; XX-board
XX board System status
Ńame´ NAME
Stat
ERR
D IAGN.
Ńame´
Oper. stn. Act
dialog 1/0 SERVICE
1/0 IMPL
3BSE 002 414R601 Rev B 5-17

S100 I/O Redundant Board
Board 1 Board 2
Stat Act Name
Stat Act
AXR1
AXR2
AXR3
Figure 5-5. System Status Display, S100 I/O Redundant board
Reference in S100 I/O Redundant Board Display : 1 Stat (Status)
Presentation : User defined name green filled Normal, the board is OK

(default DB: item designation for yellow empty The board is in warning status
the board) red cr Fault - the board is erroneous
Act (Activated)
green filled The board is in service and master
green empty The board is in service, but stand by
yellow cr board is out of service
Function : Status information for S100 I/O redundant boards

2. If the boards are out of service, see respective data base item, terminal SERVICE
Block Diagram :
Hardware Software
DB; AX Redundant
XX board 1 System status
Ńame´ NAME
Stat
ERR1
D IAGN.
Board 1
SERVICE Act
Operator 1/0
XX board 2 station
dialog ACT_BRD Ńame´
1/2 Stat
ERR2
D IAGN.
IMPL Board 2
1/0 Act
5-18 3BSE 002 414R601 Rev B

Advant Fieldbus 100
Stat 1 2 Bus Stn Name Type

1 0 AF100_1 CI522A
1 1 AC110_1 AC110
1
1 2 AC110_2 AC110
Figure 5-6. System Status Display, Fieldbus
Reference in Fieldbus Display: 1 2 (Status)
Presentation: DB item designation for the bus/unit green Normal

or a user defined unique name yellow cr Warning
red cr Fault - the bus/unit is erroneous
A / B (physical comm. media redundancy)
green The A/B branch is OK
red cr The A/B branch is erroneous
Function : Status information for an Advant Fieldbus 100 with connected stations
Plain System Messages

at fault : Fieldbus Fatal bus error bus no... Net xx Nod yy
Fieldbus No access to stn bus no... stn no... Net xx Nod yy
Actions at fault : 1. See the separate manual Advant Fieldbus 100 and Data Base Elements AC 400 Series
Block Diagram: Hardware Software

CI522A
DB; CI522A System status
DIAG_I
Ńame´ NAME (status)
ERR Bus 1
DIAGN.
DB item design.
ERR_I1/2
A or Name
IMPL B
1/0
XX Station DB; AF100S

Ńame´ NAME (status) Station 2
ERR
DIAGN. .
DB item design.
*) or Name
A
1/0 IMPL B
Incl. Advant Fieldbus 100 comm. HW
(modem, CI522A, SC5xx) *) not visible
in the element
3BSE 002 414R601 Rev B 5-19

Fieldbus PROFIBUS

1 0 PB1 CI541
1 1 PBS1 PBS
1
1 2 PBS2 PBS
Presentation: DB item designation for the bus/unit green Normal

or a user defined unique name red cr Warning
Function : Status information for an PROFIBUS-DP with connected stations

Actions at fault : 1. See the separate manual PROFIBUS-DP and Data Base Elements AC 400 Series
Block Diagram: Hardware Software

CI541
DB; CI541 System status
DIAG_I
ERR Bus 1
DIAGN.
DB item design.
ERR_I1/2 or Name
IMPL
1/0
XX Station DB; PBS1

ERR
DIAGN. .
DB item design.
or Name
1/0 IMPL
Incl. PROFIBUS comm. HW
(modem, CI541)
5-20 3BSE 002 414R601 Rev B

LONWORKS

5 100 LON1 CI572
1 1 LONDEV1 LONDEV
1
1 2 LONDEV2 LONDEV
3 4
2
Presentation : DB item designation for the LONWORKS green Normal

Network Device or a user unique name yellow cr Warning
3 Bus column shows LONWORKS SUBNET number
4 Stn column shows LONWORKS NODE number
Function : Status information for a LONCHAN with connected devices

Actions at fault : 1. See the separate manual Advant Interface to LONWORKS User’s Guide
and Data Base Elements AC 400 Series

CI572
DB; LONCHAN System status
DIAG
ERR Bus 1
DIAGN.
DB item design.
or Name
IMPL
1/0
LONWORKS Device DB; LONDEV1

ERR
.
DB item design.
or Name
1/0 IMPL
3BSE 002 414R601 Rev B 5-21

Advant Fieldbus 100 Bus Unit Display
Advant Fieldbus 100 Bus 1 Stn 2

Stat Act 1 2 Pos Subpos Name Type
3 1 AF100_2 CI522A
4 1 AF100_2 CI522A
Figure 5-9. System Status Display, Advant Fieldbus 100 Bus Unit
5-22 3BSE 002 414R601 Rev B

MasterFieldbus, Units & S400 I/O
Bus 1 Bus 2 Bus 3 Bus 4 Bus 5

A B Name
MF1
1
AX100
AX101
Figure 5-10. System Status Display, MasterFieldbus
Reference in MasterFieldbus Display : 1 2 (Status)
Presentation : DB item designation for the bus/unit green Normal

A / B (physical redundancy)
green The A/B branch is OK
red cr The A/B branch is erroneous
Function : Status information for a MasterFieldbus with connected S400 I/O units

at fault : MFb Status Bus controller error bus no... Net xx Nod yy
MFb Status Cable break bus no... node no... Net xx Nod yy
MFb Status Error in bus no...node no... Net xx Nod yy
Actions at fault : 1. See the separate manual MasterFieldbus and S400 I/O
Block Diagram :
Hardware Software
CI570 DB; CI570 System status

DIAG_I
ERR Bus 1
DIAGN.
DB item design.
ERR_I1/2
A or Name
XX unit B
DB; XX unit1)
(status) Station 2
ERR
DIAGN.
DB item design.
. A
ERRTYPE
B
Incl. MasterFieldbus comm. HW 1/0 IMPL
(modem, CI570, PM150)
1) Ex. of XX units: AX unit, DX unit
PX unit, CV unit
3BSE 002 414R601 Rev B 5-23

S800 I/O Station (non redundant FCI)

Status Act 1 2 Name Type A B Power Supply
AF100 OS_2 CI810 Text 1 Text 2

Redundant
Status Act Pos Name Type Status Act Bus Stn Pos
2 DI810_1 DI810
3 DI810_2 DI810
Figure 5-11. System Status Display, S800 I/O Station
Reference in S800 I/O Station status Display: 1 2 Status
Presentation: DB item designation for the green Normal

Station/Module yellow cr The Station/Module is in warning status
red cr Fault - the Station/Module is erroneous
1 / 2 (physical comm. media redundancy) Act (Activated)
green The 1/2 branch is OK green The Station/Module is activated
red cr The 1/2 branch is erroneous yellow The Station/Module is deactivated
green The Module is in OSP
Power Supply A/B (power supply redundancy) Text1/Text2 (physical comm. media redundancy)
green The A/B power supply is OK green The ”Text” is OK
red cr The A/B power supply is erroneous red cr The “Text” is erroneous
Function : Status information for a S800 I/O Station

at fault : Fieldbus Module error, bus no... stn no... pos no... Net xx Nod yy
Fieldbus Power supp A error bus no... stn no... Net xx Nod yy
Fieldbus Module warning bus no... stn no... pos no... Net xx Nod yy
Actions at fault : 1. See the separate manual S800 I/O User’s Guide
5-24 3BSE 002 414R601 Rev B

Block Diagram:
Hardware Software
CI810 DB; C I810 System status
Ńame´ N AME Status
ERR Station 1
DIAGN.
WARNING DB item design.
Act or Name
DIAG
A
SERVICE
B
EX_STAT1 Pow er Supply
. EX_T EXT1 A
EX_STAT2 B
EX_T EXT2
Text1
I/O Module DB; I/O Module 1) Text2
Ńame´ NAME 2
ERR
Status Module
DIAGN.
WARNING DB item design.
Act
DIAG or Name
SERVICE
1) Ex. of I/O Modules: AI820, AO810

D I821, DO820
3BSE 002 414R601 Rev B 5-25

S800 I/O Station (redundant FCI’s)

Status Act 1 2 Name Type A B Power Supply
AF100 OS_2 CI820 Text 1 Text 2
AF100 OS_2 CI820 Redundant
Status Act Pos Name Type Status Act Bus Stn Pos
2 DI810_1 DI810
3 DI810_2 DI810
Figure 5-12. System Status Display, S800 I/O Station
Reference in S800 I/O Station status Display: 1 2 Status
Presentation: DB item designation for the green Normal

Station/Module yellow cr The Station/Module is in warning status
red cr Fault - the Station/Module is erroneous
1 / 2 (physical comm. media redundancy) Act (Activated)
green The 1/2 branch is OK green The Station/Module is activated
red cr The 1/2 branch is erroneous yellow The Station/Module is deactivated
green The Module is in OSP
Power Supply A/B (power supply redundancy) Text1/Text2 (physical comm. media redundancy)
green The A/B power supply is OK green The ”Text” is OK
red cr The A/B power supply is erroneous red cr The “Text” is erroneous
Function : Status information for a S800 I/O Station

at fault : Fieldbus Module error, bus no... stn no... pos no... Net xx Nod yy
Fieldbus Power supp A error bus no... stn no... Net xx Nod yy
Fieldbus Module warning bus no... stn no... pos no... Net xx Nod yy
Actions at fault : 1. See the separate manual S800 I/O User’s Guide
5-26 3BSE 002 414R601 Rev B

Section 5.4.3 Fault Finding Principles
5.4.3 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. In the latter case, always check the following indications first,
if relevant:
• The cabinet has mains voltage connected
• All circuit boards are plugged in correctly
• All connections are made correctly
• All boards are jumpered correctly.
If these checks do not correct the malfunction, continue with the procedures described below.
Fault Finding Principles

You are notified of a fault in one or several ways, as described in Section 5.4.2, Diagnostics and
Fault Announcement.
Three main “gateways” to the source of failure can be distinguished. Figure 5-13 illustrates the
notification of faults and the principles for fault finding.
If a central operator station is available, you should especially watch for opportunities to point
out a faulty replaceable unit outgoing from a system message and information given in the
system status displays. See Section 5.4.2.1, System Status and Plain Language System
Messages. You can treat most fault finding then, in principle, as indicated under the heading
Typical Simple Scenario below.
In a more complicated situation, other measures are applicable.
See A Complex Scenario below.
The concept of FDS and LDS in Figure 5-13 represents different qualities of diagnostics
support:
FDS - Full Diagnostics Support
A faulty unit/function is pointed out.
LDS - Limited Diagnostics Support
A complex indication exists which warrants further manual fault finding.
With respect to the necessary outfit when fault finding and, to a certain degree, the need for
skilled personnel, there is a division in basic and advanced fault finding.
Basic fault finding with full diagnostics support is covered by this User’s Guide. Advanced fault
finding with limited diagnostics support is only briefly dealt with here.
Advanced fault finding presume practical knowledge in fault finding. Training courses are
arranged by Automation University Sweden Training Center.
3BSE 002 414R601 Rev B 5-27

I II III
Alarm Conclusion drawn from
process behavior
Cabinet
Announciation
System Status Display LEDs

Documentation (Halt code)
AdvaCommand
Presentation System Status
Description
(Separate
Documentation) Engineering
station
(- System messages
Indication - Faulty unit /function - Halt code)
description - Pointer to
advanced fault
Section 5.4.2.1, finding
FDS LDS Diagnostics 1) FDS LDS
Source of 1) Taken advantage of Source of

failure failure
Replacement Replacement
instructions instructions
Practical
Fault Finding Classification
Reference information
Advanced
Product fault finding 2) Covered by
methods 2) ABB Industrial
Automation Systems
University AB
Sweden
documentation Training courses
Source of
Failure
Replacement
Instructions
Figure 5-13. Fault Finding Principles
5-28 3BSE 002 414R601 Rev B

Section 5.4.3 Fault Finding Principles
Typical Simple Scenario

A typical simple scenario for a network connected controller follows.
1. 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.
2. One or several process alarms appear as a consequence.
3. The system status display for the actual controller (node) shows the status of the faulty
board.
4. In the controller or I/O cabinet, the board in question indicates red LED FAULT.
5. Replace the board on-line, that is when the controller is in full operation otherwise.
See the sections below for safety regulations and instructions on how to replace an I/O board.
Other replacement instructions, of course, apply in other situations.
A Complex Scenario
The system diagnostics does not always point out a replaceable unit. Fault finding must be done.
In, for example, a stand-alone system, the following may happen:
1. An audible alarm initialized by the run/alarm relay indicates controller shut-down.
2. If installed in any redundant system, process alarm and process shut-down indications
appear as a consequence.
3. In the controller cabinet, perhaps a complex indication exists. Different red LEDs lighten.
An halt code is shown on the processor module character display.
4. The fault is classified by you with respect to the indications. See Section 5.4.4, Fault
Classification.
5. Outgoing from the fault classification you will probably proceed with advanced fault
finding. Some hints and general fault finding procedures are given in the following
sections. However practical experiences from a training course is normally needed to get
to the source of failure.
6. When localized, the faulty module is replaced.
Common user repair is described in Section 5.4.10, User Repair.
7. For instructions for restarting a system after a fault is corrected, see
Section 5.4.16, System Restart, INIT.
A general rule when dealing with complex indications is:
A fault indication in a superior function makes indications in subordinated functions
mostly inapplicable.
For example, if the processor module indicates red FAULT, there is probably no relevance in
any red FAULT indications on communication modules.
3BSE 002 414R601 Rev B 5-29

5.4.4 Fault Classification

To guide in the advanced fault finding a rough fault classification is made outgoing from the
indications provided by the available diagnostics functions.
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:
A. Faults in the power supply system.
If there is no power supply redundancy, a serious supply failure will result in a controller
shut down.
These types of failures are distinguished from other failures, which also results in shut
down, by the lack of indications like voltage regulator LED 5 V and power distribution
unit LED LIVE (24 V). See further information in Section 5.4.9.5, Check of Power
Supply.
B. Faults which do not stop the system.
If the RUN LED indicator on processor module front is turned ON but not the HLT LED,
the system is probably still functional.
Look for red LEDs in the cabinet and try to define the limited part of the controller which
fail. Then see a suitable “Check...” instruction in this Chapter 5, Maintenance.
C. Faults which stop the system.
The red HLT indicator on the processor module front is turned ON to indicate that the
system has stopped.
It is probably meaningful to try a system restart. Especially if a software error is verified
by halt code or system message. See Section 5.4.16, System Restart, INIT.
Hardware faults also result in system halt (HLT). Section 5.4.9.9, Fault Finding by
Reducing the System gives adequate information.
D. Faults which give no indications by the built-in diagnostics.
Ask for support from ABB.
5.4.5 Test Equipment

The character display on the processor module front showing error codes and the indicating
LEDs on the specific hardware modules are normally sufficient aids when finding faults.
The following equipment simplifies the work and should be available:
Basic Fault Finding
• A Digital multimeter for calibration and test purposes.
• Test leads with 4 mm banana contacts and 2 mm reducer sockets.
• Specific documentation enclosed at delivery, drawings, and so on.
• Spare units and fuses. (The type and catalogue numbers for all units included in the
Advant Controller 410 delivery are given in the apparatus list.)
5-30 3BSE 002 414R601 Rev B

Section 5.4.6 Safety Regulations
Advanced Fault Finding

In addition:
• Advant Station 100 Series Engineering Station or Advant Station 500 Series Engineering
Station.

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. Local statutory regulations, to the degree that
they are more strict are to take precedence.
In connection to faults, fault finding and user repair there are some specific additional safety
regulations and aspects on safety. Please refer to:
• Section 5.4.7, On-line/Off-line Aspects
• Section 5.4.9.3, Safety at Start/Stop
• Notes in the “Check...” instructions and user repair instructions given.
5.4.7 On-line/Off-line Aspects

In connection to fault finding and user repair a primary decision has to be made whether the
work has to be carried out on-line (if relevant) or off-line or with the mains supply disconnected.
On-line means that all work is carried out while the controller is in full operation.
Off-line here means that the controller is shut down to a safe position, working mode
STOPPED. The mains supply is still switched on.
This is a question of system availability, possibility of fault finding, and safety.
If redundant functions are included then the system availability probably is given precedence.
Most modules located in subracks can be replaced on-line. However not all of them. See Section
5.4.10.1, Board and Subrack Mounted Unit Exchange.
Due to the risk of manual mistake in on-line handling and possible severe consequences to the
process controlled you are recommended to use this facility restrictively.
The most confident way of working is:
• The system is stopped during fault finding
• The mains voltage supply is switched off during unit replacement and when a new
function is installed.
Disconnection of the mains supply may have impact on dynamic information stored in the
application program. For example counter/register content, integrator content and so on. will be
lost if not secured by special considerations in the application program design. However this is
general design considerations. The controller should manage “normal” mains supply
interruptions.
3BSE 002 414R601 Rev B 5-31

5.4.8 Connection of Engineering Station

The engineering station communication cable can be plugged into the service port X27 on the
Processor Module PM150 front any time.
• First connect the communication cable
• Then switch on the power supply to the engineering tool.
Prepare for a session of programming Advant Controller 410.
Follow the instructions on the shield.
Work with the engineering station is supported by adequate documentation.
The detailed information of different configuration activities using an engineering tool is given
in the reference manual AMPL Configuration Advant Controller 400 Series.
If the actual Advant Controller 410 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.
5.4.9 List of General Fault Finding Procedures and Hints
5.4.9.1 Location of Malfunction

Sometimes you lack information from the controller diagnostics, telling you where the fault is
located. Suspicion about a fault is raised by the process behavior.
Experience indicates that approximately 85% of all faults occur in the process, 10% occur in the
control program and 5% in the control system hardware.
It is advisable for you to localize the malfunction with these figures in mind to minimize the
down-time.
5.4.9.2 External Factors

In an electronics system which has given satisfactory service, most malfunctions have external
causes. It is, therefore, important when you are tracing a fault to determine if any external factor
such as incorrect handling of the equipment, short circuits, welding work, lightning strike and/or
power failure has caused the malfunction.
5-32 3BSE 002 414R601 Rev B

Section 5.4.9 List of General Fault Finding Procedures and Hints
5.4.9.3 Safety at Start/Stop

The Advant Controller 410 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:
• In a control system with a monitoring character, changes in the process status are not
registered, but there is no immediate danger to the process.
• Control of continuous processes in, e.g., rolling mills and pulp and paper manufacture,
demands a high degree of continuity of the control system function.
An uncontrolled restart of the Advant Controller 410 can have very serious consequence.
DANGER - CAUTION
It is important to be aware of the local requirements for safety when starting
and stopping the Advant Controller 410.
5.4.9.4 Manual Changeover between Redundant Processor Modules

Not applicable in Advant Controller 410. The function “redundant processor modules” is not
implemented.
5.4.9.5 Check of Power Supply

The following instructions convey principles in fault finding and are supported by the power
supply block diagrams Figure 1-13 and Figure 1-14 in Chapter 1, Introduction. These figures
provide:
• Structure of apparatus used
• Presence and location of circuit breakers
• Presence and location of miniature circuit breakers (MCB’s) and fuses
• Test facilities (for voltage measuring)
• Indications to be used (LED’s).
Further details regarding connections, type of units used and so on can be found in the circuit
diagram attached the delivery.
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. mains supply (no redundancy)
• Redundant a.c. mains supply and redundant power supply regulators (total redundancy)
The general instructions also are valid for d.c. mains installations and partial redundancy.
3BSE 002 414R601 Rev B 5-33

a.c. Mains Supply

(no redundancy)
In a power supply system which includes no redundancy a serious power failure will result in
the controller total shut down. This also includes a loss of the entire I/O subrack functionality
with all the S100 I/O modules.
This situation is notified by:
• An operator station connected to this controller.
Indications obtained by:
– System message
– System status display (see Section 5.4.2.1, System Status and Plain Language System
Messages)
– Lost communication.
• Run/Alarm relay contact opens
• Process behaviour
• Green RUN LED on processor module PM150 is OFF
• All LED’s in the I/O subrack with the processor module are OFF. Besides that included in
the RAM backup power supply system. Thus:
– PM150, the LED BC will be ON.
General
Fault finding in the controller cabinet is carried out as follows.
Before replacing a power supply unit or a fuse or resetting a MCB try to check for a reason of
the fault. If deemed too time consuming, it is always possible to try the easy way and “look for
the smoke”.
Single a.c. Mains Supply - Fault Finding

Shut down of an I/O subrack with processor module is verified.
For guidance and measures to be taken, see Figure 5-14.
5-34 3BSE 002 414R601 Rev B

I/O subrack
(rear side) 24VF
Y
< 18 V
N
24 V
Fuse blown N See Figure 5-16
24V ok
Y
Replace fuse
Regulator 5V
5V Low
voltage
N Replace DSSR 122
=0V
Y See Section 5.4.10.4,
Replacement of 5 V Regulator
F1
Fuse blown N Replace DSSR 122
Y
See Section 5.4.10.4,
Replace fuse
Location of fuses and testpoints
Fuse 24 V Regulator 5 V
Terminal blocks DSSR 122
Test 24 V Fuse F1
for connection
of 24 V
0V 5V
Test 5 V
Fuse protected +24 V
to the backplane
Figure 5-14. Fault Finding, Single a.c. Mains Supply
3BSE 002 414R601 Rev B 5-35

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. That is the controller will
still be operational when a single failure exists. Diagnostics support is available. A detected
failure must be taken care of as soon as possible to regain redundancy. Normally a faulty unit
can be replaced on line.
This situation is notified by:
• An operator station connected to this controller.
Indications obtained by:
– System message
– System status display.
The faulty power supply branch A or B is pointed out.
Failure in the 5 V regulators is pointed out.
(see Section 5.4.2.1, System Status and Plain Language System Messages).
General
Fault finding in the controller cabinet is carried out as follows.
Before replacing a power supply unit or a fuse or resetting a MCB try to check for a reason of
the fault. If deemed too time consuming, it is always possible to try the easy way and “look for
the smoke”.
Redundant a.c. Mains Supply - Fault Finding
Disturbance in the I/O subrack power supply is verified.
First guidance and measures to be taken, see Figure 5-15.
I/O Subrack LEDs Diagnostic Check or replace
DSSS 171 DSSR 170

ALIVE
BLIVE
AFAIL
BFAIL
LIVE
FAIL
PBC
ON OFF ON OFF ON ON OFF Normal operation -----
ON OFF ON OFF ON OFF ON Regulator fault Replace actual DSSR 170 1)
OFF ON ON OFF ON ON OFF Supply branch A fault Check the fuses F501/F502
on I/O subrack DSRF 200
ON OFF OFF ON ON ON OFF Supply branch B fault (rear side)
1) See Section 5.4.10.4,

Figure 5-15. Fault Finding, Redundant a.c. Mains Supply
5-36 3BSE 002 414R601 Rev B

Mains Supply and 24 V Power Supply - General Fault Finding
24 V distribution (SX554) Test

> 19 V
LIVE
ON Replace 5 V Regulator
OFF
Mains supply A/B
U < min Y Take measures

N
Power switch (SX5xx)
MCB tripped Y Reset MCB

N
Power supply (SA 16x)

output Check for a disconnection
U < 19 V N in the 24 V power supply
distribution
Y
Fuse blown Y Reset/Replace fuses

N
Replace SA16x

Replacement of Power Supply Unit
Figure 5-16. Fault Finding, Mains Supply and 24 V Power Supply
3BSE 002 414R601 Rev B 5-37

5.4.9.6 Check of Backup Power Supply

The backup power supply and battery diagnostics are indicated in the system status display (see
Section 5.4.2.1, System Status and Plain Language System Messages) and by LED BC on the
Processor Module PM150 front.
Fault finding in the controller cabinet is carried out as described in Figure 5-17.
The instructions are supported by the power supply block diagrams Figure 1-13 and Figure 1-14
in Chapter 1, Introduction.
I/O Subrack LEDs Diagnostic Check or replace
SB171 PM150
CHARGE BC
ON ON Normal operation
OFF ON Discharging (Mains supply missing)

1. Check connections
OFF OFF Backup power supply fault
2. Replace Battery Unit SB5221)

3. Replace the Backup
Power Supply SB171 2)
1)
See Section 5.4.10.6, Battery Exchange
2)
See Section 5.4.10.5, Replacement of Backup Power Supply
Figure 5-17. Check of Backup Power Supply
5-38 3BSE 002 414R601 Rev B

5.4.9.7 Check of Processor Module

A description of the indicators on the module front is given to guide in the fault finding.
• Red LED F means module fault or a software error (not so likely). Replace the processor
module.
• Green LED RUN means module running normally.
The LED is turned off as a result of all kinds of system halts. If the green LED is turned off
read the system halt code on the character display and analyze the problem primarily as
described in Section 5.3, Error Messages. Take recommended measures. If not successful
you should methodically follow the fault finding instructions elsewhere in this chapter.
• Red LED HLT (HaLTed) means a serious fault. The controller has stopped. The system
halt information is probably missing or incomplete. The recommended actions are:
1. Restart the controller. See Section 5.4.15, System Restart following Maintenance
Activities.
If HLT still occurs it is possible to interpret new halt code information from the display
and continue with step 2.
2. Reload the software and restart. See example in Section 5.4.17, Loading of Application
Program.
If HLT still occurs continue with step 3.
3. Replace the processor module.
• Yellow LED TO (Time Out). Normally OFF. Sometimes it flashes under normal
conditions to indicate that an I/O board has been addressed but does not respond. A board
can be withdrawn for repair or a board can fail.
• Green LED BC means that the backup voltage for RAM is connected
• Yellow LED MIB is normally ON indicating that PM150 is current bus master on MIB.
This information is normally not relevant for the end user. However if this LED turns OFF
there is probably a serious fault in the processor module or in any of the communication
modules (submodules).
• Green DCOK indicate that 24 V d.c. supply is within range. This is a collective indication
for both supply branch A and B, if redundant branches are installed. I.e. individual branch
faults is indicated otherwise. See Section 5.4.9.5, Check of Power Supply.
• Yellow LED INHIB illuminates to indicate activation of the bus signal INHIB which is
used to prevent reading of data etc. from, for example, S100 I/O boards before data has
been stabilized. If this LED illuminates steadily, the system has stopped and there is no
execution of the program.
Read the system halt code on the character display and analyze the problem primarily as
described in Section 5.3, Error Messages. Take recommended measures. If not successful
you should methodically follow the fault finding instructions elsewhere in this chapter.
• The character display normally show the working mode of the controller (P1, P2 and so
on). See Chapter 4, Runtime Operation.
If anything else is presented, the system has probably stopped and the stop code can be
read from Section 5.3, Error Messages. This section also includes corrective actions.
CAUTION
Processor Module PM150 can not be replaced while power supply is
switched on.
See Section 5.4.10.1, Board and Subrack Mounted Unit Exchange.
3BSE 002 414R601 Rev B 5-39

5.4.9.8 Check of Process I/O

This section deals with the S100 I/O. Follow the instructions and make conclusions applicable.
The corresponding information for the S400 I/O and S800 I/O can be found in a separate user’s
guides MasterFieldbus and S400 I/O and S800 I/O User’s Guide respectively.
• Each I/O board has a red Fault indication LED. Replace a board with a LED which
indicate a fault. First read Section 5.4.10.1, Board and Subrack Mounted Unit Exchange.
• Check whether the circuit board is activated in the data base.
• If all I/O boards indicate fault check that the system is not in CONFIGURATION mode.
• The processor module PM150 is located in the I/O subrack. Special attention should be
made when replacing the processor module.
CAUTION
PM150 can not be replaced while power supply is switched on.
NOTE ALSO!
If the supply to a subrack is switched on before the PM150 is in place,
the process outputs in the subrack can set themselves in optional states!
• If the fault indicating LEDs on several I/O boards illuminate, follow instructions in
Section 5.4.9.9, Fault Finding by Reducing the System
• Check the process signal status.
The status of the digital signals (DSDI, DSDO) is indicated for each signal connection to
the process by a yellow LED. The values of analog signals can be measured at test points
on the front panel. Detailed information can be found in the manual S100 I/O Hardware.
• Check the power supply units for the actual I/O subrack. Check for blown fuses and other
reasons for voltage disconnection.
• Check fuses for process signals. Most connection units contain fuses. The coupling is
shown in the circuit diagram for the equipment delivered.
• Check signal levels on the connection unit screwed terminal. Use a digital voltmeter and
connect to the measurement terminal on the terminal blocks.
• Check the signal values in the data base in accordance with the instructions in the
reference manual AMPL Configuration Advant Controller 400 Series.
• Check the signal values in the PC diagram in accordance with the instructions in reference
manual AMPL Configuration Advant Controller 400 Series.
5-40 3BSE 002 414R601 Rev B

5.4.9.9 Fault Finding by Reducing the System

Another fast and commonly used method of fault finding, in more complex situations, when halt
code and system messages pointing out the faulty module are missing, is to reduce the system to
a minimum by withdrawing all boards except certain main boards and then returning them to
their places one by one until the fault recurs.
CAUTION
The Processor Module PM150 can not be treated that way while power
supply is switched on.
NOTE ALSO!
If the supply to the subrack is switched on before the PM150 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 5.4.10.1, Board and Subrack Mounted Unit Exchange.
The consequences to the process controlled must also be considered.
3BSE 002 414R601 Rev B 5-41

Proceed as follows:
1. Note the halt code on the processor module character display and the red LED indicators,
throughout the controller and its I/O, which illuminate
2. Perform a warm start that is an initialization with the start mode selector in position
AUTO. If not successful continue at step 3.
3. Reduce the system until only the following modules remain
– 5 V Regulator
– Backup Power Supply SB171
– Processor Module PM150
– Program card
4. Perform a new warm start. If the system does not start continue at step 5. If the system
starts the fault is probably in the communication or the I/O system. Continue as follows:
a. Expand the system by returning modules to their original location.
b. First add communication interface modules, then the S100 I/O boards, one at a time,
until the fault reappears
c. Replace the module in which the fault appears
d. Perform a warm start.
5. Perform a cold start i.e depress the ENTER button with the start mode selector in position
CLEAR. Please note that the program card with the system program must be in its
position.
If the system does not start continue at step 6. If the system starts the fault is probably in
the data base or the PC program. Continue at step 7.
6. Replace the processor module and the program card, one at a time, until the controller
starts in CLEAR mode. Perform a cold start after each replacement that is depress the
ENTER button with the start mode selector in position CLEAR.
7. Load in an available application program backup
8. Expand the system to full configuration.
5.4.10 User Repair
5.4.10.1 Board and Subrack Mounted Unit Exchange
General
In the following text, the word “board” also includes circuit board and rack mounted unit
(applicable). An example of such a unit is a voltage regulator or backup power supply.
It is important to understand the consequences of a board exchange on-line and how it affects
the current situation, for example:
• Replacement of an I/O board affects all channels on the board. It also sometimes indirectly
affects the outputs via an application function, for example a closed loop control.
• Replacement of a communication board type CI531 affects both channels on the board.
5-42 3BSE 002 414R601 Rev B

Section 5.4.10 User Repair
Before output boards (both analog and digital) are replaced, it is preferable to separate the
different outputs from the process, that is, open terminal switches on the connection units (or
take other adequate measures). In some applications, this is an absolute requirement for safety
reasons.
The system software in Advant Controller 410 checks automatically that all I/O boards function
correctly. In the event of board fault, and board exchange, the board and associated signals are
marked as faulty in the data base. While the fault marking persists, the value (VALUE) is not
updated in the data base.
The system software checks that the board is inserted and correct. If this is the case, the fault-
diode extinguishes (after 10 s), the fault marking in the data base is reset and the board resumes
its normal function.
Under the following headings, you can find general instructions for replacement of circuit
boards and information on the handling of individual circuit boards.
Practical Execution
Replace faulty or suspect circuit boards and units as described below.
1. Do not forget to read Section 5.4.6, Safety Regulations.
2. Look under the heading Additional Aspects of Individual Board Types, below, for other
useful information.
3. If necessery switch off the power supply to the Advant Controller. Then keep the start
mode switch on the front of the processor module in the AUTO position.
4. Provide access to the board by loosening the locking mechanisms:
– The bar in front of the boards in the I/O subrack.
– The screws in the handles (submodules on the processor module). First disconnect
all cables.
5. Grip the board firmly and extract the board quickly and decisively (I/O subrack).
Use both handles (submodules on the processor module).
6. Check that the new board can replace the old:
– Ensure that the eventual jumpering is the same as the old board.
See Table 5-1 and Table 5-2.
– Check for lowest revision approved variant to be used for the equipment and use
replacement of the same or higher revision number.
7. Insert the new board carefully without reaching the rear plane contacts. Ensure that the
board slides in the guides in the subrack or processor module (submodules) respectively.
8. Push in the new board/unit quickly and decisively.
9. Store extracted boards in envelopes of conductive plastic.
10. Ensure that the board contacts mate properly with the contacts in the rear plane.
Screw the locking bar in place (I/O subrack).
Fasten the screws in the handles (submodules).
3BSE 002 414R601 Rev B 5-43

11. Connect the cables (submodules).

12. Switch on the supply voltage if it is switched off. With the start mode selector in the
AUTO position, the system is automatically initialized and restarted.
13. Boards which can be replaced during operations are initialized automatically by the system
and the fault-indicating LED extinguishes automatically after approximately 10 s.
14. Perform a function test on the new board.
Additional Aspects of Individual Board Types

Table 5-1 lists controller hardware (applied in the controller subrack). For descriptions of these
board types, see the individual referrals given in the table.
Table 5-2 lists S100 I/O boards. They are described in S100 I/O Hardware Reference Manual.
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 User’s Guide
CI531 No jumpering - On-line replacement possible
- Described in:
Appendix A, Hardware Modules.
CI532V01 No jumpering - On-line replacement possible
- Described in:
RCOM AC 400 Series User’s Guide
- Described in:
MultiVendor Interface MODBUS with MS and
CI532V02
Advant Controller 400 Series
- Described in:
MultiVendor Interface Siemens 3964R
- Described in:
MultiVendor Interface MODBUS with
CI534V02 AC 400 Series User’s Guide
5-44 3BSE 002 414R601 Rev B

Table 5-1. Replacement Aspects of Individual Board Types (Controller Hardware) (Continued)

- Described in:
MultiVendor Interface Allen-Bradley DF1
- Described in:
Development Environment User’s Guide
- Described in:
Protocol Development Kit
CI541V1 No jumpering - On-line replacement is NOT possible
- Described in:
PROFIBUS-DP
CI543 No switches are used in the GCOM - On-line replacement possible
application - Described in:
MasterNet User’s Guide
CI547 Switches are used to: - On-line replacement possible
- Set node address - Described in:
- Select MB 300 or MB 300E MasterNet User’s Guide
- Set Slave number 1 - 2 for
S3 S1 S2

- Described in:
MasterFieldbus and S400 I/O User’s Guide
3BSE 002 414R601 Rev B 5-45


CI572 Switches are used to: - On-line replacement possible
- Set/reset bus termination - Described in:
(bus termination is the factory default) Advant Interface to LONWORKS User’s
Guide
S1
S2
CS513 Switches are used to: - On-line replacement possible

- Set node address - Described in:
- Select MB 300 or MB 300E MasterNet User’s Guide
- Set Slave number 7 - 8 for Advant
Controller 410
S3 S2 S1
MB510 No jumpering - On-line replacement possible

- Described in:
5-46 3BSE 002 414R601 Rev B


PM150 No jumpering CAUTION
- On line replacement not possible.
Before a Processor Module PM150 is
replaced, the mains supply to the Advant
Controller is to be switched off or the process
disconnected or switched off externally.
The supply may only be restored when the new
PM150 is installed. Important process objects
are then to be switched off externally or
disconnected to avoid damage.
When all of the red Fault LEDs on I/O boards
are extinguished, the process may be
reconnected and returned to operations in a
controlled manner, preferably in stages with
the inputs first and the most critical outputs
last.
Note! If the supply to the subrack is switched
on before the PM150 is in place, the process
outputs in the subrack can set themselves in
optional states.
- Described in:
PU535 No jumpering - On-line replacement possible
- Described in:
Free-programmable Module
Development Environment
SB522 No jumpering See Section 5.4.10.6, Battery Exchange
- Described in:
SB171 No jumpering - See Section 5.4.10.5, Replacement of
Backup Power Supply
- Described in:
3BSE 002 414R601 Rev B 5-47

Table 5-2. Replacement Aspects of Individual Board Types (S100 I/O)

DSAI 130 On-line replacement possible
S2 S1
DSAI 130A On-line replacement possible
S2 S1
S2 S1
S2 S1
5-48 3BSE 002 414R601 Rev B

Table 5-2. Replacement Aspects of Individual Board Types (S100 I/O) (Continued)

S4 S1
S2
S5
S3
S1
S4
X4
DSAO 110 On-line replacement possible

Note! In general, the electrical connections
S1
between output boards and the process is to
be broken before the board is extracted.
S401 S301 S201 S101 Alternative methods includes:
- Open terminal switches on the connection
unit
S402 S302 S202 S102
- Disconnect cable which joins the board and
W406W306W206 W106
the connection unit.

S10 S1 between output boards and the process is to
S20 be broken before the board is extracted.
S30
S40 S2 Alternative methods includes:
S50
S60 S80
S70
unit
3BSE 002 414R601 Rev B 5-49


DSAO 120A On-line replacement possible
S1
S2
S2
between output boards and the process is to
X5
Alternative methods includes:
unit

S1
S10 between output boards and the process is to
unit
S160 - Disconnect cable which joins the board and
DSAO 130A On-line replacement possible

S1
S1
X5 Alternative methods includes:
unit
DSAX 110 On-line replacement possible

S2
unit
5-50 3BSE 002 414R601 Rev B


DSAX 110A On-line replacement possible
S1
S1
unit
DSDC 111 On-line replacement possible
S1
S9
S8
S6 S10
S7
DSDI 110A On-line replacement possible
S1
S2
DSDI 110AV1 On-line replacement possible
S1
3BSE 002 414R601 Rev B 5-51


DSDI 120A On-line replacement possible
S1
S2
DSDI 120AV1 On-line replacement possible
S1
DSDO 115 On-line replacement possible

unit
the connection unit
- Switch off relevant field power supply.
DSDO 115A On-line replacement possible
S1
S1
unit
the connection unit
- Switch off relevant field power supply
5-52 3BSE 002 414R601 Rev B


DSDO 120A On-line replacement possible
unit
the connection unit
- Switch off relevant field power supply.
DSDP 140A On-line replacement possible
S1
R57
S4 R58
S2
S3
DSDP 150 On-line replacement possible
S104 S1
S110
X3
S109 S112
S10 S20
DSDP 170 On-line replacement possible
S9 S10 S1
S11
S12 S2
S13
S14
3BSE 002 414R601 Rev B 5-53

5.4.10.2 Replacement of Redundant Processor Module

Not applicable in Advant Controller 410.
5.4.10.3 Replacement of Power Supply Unit
DANGER
Power supply units should be replaced by authorized service personnel only.
The branch A or B which is to be repaired must be carefully defined.
The replacement instruction focuses on the unregulated power supply units SA16x (a.c.) and
DSSA 15x (d.c.). However the principles are valid for power switch and distribution unit
replacement as well.
Replacing a power supply unit shall always be carried out with highest safety possible.
Basically this means that voltage supply should always be switched off during repair and
installation work. Special provision is made for a system including redundancy where
replacement is urgently needed in a live system.
Before replacing a primary power supply unit, break its mains switch S1 in the power switch
unit (for the actual mains A or B). When the power supply unit is pluggable, unplug the power
cord. Where the power supply installation is fixed also switch off a safety breaker or remove the
actual fuse in the buildings mains installation before working in the power supply circuitry.
Off Line Replacement

1. 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.
2. Gain access to the connectors on the voltage supply unit.
3. Disconnect actual connectors (plugs or terminals).
4. Unscrew the screws which fasten the unit and remove unit from the frame.
5. Install new unit in the reverse order.
Reconnect all plug connectors (terminals).
6. Switch on the mains supply and test the unit function.
LED LIVE on the 24 V distribution unit (SX554) should light. A volt meter connected to
the test terminal on the distribution unit should read 19 V - 32 V.
On Line Replacement
1. Switch off the actual mains supply branch in the cabinet and wait until the capacitors in
the power supply units have discharged. When the power supply system is loaded,
the discharge takes 10 secs and when unloaded, 60 secs. Use the switch S1 on the actual
power switch unit.
2. Gain access to the connectors on the voltage supply unit.
5-54 3BSE 002 414R601 Rev B

3. Check with a volt meter that the voltage supply unit is “dead” on both the primary and
secondary sides. Any faulty voting diode can give a secondary “back” voltage.
4. Disconnect actual connectors (plugs or terminals).
5. Unscrew the screws which keep the unit in place and remove unit from the frame.
6. Install the new unit in the reverse order.
Reconnect all plug connectors (terminals).
7. Switch on the mains supply and test for the unit function.
LED LIVE on the 24 V distribution unit (SX554) should light. A volt meter connected to
the test terminal on the distribution unit should read 19 V - 32 V.
5.4.10.4 Replacement of 5 V Regulator

Different regulators are used for the different applications:
Unit(s) accessible from the rear side of the I/O subrack. See Figure 1-15 or Figure 1-16.
• Single regulator, DSSR 122
• Redundant regulators, 3 x DSSR 170.
DSSR 122
1. Switch off the mains supply.
Use the power switch S1 on the power switch unit.
2. Open the hinged frame to gain access to the unit and the connection terminals on the rear
side of the I/O subrack
3. Disconnect the 24 V supply lead at the screw terminal
4. Loosen the 5 V screw on the subrack 5 V terminal bar
5. Loosen the 0 V screw on the subrack 0 V terminal bar
6. Unscrew the screws which hold the regulator unit and remove it from the rack, lifting the
regulator upwards thus disengaging it from the 5 V, 0 V terminals
7. Check that the new unit can replace the old:
replacement of the same or higher revision number
8. Install new unit in the reverse order
9. Switch on the mains supply voltage. With the processor module start mode selector in
position AUTO the system will be automatically initialized and restarted.
10. Check 5 V (5.0 V - 5.25 V) on the test terminals using a volt meter.
DSSR 170
1. The replacement is made on line. That is with the mains supply on. The controller
operation is not disturbed.
2. Open the hinged frame to gain access to the unit on the rear side of the I/O subrack
3BSE 002 414R601 Rev B 5-55

3. Unscrew the two fixing screws and remove the regulator.

5. Install the new regulator. Tighten the fixing screws firmly.
6. Check the LED indications. F should be OFF while LIVE should be ON.
Notes on DSSR 170:
• When replacing a voltage regulator, the new regulator is to be placed in the same position
as that replaced.
• The upper fixing screw must be tightened to enable the 24 V/5 V conversion. If there is
any contact problem, adjust the position of the nut at the contact spring.
• The fuse in the regulator is readily accessible at the rear of regulator printed circuit board
when the regulator has been removed from the rack.
• The correct function of a regulator can be checked only by individual testing of the
regulator. (In a separate test rig or by removing redundant regulators one at a time).
5.4.10.5 Replacement of Backup Power Supply

On line replacement is possible of Backup Power Supply SB171.
However not during a mains supply interruption while the battery is used.
Unit accessible from the rear side of the I/O subrack. See Figure 1-14 or Figure 1-16.
Some system functionality provided by the backup power supply is essential to a safe controller
operation. This claim for a very short replacement time. Lost function during the absence of
backup power supply is:
• Backup supply voltage of RAM
• Supervision of the 24 V supply A/B for the controller subrack.
System messages is sent and spurious alarm indications is obtained in the node system
status display.
1. The replacement is made on line. That is with the mains supply on. The controller
operation will not be disturbed.
2. Disconnect the pluggable connector X1 first (24 V).
3. Unscrew the screws which hold the backup power supply and remove the unit from the
rack.
5. Install the new unit in the reverse order. End up with the connection of the 24 V supply
(X1).
6. Check the LED indicator CHARGE. It should be ON.
7. Store extracted unit in envelope of conductive plastic.
5-56 3BSE 002 414R601 Rev B

5.4.10.6 Battery Exchange

The battery should be replaced at any fault indicated by the diagnostics and regularly (see
Section 5.1.6, Backup Batteries).
1. The replacement of the Battery Unit SB522 is made on line. That is with the mains supply
on. The controller operation is not disturbed.
2. Disconnect the pluggable connector.
3. Unscrew the two fixing screws and remove the battery.
4. Install the new unit in the reverse order. Tighten the fixing screws firmly.
During the time of replacement LED CHARGE on the backup power supply will indicate OFF.
This is observed in the system status display in the operator station too.
NOTE
The battery includes cadmium and shall be treated as hazardous waste.
5.4.10.7 Replacement of Connection Unit
General
It is important to understand the consequences of a connection unit exchange on-line and how it
affects the current situation, for example:
Replacement of a connection unit affects all channels on the corresponding I/O board.
It also sometimes indirectly affects the outputs via some application function, for example
a closed loop control.
Practical Execution
Replace faulty or suspect connection units as described below:
1. See that process connections (signals and power supply) are disconnected before starting
the replacement work.
Determine where it is easiest to disconnect on a case-by-case basis because of the
differences in different applications. In some cases, you can disconnect the signals/power
supply at a cross-coupling, in other cases, at process transducers and at the location where
the power supply is distributed.
2. Disconnect the internal cable which joins the connection unit and corresponding circuit
board.
3. Label the leads so that they can be connected to the new unit correctly.
4. Disconnect the leads. Unscrew the fixing screws. Remove.
5. Install the new unit in the reverse order. Ensure that the screws make contact with the
tinned surface of the earth plane of the circuit board for effective grounding.
6. Test the function.
3BSE 002 414R601 Rev B 5-57

5.4.10.8 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. The power supply to the modem must be disconnected
locally.
Replace a faulty or suspect modem located in a modem subrack (RF 540/541) in the following
way:
1. Disconnect the power supply with the pluggable connection
2. Disconnect all other pluggable connections
3. Unscrew the fixing screws - Remove
4. Install the new unit in the reverse order
5. Test the function.
5.4.11 Adjustment of Analog Input and Output Boards

On delivery, the analog input boards are normally adjusted for voltage signals, for the current
output, analog outputs are normally adjusted with the ambient temperature 25°C and need
normally no adjustment.
The boards need adjustment at intervals, as in Table 5-3, because of component aging, if the
accuracy of the circuit is to be fully utilized. The same applies if the ambient temperature is
other than +25°C.
Table 5-3. Adjustment Interval for Analog Input and Output Boards
Board accuracy Adjustment interval

>12 bits One year
>11 bits Two years
>10 bits Three years
8 bits Five years
General instructions are provided in the adjustment instructions below. The detailed information
for individual circuit boards, for example, location of test terminals, location of potentiometers,
jumpering, function descriptions, and so on, is provided in the manual S100 I/O Hardware.
If the potentiometers are not accessible on the front, place the board on an extension board
DSFB 110. On the units which can be adjusted channel by channel, adjust the channels before
the A/D converter.
The following aids are required for the adjustments.
• A reference voltage supply unit, with adjustable output within the range 0 - 10.5 V and
with resolution 0.1 mV. The supply unit is not to have mains noise or hum in excess of
0.1 mV. If no supply unit is available, you can use a battery, a potentiometer and a digital
voltmeter with corresponding resolution.
• An adjustable voltage supply unit with rating 100 V.
• A digital voltmeter for the range 0 - 10.5 V with 0.1 mV resolution, accuracy exceeding
that required for the board by a wide margin.
5-58 3BSE 002 414R601 Rev B

Section 5.4.11 Adjustment of Analog Input and Output Boards
• An oscilloscope for checking mains noise and hum.

• Precision resistors:
– One of 500 ohm, 0.01%
– One of 300 ohm, 0.01%
– One of 100 ohm, 0.01%
• An Advant Station 100 Series Engineering Station or
Advant Station 500 Series Engineering Station.
• An extension board DSFB 110
• (A miniature soldering iron).
Adjustment Possibilities on Circuit Boards

Table 5-4 shows the adjustments possible on the various analog input and output boards.
Table 5-4. Adjustment Possibilities on Analog Circuit Boards
Type Channel adjustment Common adjustment Req. of DSFB 110 (1)

DSAI 110 -- Z,G --
(2)
DSAI 130 Z, B, G Z, G, S Yes
DSAI 130A The module is calibrated at production
DSAI 133 -- G, Automatic adjustment (3) Yes
DSAI 133A The module is calibrated at production
DSAI 146 -- G --
DSAI 155A Automatic adjustment Automatic adjustment --
DSAX 110 -- G, Automatic adjustment (3) Yes
DSAO 110 Z, G, V, L1, L2 -- Yes
DSAO 120 Z, G -- --
DSAO 120A The module is calibrated at production
DSAO 130 G -- Yes
DSAO 130A The module is calibrated at production
DSAX 110A The module is calibrated at production
DSTY 101 Z, G -- --
(1) If a potentiometer is not accessible from the front, place the board on an extension board DSFB 110.
(2) Symmetry (S), which is adjusted in a test during manufacture, has the same effect as Gain (G),
but only on positive values.
(3) DSAI 133 and DSAX 110 have automatically adjusted zero and automatically adjusted Gain caused by on board adjustable
voltage reference.
Key to the signs:

Z - Zero, G - Gain, B - Balance, S - Symmetry, V - Variable gain, L1/L2 - Limits
3BSE 002 414R601 Rev B 5-59

5.4.11.1 Channel Adjustment on DSAI 130

Channel adjustment consists of the following operations:
• Zero-point adjustment Z
• CMRR-balancing (Common Mode Rejection Ratio) B (= suppression of CMV).
Adjustment is not normally necessary except in exchange of components in this circuit.
• Full scale adjustment G.
Perform the adjustments in the order in which they are described (Z, B, G). If a certain
adjustment function is not available, the procedure is continued by setting the next parameter.
Potentiometers for adjusting the common section (A/D) are located on the lower part of the
front. The input voltage is measured at the test terminal X3. Make connections as shown in
Figure 5-18. Disconnect the process signal at the connection unit before the connections are
made.
DVM
Connection Circuit board X3 connector

unit at the front
X+
G1 U
X- OV
G2 CMV
Z B G
Figure 5-18. Connections for Channel by Channel Adjustment of DSAI 130
Adjustment of Zero Points, Channel by Channel

The zero points are adjusted, channel by channel, with G1=0.000 V, connected between the
input terminals X+ and X-, on the connection unit and with G2=0:
Adjust the signal U to 0.000 V with the channel potentiometer Z.
CMRR Adjustment, Channel by Channel

With G1 short circuited and G2=+100 V: Adjust the signal U to 0.000 V with the channel
potentiometer B. With the same connections, change G2 to -100 V and check that the signal
U=0.000 V.
5-60 3BSE 002 414R601 Rev B

Section 5.4.11 Adjustment of Analog Input and Output Boards
Full Scale Adjustment, Channel by Channel

With G1=Full scale value (FS; usually +10000 mV for voltage input and 20.000 mA over
250 ohm shunt resistor for current input), connected between the input terminals X+ and X- on
the connection unit, and with G2=0. Adjust the output signal U with the channel potentiometer
G to +10000 mV for voltage signal and +5000 mV for current signal.
Change, with the same connections G1 to -10000 mV (-20.000 mA) and check that the output
signal =-10000 mV (-5000 mV).
5.4.11.2 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)
• Adjustment of full scale value G
• Adjustment of symmetry S (only DSAI 130, normally unnecessary).
The adjustments are performed in the same order as given here (zero point, full scale value and
symmetry, if relevant).
Adjust AI units which are intended for voltage or current signals with the help of a voltage
reference. If all inputs are jumpered for current, and none are unused so that the solder jumper
can be clipped, you can use a voltage reference which can give at least 20.5 mA for a channel
jumpered for a current shunt.
In this case, set CONV_PAR on the data base element to -20..20 mA, 0..20 mA or
-5..5 V, and half the reference voltage is used instead of the values specified below as an internal
gain multiplied by 2 is used.
An input and corresponding data base element are selected for the adjustment. If an unused
input is selected, ensure that ACT is set to 1 and afterward reset to 0. Select a signal with
CONV_PAR=-10..10 V (exception in accordance with the above) or change CONV_PAR in the
data base element concerned.
Make the updating continuous by setting DEADB=-1 and FILTER_P=0 (note previous values
so that they can be reset after the adjustment).
The reference voltage for the adjustment is connected to the connection unit and the measured
value is read with an engineering station.
The potentiometers Z,G and S are located in the lower half of the front of the board.
Adjustment of the Zero Point on the A/D Converter
Adjust the reference voltage to the corresponding, a half step for the A/D converter:
DSAI 130 12 bits 1/2 bit = 1.25 mV
DSAI 133, DSAX 110 12 bits Automatic adjustment of zero
Adjust the potentiometer Z on the board front, reading the unscaled value in the data base at the
same time.
3BSE 002 414R601 Rev B 5-61

Use the command GETAB on the engineering station to read the unscaled value continuously:
GETAB
IV=AIX.Y:16 (Insert Value, AI= Analog Input, X = board number, Y = signal number,
16 is the property number of the unscaled value)
GVD (Get Value Dynamically)
Example:
IV=AI1.1:16
will show unscaled value of first input of first board.
The zero point is correctly adjusted when the value varies between zero and a value
corresponding to an increment for the A/D converter, 128 for DSAI 110 and 8 for DSAI 130.
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.
Adjust the potentiometer G while reading the value. The full-scale value (gain) is correctly
adjusted when the unscaled positive value is 32 000 ±8 (negative value 64 768 ±8) for 12-bit
boards and 32 000 ±128 (negative value 64 768 ±128) for 8-bit boards.
The Gain is automatically adjusted on DSAI 133 and DSAX 110 with help of an on board
voltage reference. However, this voltage reference may be adjusted if necessary with a
potentiometer, R9 on DSAI 133 and R14 on DSAX 110, in the same manner as above.
Adjustment of Symmetry (DSAI 130)
If the full-scale value (gain) is adjusted for negative voltage, you can adjust or check the
symmetry with the help of positive reference voltage. This is performed in the same way as for
full-scale adjustment but with positive voltage and with the potentiometer S.
Resetting - to Stop the GETAB-command
<SHIFT--BREAK> (to conclude the updating)
DV
END.
Adjustment for Boards DSAI 145/146 and DSAI 151

It is easiest to perform the adjustment of the Pt100 temperature board with accurate resistors as
references.
Select an input and corresponding data base element for the adjustment. If you select an unused
input, ensure that ACT is set to 1 and afterward reset to 0.
Select a signal with CONV_PAR=640°C or change CONV_PAR in the data base element
selected. Make the updating continuous by setting DEADB=-1 or 0 and FILTER_P = 0 (note
previous values so that they can be reinstated after the adjustment).
Connect a 100 ohm resistor ±0.01% (0°C. for Pt 100 transducer) to the selected input on the
connection unit.
5-62 3BSE 002 414R601 Rev B

Section 5.4.12 Channel Adjustment on AO Board
Note for DSAI 151: The board uses the same excitation current for a complete group of seven
transducers. If the current loop is broken, the measurement on all seven channels ceases and an
error message is sent. Avoid this by short-circuiting the input while the reference resistor is
connected.
Jumper all inputs not used.
Zero Point Adjustment
The Z potentiometer need not be field-adjusted since the software handling of DSAI 145/146
and DSAI 151 has automatic zero adjustment (which offsets any adjustment within 10 seconds).
If the Z potentiometer is not adjusted correctly, it is sufficient to set it to the middle of its range.
If, however, you find a setting where the Fault LED is lit (reference channel error), turn the
potentiometer away from this setting.
Adjustment of Full-Scale Value
Connect a 300 ohm resistor ±0.01% (which corresponds to 558°C for a Pt100 transducer).
Adjust the potentiometer G on the board front at the same time as the value in the data base is
read as it was previously. The full-scale value is adjusted correctly when the VALUE is 558°C.
(Read VALUE continuously using the subcommand GVD.)
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 when the reference resistor is
connected.
5.4.12 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. The same
applies to spares. The following channel setting can be of interest:
• Adjustment of the zero point Z
• Adjustment of gain G
• Adjustment of the variable gain V
• Setting of the limits L1, L2.
It is not certain that all circuit boards encountered in this connection have all of these adjustment
possibilities. Before the adjustment, jumper the circuit board for the mode (voltage, current) in
which it is to be used. The connection required is shown in Figure 5-19 and
Figure 5-20.
Execute the adjustments in the order in which they are described (Z, G, V, L1, L2).
3BSE 002 414R601 Rev B 5-63

The output signal is measured on the connection unit after the load is replaced with the
instrument in accordance with Figure 5-19 and Figure 5-20.
AC 410 SW Circuit board Connection unit

Voltage output
Data base AO ch
Register
VALUE and
D/A Conv.
U
DVM
Z G L1 L2
Figure 5-19. Adjustment of Voltage Output
AC 410 SW Circuit board Connection unit

Current output
Data base AO ch CR
Register
VALUE and DVM U
D/A conv. C
500 ohm
0.01%
Z G L1 L2
Figure 5-20. Adjustment of Current Output
5-64 3BSE 002 414R601 Rev B

Section 5.4.12 Channel Adjustment on AO Board
5.4.12.1 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.
Use an engineering station.
Use the command MDB to modify AO channel, for example:
MDB AO1.X <CR>
?
M10 <CR> (Modify property 10)
VALUE: 3.87 New value: 0 <CR>
End
X = channel number. The text underlined is presented by the engineering station.
Measure the voltage over the channel output on the connection unit and adjust the zero point
with the potentiometer Z until the instrument shows 0.000 V.
5.4.12.2 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>
?
M10 <CR> (Modify property 10)
VALUE: 2.19 New value: “RANGE MAX” <CR>
End
X = channel number. The text underlined is presented by the engineering station.
Adjust the gain with the potentiometer G until the instrument shows FS (Full scale).
All 8 outputs on DSAX 110 will be adjusted to full scale with the potentiometer R8 (output
voltage reference X3:3-4).
Table 5-5. Full Scale Voltages
FS “U” FS 10 mA FS 20 mA
Number of Bits
U mV U mV (500 ohm) U mV (500 ohm)
8 bit
10 bit 10 000 5 000 10 000
12 bit
3BSE 002 414R601 Rev B 5-65

5.4.12.3 Adjustment of Variable Gain, Channel by Channel

The variable gain is intended for special applications in which it is necessary for some reason to
adjust a signal within the complete range 0 - 100%.
Use the potentiometer V for the adjustment. If the variable gain is not used, screw out the
potentiometer completely so that it does not affect the measurement circuit.
5.4.12.4 Adjustment of “Limit Low” L1 and “Limit High” L2, Channel by Channel
Limit the signal with the potentiometers L1 and L2 to optional values between -100 % and
+100 %.
If the limiting function is not used, its potentiometers must be screwed out
completely to + and -.
5.4.13 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%).
5.4.14 Adjustment of Reference Voltage.

DSAI 133 and DSAX 110 have accurate internal reference voltage for self-calibration. You can
check this reference voltage and adjust as necessary with an accurate voltmeter as follows.
Measure at the test terminal X3 between pins 1 and 2 where 2 is to be at +10 V. The extension
board DSFB 110 is used for adjustment (trim potentiometer R9 for DSAI 133 and R14 for
DSAX 110 inputs and R8 for outputs at X3:3-4).
As an alternative, the board is moved to an accessible part of the I/O subrack.
5.4.15 System Restart following Maintenance Activities
Maintenance carried out On-line

If fault finding and module replacement has been made on-line the new module and its system
function will be automatically initialized and restarted within a few seconds.
Maintenance carried out Off-line

It is assumed that the controller has been manually stopped by the start mode selector set in
position STOP (followed by depressing of the ENTER button).
To get into the OPERATION mode perform as follows:
1. Reflect the consequences to the process by a restart of the controller
2. Set the start mode selector on the processor module in position AUTO
3. Depress the ENTER button
4. The controller will be in OPERATION mode within a few minutes. This is indicated by P1
on the processor module character display. If any start program in the application program,
the controller operation will restart accordingly.
5-66 3BSE 002 414R601 Rev B

Section 5.4.16 System Restart, INIT
Mains Supply has been Disconnected

It is assumed that the RAM backup has been available during the time of power supply
disconnection. To get into the OPERATION mode perform as follows:
1. Reflect the consequences to the process by a restart of the controller.
2. Check that the start mode selector on the processor module front is set in position AUTO
3. Check LED BC on the processor module. It should light indicating backup voltage for
RAM connected.
4. Switch on the mains supply.
5. The controller will be in OPERATION mode within a few minutes. This is indicated by P1
on the processor module character display. If any start program in the application program,
the controller operation will restart accordingly.
Cold Start
If for some reason the RAM content has been erased, or if severe software disturbances are
indicated, restoring of the system configuration and the application program is required.
A suitable backup must be available. The way of performing a loading of a backup depends on
the type of backup. See example and further information in Section 5.4.17, Loading of
Application Program.
5.4.16 System Restart, INIT

If the controller has stopped due to a software error it is always possible and most often
desirable to try a restart.
A processor module which has stopped indicate HLT and a certain halt code. This information
and, if any system messages available in the computer, disappears after a restart (or after they
have been read by any engineering tool!
1. Make a note of the halt code indicated on the processor module character display
2. If an engineering station is available and you have the time and knowledge proceed as
follow:
a. Set the mode selector on the processor module in position 4 (OFFLINE). Depress the
ENTER button.
b. Connect the engineering tool to the processor module in off-line symbolic mode.
A printer should be connected to the tool.
c. Use the commands LSYSHI (List SYStem HIstory), LSYSM ALL (List SYStem
Messages ALL), LTSL (List Task Switch Log) and list all messages.
d. The information from the listing is used in the continued contact with ABB.
e. Set the mode selector back to position 1 (AUTO.
3. Depress the ENTER button
4. If the initialization is successful, the controller will be in OPERATION mode within a few
minutes. This is indicated by P1 on the processor module character display.
5. If HALT again, other measures must be taken, see Section 5.4.17, Loading of Application
Program.
3BSE 002 414R601 Rev B 5-67

5.4.17 Loading of Application Program

Several methods of how to dump an application program and how to load the actual backup into
a controller are available. The possibilities and general descriptions can be found in a separate
reference manual AMPL Configuration Advant Controller 400 Series.
Knowledge in handling an engineering tool is necessary to apply general descriptions.
The maintenance organization of the plant is responsible for well developed and adapted
routines in this area.
Below one possible scenario is described to get an overview of the loading. You may see the
instruction directed to “the not so experienced maintenance personnel” which has to take care of
a program load in an emergency situation. The controller has stopped (the processor module
indicate HALT) and a simple system restart (see above section) has failed.
Of course the instructions are only valid under certain circumstances.
Important assumptions are:
• An DUAP application program dump is available on the engineering station hard disk
• The dump is performed in OPERATION mode. If not you must, after loading, make a
manual deblocking of each individual PC program. This simplified instruction does not
support that alternative.
• After the loading the controller will automatically get into OPERATION mode. Always
reflect the consequences to the process.
DANGER
Reflect the personnel and machine safety, see Section 5.4.6, Safety
Regulations.
• The identity of the dump and the net and node number of the controller must be known.
In the example of procedure below the name ABCD and net 11, node 12 are used. Please
observe that the dump usually consists of different segments designated for example:
ABCD0001.AD, ABCD0002.AD and so on.
Example of Procedure
Action Response
1. Set the start mode selector on the
Processor Module PM150 front in CLEAR
2. Check that the program card is in position.
The system software will be reloaded at the
cold start.
3. Depress the ENTER button The controller system configuration and the
application program are erased.
The processor module will indicate P2 after
about a minute.
4. Set the start mode selector in AUTO
Do not press the ENTER button!
5. Connect the communication cable between
the engineering station and the Processor
Module PM150, port X27.
5-68 3BSE 002 414R601 Rev B

Section 5.5 CPU Load Measurement
6. Switch on the power supply to the Successful Advant Station 100 Series ES
engineering station boot Windows start up.
7. If necessary start Application Builder Appropriate node found.
in AdvaBuild window to select project
and node.
8. Start On-line Builder from within the Booting engineering board
Application Builder or in AdvaBuild Press <Ctrl>, <Break>
window.
9. Press <Ctrl>, <Break> to activate the
engineering tool
10. Select 1 (Advant Controller 400) <CR>
11. Select 1 (Advant Controller 400 programming)
<CR>.
12. In the node Setup window confirm or Contact with target.
select the correct Target System. Identity presented.
13. Type LDIR SRCE:*.AD<CR>to In the example the following
check that your DUAP dump is available. ABCD0001.AD
ABCD0002.AD etc.
are listed.
14. Type LOAP <dump name>, SRCE <CR> The loading proceed. #
For example LOAP ABCD, SRCE<CR>
15. DICONFIG <CR> OK TO START UP THE TARGET, Y/N
16. Type Y <CR> After about one minute:
THE TARGET SYSTEM IS NOW IN
OPERATION MODE
The processor module will now indicate P1 (OPERATION mode) on the character display.
5.5 CPU Load Measurement

When the Advant Controller 410 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.
Use the ANPER (ANalyze PERformance) command to investigate the actual load. Using its
indications of the system load as a basis, you can adjust, for example, the chosen cycle times
and thereby optimize the use of the available performance.
The ANPER command is made up of a number of options. The first choice is between analysis
of the load of the entire Advant Controller (system load) or the load per system part (task load).
Please refer to the separate reference manual AMPL Configuration Advant Controller 400
Series for further information of the different commands and their possibilities.
3BSE 002 414R601 Rev B 5-69

5.6 Backup
5.6.1 Backup of System

After important changes in the application program a backup copy of the data base content and
the PC program should be made. Different methods using different dump/load commands exist.
A survey of the available facilities are given in Section 2.4.2.6, Dumping and Loading.
Otherwise you are referred to the separate reference manual AMPL Configuration Advant
Controller 400 Series which describe the practical work.
5.6.2 Backup of Application

If you want to store your application in a flash card (PCMCIA) on the Advant Controller 400
Series, you can use an Advant Station 130 Engineering Station which provide the following:
• AdvaBuild On-line Builder
• A flash card interface and corresponding software, CardTalk.
AdvaBuild On-line Builder supports the preparation of flash cards with application dumps,
DUAP. The AdvaBuild On-line Builder User’s Guide describes the different working
procedures in detail. Following is an overview.
Considerations
• The system program backup and the application program backup can not be mixed in one
single flash card.
• Flash cards are available in two memory sizes (currently), 4 Mbytes and 10 Mbytes.
Select a type that takes the actual application program.
• The flash card for application backup must first be formatted using the AdvaBuild On-line
Builder.
• The application program dump (DUAP) to be used should be taken while the controller is
in the operation mode (P1). This will ensure that no manual intervention is needed to get
into full operation after a shut down and an automatic restart.
Step-by-step Instruction
1. An application program dump (DUAP) for the actual controller is assumed to be available
in the engineering station.
2. Insert a suitable flash card in the desired PCMCIA slot of the engineering station.
(Two slot available.)
3. Select the On-line Builder menu for Flash Card | Write.
4. Select the desired DUAP.
5. Pushing the Enter button will start the creation of the backup flash card which is now
denoted an application program card.
6. Move the application program card to the Program Card Interface MB510 of the
controller.
The program card can be inserted on-line:
5-70 3BSE 002 414R601 Rev B

Section 5.7 System Upgrade
No configuration work needed.

The green LED on MB510 front will light.
A new item representing the added program card will be created automatically in the
system status display on the operator station.
Regarding appropriate hardware and software see Section 3.1.2.4, Backup of Application
Program.
7. The application program card is now ready for operation. However you are advised to
make a functional test of the backup in a non-critical situation. I.e. perform a cold start of
the controller when a possible shut down is accepted from a process control viewpoint.
Any checksum error of the original DUAP file will be detected in connection to the
downloading to the controller RAM.
Maintenance
During normal operation a program card is continuously supervised. The supervision is partly
based on checksum calculation. For the application backup the checksum is calculated in
connection to the program card insertion. (For the system software backup the checksum is
established during the system program generation, that is, part of the code.)
A red F LED on the MB510 module front indicates hardware error, checksum error or missing
program card. If the red F LED is turned on and if the application program card is removed and
after that reinstalled again and the red F LED turns off, then you must arrange for a functional
test of the backup. This should be performed in a non-critical situation.
In connection to the reinstallation of the hardware a new checksum calculation is made, possibly
hiding a memory error with respect to the original DUAP file. The same apply to any
replacement or later installation of an application backup program card. Always perform a
functional test for safety’s sake.
5.7 System Upgrade

How to change a program card including the system software to a variant with an other
assembly of program modules, i.e. an other functional assembly, is described in Section 2.6.5,
Enlargement of the System Software.
Revision of system software (system upgrade) is dealt with in the same way.
If you just want to see the content of program modules in your system, please read the label on
the program card. The card may be extracted and inserted during operation. System messages
will be sent to the operator station. Or preferably you can use the engineering station command
SHTARG (Show Target).
3BSE 002 414R601 Rev B 5-71

5-72 3BSE 002 414R601 Rev B

Section A.1 List of Hardware Modules
Appendix A Hardware Modules
A.1 List of Hardware Modules

By way of introduction, see below a complete list of all types of hardware modules related to
the Advant Controller 410. The list includes modules like circuit boards, power supply units and
connection units. They are listed in alphabetical order.
A reference is given telling you where to find a module description, including important
technical data:
Table A-1. List of Hardware Modules
Type Denomination Description

AI8xx Analog Input Modules S800 I/O User’s Guide
AO8xx Analog Input Modules S800 I/O User’s Guide
CI522A AF 100 Communication Interface Advant Fieldbus 100
CI531 RS-232-C Communication Interface, two channels Section A.2, CI531 - RS-232-C
Communication Interface
CI532V01 RCOM Communication Interface RCOM AC 400 Series User’s Guide
CI532V02 MODBUS Communication Interface MultiVendor Interface
MODBUS with MS and CI532V02
AC 400 Series
CI532V03 Siemens 3964R Communication Interface MultiVendor Interface
Siemens 3964R
CI534V02 MODBUS Communication Interface MultiVendor Interface
MODBUS with CI534V02
CI534V04 Allen-Bradley DF1 Communication Interface MultiVendor Interface
Allen-Bradley DF1
AC 400 Series
CI535 Free-programmable MVI Module MultiVendor Interface
(C language) Development Environment
CI538 Free-programmable MVI Module (C language) MultiVendor Interface
CI541V1 Communication Interface Module PROFIBUS-DP
AC 400 Series
CI543 GCOM MasterNet User’s Guide
3BSE 002 414R601 Rev B A-1

Table A-1. List of Hardware Modules (Continued)

CI570 MasterFieldbus Controller MasterFieldbus and S400 I/O User’s
Guide
CI572 Communication Interface Module Advant Interface to LONWORKS User’s
Guide
CI810A Advant Fieldbus 100 Communication Interface S800 I/O User’s Guide
CI820 Redundant Advant Fieldbus 100 Communication S800 I/O User’s Guide
Interface
CI830 PROFIBUS Fieldbus Communication Interface S800 I/O User’s Guide
CS513/CI547 MB 300, MB 300E, MasterNet User’s Guide
Communication Interface
DI8xx Digital Input Modules S800 I/O User’s Guide
DO8xx Digital Output Modules S800 I/O User’s Guide
DP8xx Pulse / Frequency Measuring Modules S800 I/O User’s Guide
DSAI 1xx Analog Input Boards S100 I/O Hardware Reference Manual
DSAO 1xx Analog Output Boards S100 I/O Hardware Reference Manual
DSAX 110 Analog Input Board S100 I/O Hardware Reference Manual
DSAX 452 Analog Input/Output Unit MasterFieldbus and S400 I/O User’s
Guide
DSDC 111 Motor Drive Control S100 I/O Hardware Reference Manual
DSDI 1xx Digital Input Boards S100 I/O Hardware Reference Manual
DSDI 4xx Digital Input Units MasterFieldbus and S400 I/O User’s
Guide
DSDO 1xx Digital Output Boards S100 I/O Hardware Reference Manual
DSDP 1xx Pulse/Frequency Measuring Boards S100 I/O Hardware Reference Manual
DSDX 4xx Digital Input/Output Units MasterFieldbus and S400 I/O User’s
Guide
DSRB 110 Dummy Board S100 I/O Hardware Reference Manual
DSRF 198 I/O Subrack with DSSR 122 S100 I/O Hardware Reference Manual
DSRF 199 I/O Subrack with DSSR 170 S100 I/O Hardware Reference Manual
DSSB 170 Energy Reservoir Section A.3, DSSB 170 - Energy
Reservoir
DSSR 122 Voltage regulator 5 V, for single supply S100 I/O Hardware Reference Manual
A-2 3BSE 002 414R601 Rev B


DSSR 170 Voltage regulator 5 V, for redundant supply S100 I/O Hardware Reference Manual
DSSS 171 Voting unit S100 I/O Hardware Reference Manual
DSTA xxx Connection Units, for analog signals S100 I/O Hardware Reference Manual
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 S100 I/O Hardware Reference Manual
DSTC 404 Terminator MasterFieldbus and S400 I/O User’s
Guide
DSTC 406 Terminator MasterFieldbus and S400 I/O User’s
Guide
DSTC 451 Over-voltage protection unit MasterFieldbus and S400 I/O User’s
Guide
DSTC 452 Coaxial Modem, for MasterFieldbus MasterFieldbus and S400 I/O User’s
Guide
DSTC 454 Optical Modem, for MasterFieldbus 2 Mbit/s MasterFieldbus and S400 I/O User’s
Guide
DSTC 454L Optical Modem, for MasterFieldbus 375 kbit/s MasterFieldbus and S400 I/O User’s
Guide
DSTD xxx Connection Units, for digital signals S100 I/O Hardware Reference Manual
DSTK xxx Internal cables S100 I/O Hardware Reference Manual
DSTX xxx Connection Units, for special applications S100 I/O Hardware Reference Manual
DSTY 101 Isolation Amplifier S100 I/O Hardware Reference Manual
DSXW 1xx Weighing Boards Weighing User’s Manual
MB510 Program Card Interface Section A.4, MB510 - Program Card
Interface
PM150V Processor Module Section A.5, PM150V - Processor
Module
PU535 Free-programmable Module (C language) Free-programmable Module
RB520 Dummy Module Section A.6, RB520 - Dummy Module
RE810 Wall Cabinet S800 I/O User’s Guide
RF540, RF541 Modem Subrack Section A.7, RF540, RF541 - Modem
Subrack
3BSE 002 414R601 Rev B A-3


RM500 Cabinet Appendix B, RM500 Cabinet - Data
Sheet
SA1xx Power Supply Units Section A.8, SA1xx - Power Supply
Units
SB171 Backup Power Supply Section A.9, SB171 - Backup Power
Supply
SB522 Battery Unit Section A.10, SB522 - Battery Unit
SD150 d.c./d.c. Converter Section A.11, SD150 - d.c./d.c.
Converter
SD81x Power Supply S800 I/O User’s Guide
SR122 Regulator 24 V/5 V (Single) S100 I/O Hardware Reference Manual
SR170 Regulator 24 V/5 V (Redundant applic.) S100 I/O Hardware Reference Manual
SV540, SV541 Power Distribution Unit Section A.12, Power Switch and
(with isolation transformer) Distribution Units
SV542, SV543 Power Distribution Unit Section A.12, Power Switch and
(with isolation transformer) Distribution Units
SX540 Power Switch and Distribution Unit Section A.12, Power Switch and
Distribution Units
SX541 Power Distribution Unit Section A.12, Power Switch and
Distribution Units
Distribution Units
Distribution Units
Distribution Units
Distribution Units
SX554 Distribution Unit 60 V d.c. Section A.13, SX554 - Distribution Unit
60 V d.c.
TB8xx Module Bus Modem S800 I/O User’s Guide
TB805, TB806 Cable Adapter S800 I/O User’s Guide
TB807 Terminator S800 I/O User’s Guide
A-4 3BSE 002 414R601 Rev B


TC501Vxxx Cable adapter S800 I/O User’s Guide
TC505 Connection Unit Advant Fieldbus 100 User’s Guide
TC512Vx Advant Fieldbus 100 Twisted Pair Modem. Advant Fieldbus 100 User’s Guide
TC513Vx Advant Fieldbus 100 Twisted Pair/Coaxial Modem Advant Fieldbus 100 User’s Guide
TC514Vx Advant Fieldbus 100 Twisted Pair/Optical Modem. Advant Fieldbus 100 User’s Guide
TC515Vx Advant Fieldbus 100 Twisted Pair/Twisted Pair Advant Fieldbus 100 User’s Guide
Modem.
TC516 Advant Fieldbus 100 Twisted Pair Modem for bus Advant Fieldbus 100 User’s Guide
redundancy
TC560Vx Optical Modem, for S100 I/O bus extension (Near S100 I/O Hardware Reference Manual
side)
TC561Vx Optical Modem, for S100 I/O bus extension S100 I/O Hardware Reference Manual
(Far side)
TC562 Modem for RS-232-C, 23 V Ref. Westermo Teleindustri AB
TC570 MasterFieldbus Connection Unit MasterFieldbus and S400 I/O User’s
Guide
TC625 Advant Fieldbus 100 Coaxial Modem Advant Fieldbus 100
TC630 Advant Fieldbus 100 Coaxial/Optical Modem Advant Fieldbus 100
TKxxx Cables Depending on application
(S100, S800, MasterNet, Advant
Fieldbus 100 and so on.)
TU8xx Module Terminator Unit S800 I/O User’s Guide
TX507 Capacitive decoupling device See Section 2.2.5.5, Grounding of
3BSE 002 414R601 Rev B A-5

A.2 CI531 - RS-232-C Communication Interface
Two RS-232-C communication interface

Modem support CI ABB
531
Description F R
CI531 is a submodule destined to the carrier modules SC510 and SC520 X4

in Advant Controller 450 and 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.
The communication channels support communication speeds up to 19.2 kbaud
which is the limit set by the system software.
Both channels run at this speed simultaneously. X5
The maximum communication distance without modem is 15 m.

The modem signals which are supported can be found in Table A-2 below.
Communication pins are short-circuit proof.
Front View
Technical Data
Indicators
LED R (green) on module front. Indicates module running normally.
LED F, Fault (red) on module front.
Jumpers
The board contains one jumper for special purposes.
In normal operation, always keep jumper S1 in position 3 - 4 (“parking place”).
The component and position indications are found on the printed circuit board.
Connectors
Serial channels 1 and 2 connectors (X4 and X5):
- Connector type Nine-pole male DSUB (DE9P)
- Placement On module front
- Pin designation See Table A-2 below.
A-6 3BSE 002 414R601 Rev B

Section A.2 CI531 - RS-232-C Communication Interface
Table A-2. Pin Designation for Channels 1 and 2. Connector X4 and X5

1 DCD Data Carrier Detect
2 RD Receive Data
3 TD Transmit Data
4 DTR Data Terminal Ready
5 GND Ground
6 DSR Data Set Ready
7 RTS Request To Send
8 CTS Clear To Send
9 RI Ring Indicator
Power Supply
5V typical 400 mA
max. 670 mA
24 V max. 40 mA
Power loss (heat) typical 3W
Mechanical Data
Module size: Occupying one submodule slot (H = 95 mm, L = 140 mm, connector not included)
Weight: 0.13 kg (0.29 lbs.)
3BSE 002 414R601 Rev B A-7

A.3 DSSB 170 - Energy Reservoir
• For use with 24 V direct d.c. supply

• Provides a backup time of about 5 ms at full load.
Description
The Energy Reservoir DSSB 170 is a capacitor unit intended for use with
24 V direct supply (without d.c./d.c. converter). In the event of mains
power failure, the unit provides the system with energy necessary for
storage of important data.
DSSB 170 is built up on a 19-inch apparatus plate.
The controller and the first I/O subrack require one energy reservoir.
Additional I/O subracks need a second unit.
The following description refers to the block diagram (next page).
The capacitor charging current is limited with a low-resistance power resistor.
The energy stored in the capacitors is discharged via a resistor when the unit is
disconnected from the mains power supply and the load.
Unregulated d.c. supply is connected at the terminals X1:1 - 4. The output
X2:1 - 4 supplies the 5 V regulator units with 24 V.
A serial diode prevents the energy stored in the unit from leaking back to the
supply mains in the event of a power failure.
465 (18”)
7 x 13 (x4)
X2
177 (7”) 101.5 (4”)

X1
37.5 (1.5”)
482 (19”)
20 (0.8”)
75 (3”)
All measurements in mm (in.)
A-8 3BSE 002 414R601 Rev B

Section A.3 DSSB 170 - Energy Reservoir
Technical Data
Table A-3. DSSB 170, Operating Data
Item Value
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
Mechanical Data
Width 482 mm (19”)
Height 177 mm (7”), 4 U
Depth 75 mm (3”)
Weight 2.8 kg (6.2 lbs.)
Block Diagram
DSSB 170
X1 X2
1 1
2 2
3 3
4 4
3BSE 002 414R601 Rev B A-9

A.4 MB510 - Program Card Interface
• Holds flash PROM of the type PCMCIA

• Submodule which fits into Submodule Carrier SC5xx or Processor Module PM150.
Description
Utilizing an MB510 is one method of program card installation in an
A program card is equipped with flash PROM for different use. For example
to store and backup the system program of the controller.
An optional use is to store and backup the application program (separate program card).
The flash PROM content is loaded into the processor module RAM
during the primary initialization of the controller.
The diagnostics are mainly based on cyclic checksum calculation.
A red LED on the module front indicates hardware error, checksum error or
missing program card.
MB ABB
510
F RUN
Eject button
Arrow to indicate
top of program card
Front view
A-10 3BSE 002 414R601 Rev B

Section A.4 MB510 - Program Card Interface
Technical Data
Indicators
LEDs on module front:
F (red) Module error
RUN (green) Module running normally
Power Supply
5 V d.c. typical 10 mA
max 170 mA (when reading)
Power loss (heat) typical 0.05 W
Mechanical Data
Module size: occupying one submodule slot
Module weight 0.12 kg (0.26 lbs.)
Block Diagram
MB510
Interface logic
Fault Control
Run
Control
Contact to
Contact carrier module
Program card Buffers

PCMCIA 2.0 Address Address
Data Data
3BSE 002 414R601 Rev B A-11

A.5 PM150V - Processor Module
• 25 MHz 68020 Processor

• 4 or 8 Mbyte Dynamic RAM with ECC
• Interface to up to four submodules on module front
• Two RS-232-C interfaces control
1 5 F
• One slot for PCMCIA program card on front RUN
• Service tool interface on front DCOK HLT TO

INHIB MIB
• Boot PROM and SRAM BC
Description
1=AUTO
PM150V is a processor module for Advant Controller 410. X27 X17 2=STOP
SERVICE COM1 3=CLEAR
It is designed to fit into DSRF 198/199 S100 I/O subracks. 4=OFFLINE
The Motorola 68020 processor is a 32-bit virtual memory 2

3
4
microprocessor with dynamic bus sizing and 256-byte 1
instruction cash memory. PM
ENTER 150V
2 3 4
The dynamic RAM is organized as a 32-bit memory with
an 8-bit cyclic redundancy checksum and can be supplied with
a 5 V backup supply. X6
COM2
The module has a bus interface with a total

of 2 Mbyte address space and a separate 64 kbyte
I/O address map. The interface includes two interrupt
levels and is of single master type,
i.e., no bus arbitration is used.
There are also interfaces for up to four submodules in the

front. The submodule interfaces support bus arbitration
with up to four participants and a fairness scheme.
The module front has LED indicators for status informa-

tion, a start mode selector switch and an ENTER push
button to manually initialize the controller.
Front view
The operation description of these facilities can be
found in this manual.
Connections and slot disposition in AC410
A label on module side gives the full identification 1-4 Submodules
and information of actual memory size.
5 Program card PCMCIA (system program backup)
Available versions are designeted PM150V04 or X6 Printer
PM150V08.
X17 MasterView 320
X27 Engineering station
A-12 3BSE 002 414R601 Rev B

Section A.5 PM150V - Processor Module
Technical Data
Memory
Dynamic RAM 4 or 8 Mbyte for system software and application program.
Indicators
LEDs on module front:
F (red) Module error
RUN (green) Module running normally
HLT (red) CPU halted
TO (yellow) Bus time-out
MIB (yellow) PM150 is current bus master on MIB
DCOK (green) 24 V d.c. supply is within range
INHIB (yellow) INHIB is active
BC (green) Backup voltage for RAM connected
Power Supply (submodules not included)

max. 3500 mA
max. 80 mA
Power loss (heat) typical 13 W
Mechanical Data
Module size: 6 U, 24 TE
Module weight 2.7 kg (5.5 lbs.)
Table A-4. Pin Designation for Connector X6 and X17
Applied to
X6 (printer) X17 (MV 320)
1 DCD Data Carrier Detect No Yes
2 RD Receive Data Yes Yes
3 TD Transmit Data Yes Yes
4 DTR Data Transmit Ready No Yes
5 GND Ground Yes Yes
6 DSR Data Set Ready No Yes
7 RTS Request To Send No Yes
8 CTS Clear To Send No Yes
9 RI Ring Indicator No Yes
3BSE 002 414R601 Rev B A-13

A.6 RB520 - Dummy Module
Description
Empty slots within a Processor Module PM150 should be equipped with dummy modules.
The reason is:
• Keeping air vented in a settled way
• Exterior appearance
RB520 is a dummy module for a submodule slot, substituting, for example, communication interfaces.
RB520
Front view
A-14 3BSE 002 414R601 Rev B

Section A.7 RF540, RF541 - Modem Subrack
A.7 RF540, RF541 - Modem Subrack
• Destined for auxiliary equipment

• Screw or top hat rail assembly of units
• 24-inch standard (RF540) and 19-inch standard (RF541)
• Includes cable duct
Description
RF540 and RF541 are subracks for assembly of auxiliary equipment like modems and certain
connection units for communication links.
RF541, the 19-inch variant, is described below. RF540 for 24-inch standard differs in width and
number of units only.
A maximum of nine modems, for example type TC625 or TC630 for Advant Fieldbus 100,
can be fixed by two screws included in the modem design. (RF540 12 modems.)
An alternative top hat rail is available for flexible application.
The subrack provides two contact groups which simplify 24 V distribution from the cabinet
supply to the units.
The pluggable connection of the power supply implies increased maintainability.
RF541
Front view Side view
1 2 3 4 5 6 7 8 9
10
228.5
266 (10.5”) (6 U)
(9”)
171
(6.7”) 11
95
(3.7”)
38
(1.5”)
155 (6.1”)
465 (18”)
482 (19”)
3BSE 002 414R601 Rev B A-15

Technical Data
Mechanical Data
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.)
Block Diagram
Application of contact groups
.
RF541
10 (13, RF540)
24V
0V from cabinet supply
to first unit
to second unit
etc.
11 (14, RF540)
As above
A-16 3BSE 002 414R601 Rev B

Section A.8 SA1xx - Power Supply Units
A.8 SA1xx - Power Supply Units
• 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.
Description
SA1xx is a series of power supply units converting single phase a.c. to smooth
but unstabilized 24 V or 48 V d.c. A unit includes a transformer giving galvanic isolation
between the mains voltage and the d.c. output.
It also includes a full wave rectifier and a filtering capacitor.
The power supply unit is internally loaded to reduce the voltage at d.c. load switch
off and to discharge the capacitor at mains switch off.
Electric installation: Plug-in contacts. Primary connector EN 60 320, C20.
Mechanical installation: Rack or wall mounted, 19-inch width.
Front view Side view
3BSE 002 414R601 Rev B A-17

Technical Data
Table A-5. SA1xx, Individual Technical Data
Parameter SA161 SA162 SA167 SA168 SA171 SA172

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 450 VA
Mains load W 320 W 705 W 320 W
cos φ 0.7 min. 0.75 min. 0.7 min.
Efficiency factor 85% typ.
Output voltage at max. current 26 V, 10 A 25 V, 25 A 50 V, 5 A
Ripple 100 Hz, peak to peak 2 V max. 1 V max. 4 V max.
r m s (at max. current) 0.7 V max. 0,35 V max. 1.4 V max.
Maximum load 10 A/260 W 25 A/600 W 5 A/260 W
d.c. voltage slope at mains blackout 200 mV/ms 250 mV/ms 250 mV/ms
and maximum current
Safety Classification
Class I according to IEC 536 (earth protected).
Protection Rating
IP20 according to IEC 529 (IEC 144).
Insulation
Rated insulation voltage 400 V a.c.
Dielectric test voltage 3250 V a.c., 50/60 Hz
A-18 3BSE 002 414R601 Rev B

Section A.8 SA1xx - Power Supply Units
Fuses
Table A-6. Fuses in SA1xx
Fuse SA161 SA162 SA167 SA168 SA171 SA172

F1 a.c. (Midget Fuse, Fast) 10AF 6AF 15AF 10AF 10AF 6AF
F2 d.c. (with reset button, Time Lag) 15AT 15AT 30AT 30AT 8AT 8AT
Mechanical Data
Dimension: width 482 mm (19”)
height 177 mm (7”) (corresponds to 4 U height modules in a cabinet)
depth 255 mm (10”)
Weight: SA161/162 15 kg (33 lbs.)

SA167/168 24 kg (53 lbs.)
SA171/172 15 kg (33 lbs.)
Maintenance Parts
Midget Fuse, 10 * 38 mm 6 AF (fast), ABB part no. 5672 827- 6
10AF 5672 827- 10
15AF 5672 827-15
Block Diagram
SA1xx
SA167/168
only F2
X2
X1 +
F1 1
L1 (L) + d.c.
output
a.c. -
mains 2
F1
L2 (N)
GND
PE
3
3BSE 002 414R601 Rev B A-19

A.9 SB171 - Backup Power Supply
• Module included in backup power supply system for RAM

• Connectable to 24 V d.c. supply
• Two main modes of operation; battery recharging and battery discharging
• Fits NiCd battery unit SB522
• Provides auxiliary inputs; alarm channel, external time synchronization and
RUN alarm relay output
Description
SB171 holds four different functions: Backup Power Supply/Battery Charger, Status Collector,
External Time Synchronization, and RUN Signal Handler. These are described separately below.
The module is positioned at the rear side of the I/O subrack (containing the processor module)
to interface with the backplane bus and the battery.
24 V d.c. supply voltage, alarm signal, time synchronization and RUN signal are connected to
two groups of terminal blocks (X1, X2). The battery is connected via a separate connector (X4).
Flat cable (X3) included in the SB171 design is used to join the backplane bus.
Backup Power Supply/Battery Charger
The battery charger works together with one single battery package, e.g., SB522. These two modules
are intended to be used for current supply of processor module RAM in the event of mains supply drop out.
The capacity expressed in time of backup depends on the application. Please refer to the actual
Advant Controller documentation.
The input energy is converted and used for 5 V internal unit supply and by a controlled current generator
for battery charging. Input and output to the battery are not galvanically isolated.
During normal operation, a LED CHARGE on the module front lights up.
A-20 3BSE 002 414R601 Rev B

Section A.9 SB171 - Backup Power Supply
Diagnostic functions continuously supervise the operation. Error and other status information is
available for processing by the system status function.
82 (3.2”) 49 (1.9”)
4
SB171 X1
1
8
Label
127 (5”) X2
CHARGE
X4 X3 1
All measurements
in mm (in.)
Description (Continued)
Status Collector
An opto-isolated digital input for general alarm purposes is provided. The input is linked to the software
and the system status indication named F1.
External Time Synchronization
To achieve external synchronization of the Advant Controller system calendar clock, the “minute pulse”
is connected to SB171. The input is opto-isolated.
RUN Signal Handler
The module also makes a RUN-signal controlled relay contact externally available.
As long as the system RUN-signal is active, the relay contact is closed.
Technical Data
Input Data
Mains supply: 24 V d.c., variation -20% to +20%; ripple <15%
Max. power: 10 VA
Safety Classification: Class I according to IEC 536 (earth protected)

Protection Rating: IP20 according to IEC 144
Insulation: No
Fuses: No
3BSE 002 414R601 Rev B A-21

Power Supply of RAM

Output voltage at normal operation: 5.3 V ±0.15 V (zero load)
Output voltage at backup operation: 5.6 V ±0.1 V (0.5 A load) 1)
Max. current: 0.5 A (limit at 0.6 A) 2)
Notes:
1) The output voltage level is raised during backup operation to compensate for voltage drops in voting circuitry.
2) The output current is short-circuit proof.
Battery Charging
Designed to NiCd battery 12 V, 4 Ah, e.g., SB522.
Recharging current 160 mA ±10 mA
Recharging time
(totally discharged battery) <60h
Indicators
LED on module front:
CHARGING Indicates normal operation
Table A-7. Electrical Data, Input/Output Signals Connector X2
Signal Signal Filter Pulse Trigg

Pin id Signal Name Isolation
“0” “1” Hw/Sw Length Flank
X2.1 F1+ -50 to +2 V +12 to Opto 1ms/100ms >100ms Positive
+60 V
.2 F1-
.3 SYNC+ 1ms/-- ms >10ms

.4 SYNC-
.5 RUN-NO Relay contact: Max. 250 V a.c. or d.c.

Max. 8 A resistive load ( For processor module RUN)
.6 RUN -COM Contact opening time max. 8 ms
.7 --- Unused terminals
.8 ---
Mechanical Data
Dimension: width 82 mm (3.2”)
height 127 mm (5”)
depth 49 mm (1.9”)
A-22 3BSE 002 414R601 Rev B

Section A.9 SB171 - Backup Power Supply
Block Diagram
SB171
X1 24 V
1 24 VF 5V
d.c. 5V
2 0V d.c. 0V
X4
4 Ubat 1
1 LIVEP
0V
CHARGE
X1 CHARGE
3 LIVE24_A
X3
4 LIVE24_B
X2
1 F1+ 5VB
opto F1
2 F1 -
3 SYNC+ SYNC
opto
4 SYNC -
0V
RUN
5 RUN-NO
6 RUN-COM
3BSE 002 414R601 Rev B A-23

A.10 SB522 - Battery Unit
• Rechargeable 12 V, 4 Ah NiCd battery

• Charging and discharging via the battery charger
• Fits Battery Charger SB171, SB510, SB511 or SB512
• Used for backup current supply of RAM.
Description
SB522 includes 10 NiCd cells size D organized in two lines.
The battery package as well as the connecting device are semi-protected.
There is a built-in non-replaceable fuse to protect against shorts
and results such as fire.
Store SB522 in a charged or discharged condition without
considerable influence to useful life.
To be installed vertically in a well-ventilated place.
260 (10.2”)
max. 40 (1 .6”)
max. 341 (13.4”)
6.4 (0.25”)
max. 71 (2.8”)
325 +/- 1 (12.8”)
A-24 3BSE 002 414R601 Rev B

Section A.10 SB522 - Battery Unit
Technical Data
Electrical Data
Nominal battery voltage 12 V
Capacity 4 Ah (one-hour discharge)
Internal, non-replaceable fuse 20 A (quick action)
Mechanical Data
Dimension: width max. 71 mm (2.8”)
height max. 350 mm (13.8”)
depth max. 40 mm (1.6”)
Reliability Figures
Useful life >3 years
Maintenance
Replace the battery after three years of normal operation.
The battery includes cadmium and is to be treated as hazardous waste.
Maintenance Parts
Battery Unit SB522
Block Diagram
SB522
+12 V X1:4
20AF
0V X1:1
3BSE 002 414R601 Rev B A-25

A.11 SD150 - d.c./d.c. Converter
• 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.
Description
SD150 is a d.c. voltage converter for 24 V and 48 V d.c. networks.
It is intended to supply the voltage regulator units in a controller
with 24 V d.c. unstabilized voltage. It also provides galvanic isolation
between the d.c. network and the d.c. output.
SD150 includes a mains filter, circuits for limitation of power output,
protection of input against incorrect polarity and overvoltage protection
of the output.
Adjustment controls for output voltage, current limitation and overvoltage
protection are located on the front of the unit.
480 (18.8”)
132 (5.2”)
89 (3.5”)
IN OUT
420 (16.5”)
21.5 (0.84”)
465 (18.2”)
Front view
Side view
M6 (4x)
316 (12.4”)
337 (13.2”)
50 (1.96”)
A-26 3BSE 002 414R601 Rev B

Section A.11 SD150 - d.c./d.c. Converter
Technical Data
Table A-8. SD150, Operating Data
Item Value
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
Safety Classification Mechanical Data

Class I according to IEC 536 (earth protected) width 480 mm (18.8”)
Protection Rating depth 337 mm (13.2”)
IP20 according to IEC 529 (IEC 144) height 132 mm (5.2”), 3 U
Insulation weight 10 kg (22 lbs.)
Rated insulation voltage 2000 V d.c.
(Input/case or input/output.)
Block Diagram
SD150
+ +
=
IN OUT
- = -
PE
3BSE 002 414R601 Rev B A-27

A.12 Power Switch and Distribution Units
Description
Power Switch and Distribution units (PSD units) are modular designs fitting 19-inch rails.
A rail houses up to three units.
Use PSD units to switch on/off the mains supply to an Advant Controller installation
and for internal power distribution.
Normally the modular box has three socket outlets. The internal connections are made
pluggable to the PSD unit.
Some PSD types have extra terminal blocks to permit series connection of additional units
and thus expand the number of socket outlets and matching miniature circuit breakers.
PSD units designed to be directly connected to the mains supply are equipped with a main
power switch labeled S1. Expansion units lack the switch S1.
PSD units are divided into two categories:
• Main power supply for the Advant Controller
(for connection to mains A or the redundant mains B, a.c. or d.c.)
• Auxiliary power supply for, for example modems, battery charger, etc.
(for connection to mains C, a.c. only).
These PSD units are referred to by “main” and “aux,” respectively, in the Table A-9, under the heading below, Technical Data.
Different types of PSD units are available to meet various requirements. See Table A-9.
The figure below represents the generalized appearance of the different types.
36 (1.4”) 7 (x4) (0.28”)
130 (5.1”) 95 (3.7”)
159 (6.2”) 177 (7”)
202 (8”)
Isolation transformer
Example of equipment 130 mm (5”) deep behind apparatus plate
SV-types only
Technical Data
Technical data for the individual variants available are given in Table A-9.
A-28 3BSE 002 414R601 Rev B

Table A-9. Individual Technical Data
Parameter SV540 SV541 SV542 SV543 SX540 SX541 SX542 SX550 SX551 SX555
Category Supply main/aux aux aux aux aux main main aux main main main
Distributor expands..... -- -- -- -- -- SX540 -- -- SX550 --

Expandable Y/N N N N N Y Y N Y Y N
Mains input Single Single Dual Dual Single Single Single Single Single Single
Mains Type of network any any any any any any TN any any any
PRI
Install. category III III III III III III II III III III
Frequency , Hz 50 60 50 60 50/60 50/60 50/60 0 0 0
Rated insulation voltage, V 250 250 250 250 250 250 250 60 60 30
Dielectr. test voltage a.c., V 3250 3250 3250 3250 3250 3250 2200 1000 1000 1000
Rated input voltage, V 230 120 230 120 230/120 230/120 230/120 48 48 24
Rated input current, A 1.6 3.2 1.6 3.2 35 35 25 80 80 100
Primary fuse external, A ≤35 ≤35 ≤35 ≤35 ≤35 ≤35 ≤25 ≤80 ≤80 ≤100
Primary fuse internal, A Miniature Circuit Breaker, see Block Diag. -- -- -- -- -- --

Outlet fuse, A -- -- -- -- Miniature Circuit Breaker, see Block Diagram
SEC Type of network TN TN TN TN -- -- -- -- -- --

Install. category II II II II -- -- -- -- -- --
Rated insulation voltage, V 250 250 250 250 -- -- -- -- -- --
Dielectr. Test voltage a.c.,V 2200 2200 2200 2200 -- -- -- -- -- --
Rated output voltage, V 230 120 230 120 -- -- -- -- -- --
Rated output current, A 1.3 2.5 1.3 2.5 -- -- -- -- -- --
Outlet fuse Miniature Circuit Breaker, see Block Diagram
Note: TN defined by standard EN 60 950. Install category II and III according to IEC 664.
Safety Classification
Class I according to IEC 536 (earth protected)
Protection Rating
IP20 according to IEC 529 (IEC 144)
Mechanical Data
SX-types SV-types (including isolation transformer)
Width 202 mm (8”) 202 mm (8”)
Height 177 mm (7”) 177 mm (7”) (corresponds to 4 U height modules in a cabinet)
Depth 95 mm (3.7”) 95 mm (3.7”) + 130 mm (5”) at the rear side of the apparatus plate
(Hole pattern is given in separate detailed dimension drawing.)
Weight 2.5 kg (5.5 lbs.) 10 kg (22 lbs.)
Block Diagram
SV540, SV541
X2
T1 PE
X1 F1 L
F3
L1
L2 X3
N L
PE
N
PE
X4 L
N
SV540 SV541 PE
120 V, 300 VA
T1 Isol. transf. 230 V, 300 VA
F1 MCB K 10A K 10A
X5 L
F3 MCB K 1.6A K 3A
2 10 mm2
N
X1, X2 Screw term. 10 mm
PE
X3 - X5 Outlet socket 10A 10A
A-30 3BSE 002 414R601 Rev B

Section A.12 Power Switch and Distribution Units
SV542, SV543
K1 T1 X1PE
F1 L
F1 F3
1
3
N X3 L
X1PE
N
PE
F2 F2
1 X4 L
3 N
X1PE PE
SV542 SV543
120 V, 300 VA X5
T1 Isol. transf. 230 V, 300 VA L
F1, F2 MCB K 10A K 10A N
PE
F3 MCB K 1.6A K 3A
2 10 mm2
X1 Screw term. 10 mm
F1, F2 Screw term. 35 mm 2 35 mm 2

SX542
X2
PE
X1 F1
L
N X3 L
PE
N
PE
X4 L
N
PE
SX542
F1 K 10A
X5 L
N
X1 - X2 Screw term. 10 mm2
PE
X3 - X5 Outlet socket 10A
3BSE 002 414R601 Rev B A-31

SX540, SX550
X2 L1
X1 S1 L2
L1
PE
L2
PE
F1
X3 L1
L2
PE
SX540 SX550 X4 L1
L2
S1 Power switch
PE
F1, F2 MCB K 16A K 25A
2 35mm2
X1, X2 Screw term. 16mm
F2 X5 L1
L2
L1, L2 Design. as is L+, L- PE
SX541, SX551
X2 L1
X1 L2
L1
PE
L2
PE
F1
X3 L1
L2
PE
SX541 SX551 X4 L1
L2
PE
F1, F2 MCB K 16A K 25A
2 35mm2
X1, X2 Screw term. 16mm
F2 X5 L1
L2
L1, L2 Design. as is L+, L- PE
A-32 3BSE 002 414R601 Rev B

Section A.12 Power Switch and Distribution Units
SX555
S1
L+ S1
1
L-
3 F1
X1PE F1 L+
1
L-
3
SX555
S1 Power switch
F1, F2 MCB K 50A
X1PE Screw term. 35 mm2 F2
F2 L+
S1, F1, F2 Screw rerm. 35 mm2 1
L-
3
3BSE 002 414R601 Rev B A-33

A.13 SX554 - Distribution Unit 60 V d.c.
Description
Use the power distribution panel SX554 unit for distribution
of 24 V or 48 V d.c. tension within an Advant Controller 410/450.
It mounts right below an SA1xx power supply unit and may be utilized
as a support during replacement of a heavy-weight power supply unit.
SX554 is a connector printed circuit board mounted in a steel frame.
It has two screw terminals for the power inlet, and one fast-on tab connected
to the steel frame (for example, used for grounding a cable shield).
Fast-on tabs are utilized for the unfused power outlets to controller and
I/O subracks and for the five two-pole male connectors fused 10A for connection to
low-power consumption units like modems, backup battery chargers and
field equipment.
The SX554 has an LED indicating a voltage at the power inlet,
one outlet X12 which can be used for remote sensing/measuring
the input terminal voltage, and a dual fast-on tab outlet fused 1A.
465 (18”)
Label X14
X1 X2 X3 X4 X5 X15 F2 F1 X21 X22 X10 X11 Live X12 X23 32 43
(1.3”) (1.7”)
4 (0.16”)
420 (16.5”)
482 (19”)
Front view
A-34 3BSE 002 414R601 Rev B

Section A.13 SX554 - Distribution Unit 60 V d.c.
Technical Data
Indicators
LED LIVE (green) on module front. Indicates a voltage at the power inlet.
Electrical Data
Input voltage: 24 V or 48 V d.c.
Rated input current: 30 A
External fuse 30AT (slow) max. Short-circuit protection for the equipment.
Installation Category: II according to IEC 664
Rated insulation voltage: 60 V (Dielectric test voltage 1000 V a.c.)
Fuses
F1 - Thermal overload protection with reset button, 10AT (time lag)
F2 - Miniature Fuse Link, 1AF (fast)
Mechanical Data
Width 482 mm (19”)
Depth 240 mm (9.4”)
Height 43 mm (1.7”), corresponds to 1 U height module in a cabinet
Weight 1 kg (2.2 lbs.)

Maintenance Parts
Miniature Fuse Link, 5 x 20 mm 1AF ABB part no. 3BSC 770 001 R44
Block Diagram
SX554
+ X10a
- b
+ X11a
- b
R2
+ X12
F1 X14
X21 + F2
LIVE + X15
10AT 1AF
X22 -
Terminal Description + X1
1
X21, X22 screw term. 10 mm 2 power inlet -
2
X23 GND X23 tab 6.3 x 0.8 mm RFI ground conn.
X2 - X4
X10, X11 tabs 6.3 x 0.8 mm non fused power outlets
X1 - X5 male conn. 2-pole fused 10A power outlets + X5
1
X14, X15 tabs 6.3 x 0.8 mm fused 1A aux. pow. outlets -
X12 tabs 6.3 x 0.8 mm R = 3.3 k aux. sign. outlet 2
3BSE 002 414R601 Rev B A-35

A-36 3BSE 002 414R601 Rev B

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. The third protection class has no ventilation and
complies with IEC 529 IP54. See Table B-3 and Table B-4.
Figure B-1. RM500 Cabinet - Front View

The cabinets are delivered in a light grey RAL 7035 Structure color.
Two versions - RM500V1 and RM500V2 - with different dimensions are available (see
Table B-1).
RM500V1 cabinets are provided with a single or a double door (two doors, each half the size of
a single door). See Figure B-3. Double door is standard in all deliveries starting from
AC400*1.5/2
All frame components are made of alu-zinc-coated steel and the welded parts are electro-
galvanized.
A grounding point (an M10 screw) is located towards the front of the cabinet in the bottom left
hand corner.
3BSE 002 414R601 Rev B B-1

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
Characteristics RM500V1(1) RM500V1 RM500V2

Height = 1925 mm Height = 2125 mm Height = 2225 mm
(75.8 inch.) (83.7 inch.) (87.6 inch)
Dimensions
Cabinet(2) WxDxH 800x512x1925 mm 800x512x2125 mm 700x637x2225 mm
(31.5x20.2x75.8 inch.) (31.5x20.2x83.7 inch.) (27.6x25.1x87.6 inch.)
End Panel(3) W1xD1 20x530 mm 20x530 mm 20x655 mm
(0.8x20.9 inch.) (0.8x20.9 inch.) (0.8x25.8 inch.)
Cable Entry W2xD2 660x311 mm 660x311 mm 560x436 mm
(26.0x12.2 inch.) (26.0x12.2 inch.) (22.0x17.2 inch.)
Weight(4) 150-200 kg 150-200 kg 150-200 kg
(330-440 lbs) (330-440 lbs) (330-440 lbs)
Doors(5) Single/Double Single/Double Single
Mounting Planes 19”/24” 19”/24” 19”
U-Modules(6) 39U/37U 43U/41U 45U/43U
Cabinet/Hinged Frame
Swing Radius(7)
Single Door (SD) 793 mm (31.2 inch.) 793 mm (31.2 inch) 693 mm (27.3 inch.)
Double Door (DD) 415 mm (16.3 inch.) 415 mm (16.3 inch.) -
Subrack (S100 I/O) in Hinged Frame 600 mm (23.6 inch.) 600 mm (23.6 inch.) 600 mm (23.6 inch.)
(SR)
(1) Starting from AC410*1.5/2 this height is no longer included in the standard price lists.
(2) The dimensions includes door and rear plate.
(3) W1xD1 shows the dimension for a single end panel. When mounting two end panels to a cabinet add 2x20 mm at the cabinet width, W
but use D1 as cabinet depth.
(4) The weight does not include equipment to be installed within the cabinet.
(5) Double door is standard starting from AC410*1.5/2 for RM500V1.
(6) U-Modules, see Appendix D, Item Designations.
(7) The space required for door(s) and the hinged frame. See Figure B-3.
B-2 3BSE 002 414R601 Rev B

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 414R601 Rev B B-3

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. Tighten the M8 screws to 20 Nm
maximum and the M6 screws to 10 Nm maximum.
B.4 Mounting Cabinets to the Floor

When fixing the cabinet to the floor use four or six M12 screws where Figure B-4 indicates, one
at each corner in the first left hand cabinet in a row of cabinets and screw the following cabinets
with two screws each at the right hand side. The bottom angle hinges features holes, 14 mm
(0.6”) in diameter. These holes permit you to adjust the cabinet location after holes are drilled in
the floor. If drilling is necessary, make sure that no dust or other foreign matter enters the
equipment in the cabinet. Please notice the minimum distances from cabinet to walls and ceiling
(see Section 2.1.12, Weight and Mounting Dimensions and Figure 2-5). Use washers between
the floor and the cabinet bottom to level the cabinet floor into a horizontal position.
Figure B-4. Position of the Holes for fixing the Cabinet(s) to the Floor
Table B-2. Distances in Figure B-4
Symbol in
RM500V1 RM500V2
Figure B-4
X 69 mm (2.7”) 69 mm (2.7”)
W3 702 mm (27.6”) 602 mm (23.7)
W 800 mm (31.5”) 700 mm (27.6”)
B-4 3BSE 002 414R601 Rev B

Section B.5 Protection Rating
Table B-2. Distances in Figure B-4 (Continued)
Symbol in
RM500V1 RM500V2
Figure B-4
Y 56 mm (2.2”) 56 mm (2.2”)
D3 419 mm (16.5”) 544 mm (21.4”)
Dtot 531 mm (20.9”) 655 mm (25.8”)
B.5 Protection Rating

Cabinets are available for different environmental protection classes,
see Table B-3.
Table B-3. RM500 cabinet protection classes
Protection class
Type
RM500
(1) (2)
Ventilated, not EMC-proof IP 21
Ventilated, EMC-proof (2) IP 21
(3)
Ventilated IP 41
Sealed IP 54
(4)
Sealed with heat exchanger IP 54
(1) Advant Controller 410 with S100 I/O, installed in this cabinet is not verified for
CE-marking. No longer included in standard price lists, starting from
AC400*1.5/2.
(2) Standard cabinet without filter on ventilation grilles.
(3) Ventilation grilles are covered with metallic net to prevent insects to enter the
cabinet. A heater is included to heat the cabinet when the controller is not in use.
(4) Available as a standard sealed cabinet with heat exchanger as an option.
Table B-4. Available Degree of Protection Ratings for RM500
RM500V1(1) RM500V1 RM500V2

H=1925 mm (75.8 inch.) H=2125 mm (83.7 inch) H=2225 mm (87.6 inch.)
IP21 IP41(2) IP54 IP21 IP41(2) IP54 IP21 IP41(2) IP54
Cabinet with or without X X X X X X X X X
hinged frame
Cabinet for OOCU X X X X X X
Cabinet, NOT verified X X X
for CE marking
(1) No longer included in standard price lists, starting from AC400*1.5/2.
(2) IP41 includes a heating element, and the ventilation grilles are covered with nets.
3BSE 002 414R601 Rev B B-5

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. Permitted Power Dissipation for RM500
Protection Class 15o C Temperature Rise 30o C Temperature Rise

IP21 700 W 1.400 W
IP41 500 W 1.000W
IP54 300 W 600 W
The CPU subrack is provided with a fan unit to equalize the temperature difference in the
subrack.
B-6 3BSE 002 414R601 Rev B

Section C.1 Delivery Binder Content
Appendix C Delivery Documentation
C.1 Delivery Binder Content

As a complement to the user documentation, there is a binder which contains other pertinent
documentation related to the delivery. This pertinent documentation is referred to as the
Delivery Binder.
The Delivery Binder has the same content structure for all Advant products.
The Delivery Binder includes the following documents:
Order Reference Sheet
A document which contains the ABB order reference number. This number serves as the
basis for all subsequent references to this delivery.
Delivered Version Specification
A document which contains the general system release information.
System Log
This is a series of blank forms suitable for logging hardware and software repairs,
modifications or expansions of the product. These forms are used by the service engineers
in the initial commissioning as well as by customers after delivery from ABB.
Delivery Specification
The information in this document specifies all parts of value which are included in the
initial delivery (the actual List of Apparatus).
When subsequent changes to the product occur, the list of new parts is included here, too.
License Certificate
This certificate is the end user’s evidence that he has purchased the right to use the
specified (software) products. The document contains the end user name and a list of the
particular software packages under license, as well as a list of our standard terms and
conditions.
Inspection and Test Record
This document, filled in by the production department, specifies which test specifications
and delivery test procedures the equipment has been subject to.
Release Notes
Latest product information which is not covered by the standard user documentation.
Terminal Diagram
A block diagram where all hardware modules (circuit boards and units) are represented by
functional symbols and where all interconnections between the modules are shown.
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 414R601 Rev B C-1

Appendix C Delivery Documentation
C-2 3BSE 002 414R601 Rev B

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. This designation consists of a letter followed by a numerical
combination. The letter specifies the mounting plane, and the numbers designate the level in the
cabinet and the position in the cabinet.
This description applies to cabinet type RM500 and Advant Controller 400 Series.
D.2 Cabinet
Mounting planes in cabinets are designated as shown in Figure D-1.
Figure D-1. Item Designation of Mounting Planes
A = left-hand side of cabinet

B = rear mounting plane, 19”
C = right-hand side of cabinet
D = front of door
E = rear of door
F = optional location, free
H = extra mounting plane in front of B, 24”
T = ceiling location
U = front of hinged frame, 19”
V = rear of hinged frame, 19”.
3BSE 002 414R601 Rev B D-1

When there are several cabinets, they are designated 1 and 2 from the left.
The mounting planes are for example 1B, 2B and so on.
All mounting planes A, B, C, D, E, H, V (hinged frame) and U (hinged frame) are divided
vertically into height modules (U), 1U = 44.45 mm (see Figure D-1).
Mounting planes B, U and V are for 19” units and H is for 24” units.
The mounting planes A and C have a horizontal partition of 25 mm. They are numbered 1, 2, 3
and so on from the rear and forward (see Figure D-1).
Figure D-2. Cabinet with Door Removed
The levels specified are those of the upper left-hand corners of the units installed.
The cabinet is designated with a letter combination followed by figures. The + sign prefix
indicates that the designation is location-oriented.
D-2 3BSE 002 414R601 Rev B

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).
The disposition of the subracks in terms of number of relevant modules are specified in the
respective product documentation.
Location-Oriented Item Designations

The first module in a controller subrack is designated 102, the next 108, and so on.
102
156
108
1 56 85
. 1
6
7
12
756
Please note!
The given location-oriented item designation
should not be mixed up with the module
item designation in the computer infrastructure (address)
where the positions are designated from the left 1, 2, 3, etc.
See Figure D-5
Figure D-3. Item Designation in Controller Subrack 12 SU
3BSE 002 414R601 Rev B D-3

1 26 85
1
102
6
7
726
18
Figure D-4. Item Designation in Controller Subrack 18SU
Address
.
1 B Voltage Voltage
l Reg. Reg.
Sub- i
positions n 1 2
d
2 Backup Backup S
Power Power u
Supply Supply p
e
1 2 r
v.
Address/Position 1 2 3 4 5 6 7 8
Figure D-5. Addresses in Controller Subrack 12 SU
D-4 3BSE 002 414R601 Rev B

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.
See Figure D-6.
The item designation of the modules gives their location in the subrack. The module marked in
the figure is at module location 25. The 1 in the designation refers to the uppermost level,
level 1 in the equipment frame.
1 5 9 25 81
1
2
Item design. 125 3

4
5
6
Figure D-6. Item Designation in I/O Subrack
3BSE 002 414R601 Rev B D-5

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).
1 4 9
Item design. 4 10
11
Figure D-7. Item Designation in Modem Subrack, 19 inches
1 4 12
Item design. 4 13
14
Figure D-8. Item Designation in Modem Subrack, 24 inches
Modems mounted on a bracket are numbered 1 and 2 as in Figure D-9.
Figure D-9. Modem Mounted on a Bracket
D-6 3BSE 002 414R601 Rev B

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, etc., from the top downward. With several circuit
boards in a unit, the boards are designated 1, 2, 3, etc., and the connectors on the different
boards are designated X21, X22, X31, and so on.
Other plug-in circuit boards in the front of the units have sequential numbers 1, 2, 3, and so on.
Numbering of
circuit boards
1 2 3
2
1 (Slot)
1 (Slot)
(Slot) X1
X1 X1
X31
X2 2 X21
(Slot)
X22
Module front Module front with Front of unit with several contacts
with contacts slots for submodules and slots for submodules
Figure D-10. Numbering of Submodules and Connectors on the Front
Connectors on the Rear Side

Connectors are numbered X1, X2, and so on, from the top downward.
Jumper group
S2 S1
X1
Front Rear side
X2
Figure D-11. Numbering of Connectors on the Rear Side
3BSE 002 414R601 Rev B D-7

Connection Units
The item designation code for the contacts of the connection unit are shown in Figure D-12.
The connector for internal connections in the cabinet is always designated X80.
The terminal block group or connector for external connections is designated X90.
If there are more connectors, these are designated X81, X82, or X91, X92, and so on.
X91
X92
1 - - - - - - - - - - - - - - - - - 46 1 - - - -5
X90 X90
X80 X80
Figure D-12. Connection Units, Connection and Terminal Numbering
When more than one connection unit is mounted on the same mounting bar, the units are
numbered as follows:
The mounting bar for connection units is divided in width modules à 20mm, which is a multiple
of the standard connection unit width.
19 inch 24-width modules
24 inch 30-width modules
The item designation specified for a connection unit is that module number covered by the
upper left-hand corner of the unit installed.
B4.1 B4.13
1 13 24
Level B4
19” design
Figure D-13. Location of Connection Units on a Mounting Bar
Figure D-14 shows a typical connection between connection unit B1.1 and I/O board U4.125.
The item designation of the board gives its location in the subrack.
D-8 3BSE 002 414R601 Rev B

Section D.7 Mains Units
This connection is designated U4.125.X2 - B1.1.X80.
U4.125 (Hinged frame) B1.1 (Rear mounting plane)
S2 S1 X90
X80
X1
Flat
Cable
X2
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. The code for a process connection to pole 3 becomes B1.1.X90:3.
B1.1.X90:3
+QA1
B1.1
1 2 3 4 5 Etc
Connection
X90 Unit
X80
Figure D-15. Terminal Block Numbering
D.7 Mains Units
1 2 1 2 3
Mounting plate 19” Mounting plate 24”
Figure D-16. Location of Mains Units
The mounting plates can carry two or three mains units. The mains units are numbered 1, 2, 3,
as in the figure. The mounting plates are 3 U high.
3BSE 002 414R601 Rev B D-9

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,
D-10 3BSE 002 414R601 Rev B

Section D.8 Examples of Item Designation in Cabinets
Table D-1. Designation of Items in Figure D-17
Connection point A
No. Instar.
Item designation Terminal
1 1B2 126 2 X1
2 1B2 780 X1
3 1B12 3 X2
4 1B12 11 X3
5 2U5 121
6 1C32.x(1) X1
7 2H15 13 X80
8 1H35 2 F1X3
(1) x stands for 1, 2, 3 etc.
3BSE 002 414R601 Rev B D-11

D-12 3BSE 002 414R601 Rev B

Section E.1 General
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 410 and its I/O.
Use this information:
• When dimensioning the supply to the system
• When calculating the heat generated in RM500 cabinet.
The values given in the tables are typical and adapted to these kind of applications.
It is assumed that 70 percent of the channels on a board are active simultaneously.
Use the tables as forms in your own calculation.
E.2 Calculation Algorithms and Forms with Technical Data

Current Consumption
When calculating the current consumption, focus on current per power supply unit.
Consider the available capacity given in Section 3.1.4 Power Supply.
Obtain the current consumption with 24 V, Itot , in the following way:
I tot = I 24V + 0.37 × I 5V
where I24V = current consumption 24 V, obtained from the tables.

I5V = current consumption 5 V, obtained from the tables.
0.37 = conversion factor.
Heat Dissipation
When calculating heat dissipation, focus on heat per cabinet.
Consider the permitted power dissipation given in Section 3.1.11, Heat Dissipation.
The total power dissipated in the cabinet can be written:
PTotal = ( ∑ P C – module ) + ( ∑ P IO – board ) + ( ∑ P Voltagesupplyunit ) + ( ∑ P Sundry )
3BSE 002 414R601 Rev B E-1

Table E-1. Current Consumption and Power Dissipation, Controller Modules
Type Current Consump. (A) Tot. Power No. of Total

Comments
Designation 5V 24 V Dissipation (W) Boards Itot, Ptot
CI522A 0.6 - 3.3

CI531 0.4 0.04 3
CI532Vxx 0.4 0.04 3
CI534Vxx 0.4 0.04 3
CI535 0.4 0.04 3
CI538 0.4 0.04 3
CI541V1 0.85 0.25 11
CI543 0.6 0.25 9 (1)
CI547 0.6 0.25 9 (1)
CI570 0.9 - 5
CI572 0.35 - 1.75
CS513 0.25 0.25 8 (1)
MB510 0.01 - 0.05
PM150V 2.3 0.05 13
PU535 0.4 0.04 3
Sum
(1) 6 W dissipated in the transceiver connected to the module.
E-2 3BSE 002 414R601 Rev B

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 Itot, Ptot
Designation +5 V +24 V Dissipation (W) Boards
DSAI 130 0.25 0.11 3.8

DSAI 130A 0.15 0.15 4.4 0.1 W/ch on connection unit
at 20 mA
DSAI 133 0.45 0.13 5.4
DSAI 133A 0.26 0.1 3.7 0.1 W/ch on connection unit
at 20 mA
DSAI 146 0.25 0.10 3.8
DSAI 155A 0.25 0.10 3.8
DSAX 110 0.48 0.17 7.7
DSAX 110A - - - 0.1 W/ch on connection unit
at 20 mA
DSAO 110 0.30 0.53 14.0
DSAO 120 0.30 0.28 8.2
DSAO 120A 0.35 0.58 14
DSAO 130 0.30 0.22 8.6
DSAO 130A 0.25 0.54 11
DSDC 111 1.40 0.10 12.0
DSDI 110A 0.46 - 5.5 With DSTD 150 A, DSTD 190
DSDI 110A 0.46 8 mA/ch 12 With 4 x DSTD 195
DSDI 110A 0.46 - 7.5 With 4 x DSTD 196
DSDI 110A 0.46 8mA/ch 17.0 With 4 x DSTD 197
DSDI 110A 0.46 8mA/ch 18.5 With 4 x DSTD 198
DSDI 110AV1 0.23 - 4.4 With DSTD 150A
DSTD 190V1
DSDI 110AV1 0.23 - 4.4 With 4x DSTD 195/
DSTD 196P/DSTD 197/
DSTD 198
DSDI 120A 0.46 - 8.8
DSDI 120AV1 0.23 - 7.7
3BSE 002 414R601 Rev B E-3

Table E-2. Current Consumption and Power Dissipation, S100 I/O Boards (Continued)

Type Tot. Power No. of
Comments Itot, Ptot
Designation +5 V +24 V Dissipation (W) Boards
DSDO 115 0.65 22 mA/ch 7.8 With DSTD 108/108L

DSDO 115 0.65 - 7.7
DSDO 115A 0.27 - 11 With DSTD 110A,
DSTD 190V1
DSDO 115A 0.27 - 1.4 With DSTD 108P,
DSTD 108LP
DSDO 115A 0.27 - 1.4 With DSTD 109P
DSDO 120 0.65 - 12.0
DSDP 140A 1.1 0.15 6.7
DSDP 150 1.0 - 7.0/7.8 Input/Output
DSDP 170 0.6 - 4
Sum
Table E-3. Current Consumption and Power Dissipation, Power Supply and Sundry

Type Tot. power No. of
Comments Itot, Ptot
Designation +5 V +24 V Dissipation (W) Units
DSSR 122 - - 65.0 With max. load

(1)
DSSR 170 - - 23.0 With max. load 2
DSSS 171 - 0.1 6
DSTD 108P - 0.13 2.7 70% of all channels activated
DSTD - 0.13 2.7 70% of all channels activated
108LP
DSTD 195 - 0.045 1.6 70% of all channels activated
(1)
SA1xx - - 100 Approx. for all types of power
supply units
SB171 - 0.25 2.5
TC512V1 - 0.1 2
E-4 3BSE 002 414R601 Rev B

Section E.2 Calculation Algorithms and Forms with Technical Data
Table E-3. Current Consumption and Power Dissipation, Power Supply and Sundry (Continued)

Type Tot. power No. of
Comments Itot, Ptot
Designation +5 V +24 V Dissipation (W) Units
TC513V1 - 0.1 2
TC514V2 - 0.1 2
TC515V2 - 0.1 2
TC516 - 0.1 2
TC562 - 0.15 3
TC570 0.02 0.5
TC625 0.13 3
TC630 0.1 2.4
Sum
(1) Redundant power supply units should not be included in the calculation of number of units.
3BSE 002 414R601 Rev B E-5

E-6 3BSE 002 414R601 Rev B

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) (ms) (ms) per signal
AI A) B) C)
_______ ms F) G)
_______ E+H
____ 0.23 0.16

E)=100*A*B/C H)=A*G*F/10
E)
_______% _______%
H)
________%
AIC A) B) C)
_______ ms F) G)
_______ E+H
____ 0.005 0.18

E)=100*A*B/C H)=A*G*F/10
E)
_______% _______%
H)
________%
DI cycl. A) B) C)
______ ms F) G)
_______ E+H
____ 0.26/board 0.08

D) E)=100*A*B/C/D H)=A*G*F/10
E)
_______% _______%
H)
________%
___ch/board
DI interr. A) F) G)
_______ E+H
____ 1.0
H)=A*G*F/10
_______%
H)
________%
DIC A) B) C)
_______ ms F) G)
_______ E+H
____ 0.005 0.10

E)=100*A*B/C H)=A*G*F/10
E)
_______% _______%
H)
________%
Total %
3BSE 002 414R601 Rev B F-1

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
AO A) B) C)
_______ ms F) G)
_______ E+H
____ 0.02 0.20

E)=100*A*B/C H)=A*G*F/10
E)
_______% _______%
H)
________%
AOC A) B) C)
_______ ms F) G)
_______ E+H
____ 0.005 0.10

E)=100*A*B/C H)=A*G*F/10
E)
_______% _______%
H)
________%
DO A) B) C) _______ ms F) G) _______ E+H
____ 0.01 0.15

E)=100*A*B/C H)=A*G*F/10
E) _______% _______%
H) ________%
DOC A) B) C)
_______ ms F) G)
_______ E+H
____ 0.005 0.07

E)=100*A*B/C H)=A*G*F/10
E)
_______% _______%
H)
________%
Total %
F-2 3BSE 002 414R601 Rev B

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)
A) B) C)=A*100/B D) C*D)
C)
A) B) C)=A*100/B D) C*D)
C)
A) B) C)=A*100/B D) C*D)
C)
A) B) C)=A*100/B D) C*D)
C)
A) B) C)=A*100/B D) C*D)
C)
A) B) C)=A*100/B D) C*D)
C)
A) B) C)=A*100/B D) C*D)
C)
A) B) C)=A*100/B D) C*D)
C)
A) B) C)=A*100/B D) C*D)
C)
A) B) C)=A*100/B D) C*D)
C)
A) B) C)=A*100/B D) C*D)
C)
A) B) C)=A*100/B D) C*D)
C)
A) B) C)=A*100/B D) C*D)
C)
A) B) C)=A*100/B D) C*D)
C)
A) B) C)=A*100/B D) C*D)
C)
A) B) C)=A*100/B D) C*D)
C)
Total %
3BSE 002 414R601 Rev B F-3

F-4 3BSE 002 414R601 Rev B

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 Appr. RAM

AI/AO S100 I/O x 0.30
S800 I/O x 0.27
DI/DO S100 I/O x 0.26
S800 I/O x 0.14
Calculated signals For presentation and event handling in x 0.30
Advant Station 500 Series Operator Sta-
tions (including signals via
Advant Fieldbus 100)
S800 I/O No. of S800 I/O stations on fieldbus x 0.40
PIDCON Excl. I/O x 1.50
MANSTN Excl. I/O x 0.80
RATIOSTN Excl. I/O x 1.00
GENCON Excl. I/O x 0.50
GENBIN Excl. I/O x 0.50
GENUSD Excl. I/O x 0.50
VALVECON Excl. I/O x 0.60
MOTCON Excl. I/O x 0.80
(1)
GROUP Excl. I/O 1 x 3.00
SEQ Excl. I/O x 1.00
DAT No. of DB elements x 0.02
TEXT No. of DB elements x 0.14
3BSE 002 414R601 Rev B G-1

Table G-1. Calculation of RAM Requirement (Continued)
Factor Appr. RAM

Table handling No. of tables (2) x 4.90
MasterView 320 Basic requirements for QC01-LOS11 1 x 231.00
No. of displays (3) x 2.00
(4)
No. of MV 320 with event lists x 9.00
Central operator station Basic requirement for QC01-OPF11 1 x 836.00
Advant Station 500 Series
No. of trend data storage logs (5) x 12.00
Operator Station and IMS
Station or MasterView 800/1 Group alarm, No. of group objects x 0.13
No. of group members x 0.09
MasterBatch 200/1 Basic requirement for QC01-BAT11 1 x 411.00
No. of SECCON x 1.7 + OPCON x 6.0 + x 1.00
TANKCON x 1.8
No. of processes (6) x 25.00
PROFIBUS- DP No. of Profibuses 1 x 1.20
Number of PROFIBUS slaves 1 x 0.80
LONWORKS No. of LONWORKS Communication mod- x 65
Network ules CI572.
No. of LONWORKS devices x 0.2
No. of LONWORKS variables x0.06
(input and outputs)
No. of LONWORKS multiple network vari- x 0.33
able
No. of LONWORKS Event Treat x 0.14
No. of MasterBus 300/300E, RCOM/RCOM+, GCOM and MultiVendor x 10.00
Interfaces
User Defined PC Elements Basic requirements for QC01-UDP11 1 x 132.00
Storage of user defined PC elements (7) 1 x 150.00
Space for storage of User Diskette content (7) x 100.00
Basic requirement for QC01-BAS11 1 x 1904.00
G-2 3BSE 002 414R601 Rev B

Section G.1 Form for Memory Calculation
Table G-1. Calculation of RAM Requirement (Continued)
Factor Appr. RAM

Spare RAM area (8) 1 x 40.00 40.00
Total RAM requirement (9)
(1) The figures are calculated for eight steps (MOTCON not included).
(2) The figures are calculated for one table with 10 rows and 100 values per row.
(3) The figures are calculated for 40 text strings with 20 characters and 30 dynamic values.
(4) The figures apply to 100 events per list.
(5) The figures are calculated for one log with 10 variables, each with 240 stored values. Each value takes approximately 5 bytes.
(6) The figures are calculated for 50 storage vessels, four sections and 20 operations with six recipe variables each.
(7) This is a recommended starting value. Adjustment of this figure might be necessary to do when the real need is known.
(8) Recommended value for most systems.
(9) Must be less than the RAM size of the processor module (4 or 8 Mbyte).
3BSE 002 414R601 Rev B G-3

G-4 3BSE 002 414R601 Rev B

Section H.1 Compact Version of Advant Controller 410
Appendix H Product Variants
H.1 Compact Version of Advant Controller 410

A compact product variant is offered to meet special customer requirement which include:
• Small dimension
• Simple incorporation in other system products
• Possibility to use available power supply 24 V d.c.
• Functionality comparable to the common Advant Controller 410
Description
The compact Advant Controller 410 consist of a single subrack with attached battery unit for RAM backup. Ten S100 I/O board
slots have been used for a built in modem subrack which accommodate maximum four modems. The remaining five I/O slots
may be used freely. From the functional viewpoint this is the only limitation with reference to the common standard
Since some of the electronic modules, for example the 5 V regulator, are mounted on the rear side of the subrack this side must
be accessible for maintenance reason.
Connection of Advant Station 100 ES

Program Card position (system program backup)
Front view
Connection of MasterView 320
1 ABB TC xx x ABB TCxxx AB B TCx xx ABB TCx xx
2 3 4
Battery Unit
SB520
Processor Module Cable duct

PM150 Dummy Modules Modems
1...4 indicates (S100I/O can be used )
submodule positions
Connection of printer
3BSE 002 414R601 Rev B H-1

Appendix H Product Variants
Technical Data (Supplement to Section 3.2 in this User’s Guide)

Power Supply
24 V d.c. (S100 I/O boards not included) typical 2 A
Power loss (heat) typical 50 W
Power Supply Requirement Specification
Voltage range 19.2 - 30 V (incl. ripple)
Destroying voltage >35 V
Ripple voltage accepted max 2 V p-p at f= 120 Hz
System start up voltage >18 V
System shut down voltage <19 V
Voltage decay 18 V ⇒ 16 V max 0.4 V/ms at primary voltage black-out and maximum current load
Maximum under-voltage (<19 V) period 1/2 period at a.c. mains
1 ms at d.c. battery power supply
10 ms at d.c. other than battery power supply
Type of load almost constant power (maximum current drain at voltages around 16 V)
The power supply device must conform
to the following standards:
Electrical safety, degree of protection ABB PA Standard 3BDU 000 002
Electromagnetic compatibility ABB PA Standard 3BSE 000 200
Environmental conditions ABB PA Standard 3BSE 000 170
Mechanical Data
Width 482 mm (19”)
Depth 335 mm (13.4”)
Height 266 mm (10.5”), 6S (excl. cable duct)
Weight 15 kg (33 lbs.)
Front view 7 x 13 (x8) Side view

465 (18.3”) min. 100 (3.9”)
335 (13.4”)
228.2
(9”)
171
(6.7”) 266
(10.5”)
94.8 6S
(3.7”)
37.6
(1.5”)
88
(3.5”)
2S
482 (19”)
H-2 3BSE 002 414R601 Rev B

Section I.1 Example of Halt Code Printout
Appendix I Halt Codes
I.1 Example of Halt Code Printout

You can obtain the result of the command LSYSHI as a printout on the printer with the
command HARDCOPY in accordance with Figure I-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
SSP H’004800DA
D0 H’00000069 D1 H’00000834 D2 H’004A00DC D3 H’0000FFFF
D4 H’00000172 D5 H’000003E5 D6 H’00002544 D7 H’000182D8
AO H’00480128 A1 H’00480128 A2 H’0048545E A3 H’0001C9F6
A4 H’00052886 A5 H’0048246E A6 H’00480100 A7 H’0048246A
System stack
H’004800DA H’2704 H’0000 H’5244 H’002C
H’004800E2 H’0165 H’C20A H’FFFC H’3A79
H’004800EA H’2400 H’0000 H’ODEE H’0048
H’004800F2 H’246E H’0048 H’0100 H’0000
H’004800FA H’0000 H’760A H’0070
System halt code = 05
Bus time-out error in system or kernel mode
Figure I-1. Example of LSYSHI Printout
3BSE 002 414R601 Rev B I-1

I.2 List of Halt Codes and Corrective Actions

Typical halt codes which can be read with the command LSYSHI and corrective measures are
listed in this section. Further fault finding and user repair is described in Chapter 5,
Maintenance.
DANGER
You should carefully follow general safety instructions given in Chapter 5
when fault finding and operating an Advant Controller system to minimize
the risk of injury to personnel and damage to the equipment.
NOTE
In all situations when the controller has stopped you should carefully read all
halt codes and system messages available before you proceed. See Section
5.3.2.1, Reading of System Messages.
Table I-1. List of Halt Codes
Halt
Significance Corrective actions
Code
00 Debug trap in system mode The halt codes 0 - 5 do not normally appear in a
system after commissioning but if one should appear,
01 Fault in system mode (probably memory or bus
it is probably due to interference, program error or
fault) special hardware fault.
02 Fault in system mode (probably memory or bus
fault)
03 RAM fully occupied
04 Addressing error in system mode
05 Bus fault in system mode (e.g. impermissible
board extraction or memory error)
07 Memory error. RAM test. Replace the processor module
09 Overload, STALL ALARM Note the error code and the red LED indicators which
have illuminated. LSYSHI gives the level of the
overload and indicates the type of overload which
has occurred.
S§LOSTAL = 0 :
Hardware fault but not memory board fault. Replace
the faulty hardware.
S§LOSTAL = -1 :
Overload on PC level.
Extend cycle times on PC.
Hardware fault is possible; I/O board or
communication board.
Replace the faulty hardware.
I-2 3BSE 002 414R601 Rev B

Section I.2 List of Halt Codes and Corrective Actions
Table I-1. List of Halt Codes (Continued)
Halt
Code
0A Memory error. The address to the incorrect Replace the processor module.
position is in the address register A0. The error
code appears during the test of the RAM which
is only performed on initialization of the system.
0b System program check sum test error. RAM test. Replace the processor module.
0C Autotest error. Instruction test failed. Replace the processor module.
0d Autotest error. Interval timer test failed. Replace the processor module.
0E Autotest error. Interrupt controller test failed. Replace the processor module.
0F Autotest error. Bus error test failed. Replace the processor module.
10 Level 7 interrupt. Power failure. Follow instructions in Section 5.4.9.5, Check of
Power up after power fail in a system that has no Power Supply.
power fail handling, neither warm start up nor
power fail restart.
16 Serious program error. Follow instructions in Section 5.4.16, System
Restart, INIT.
17 Wrong processor module type in the system. Replace the processor module.
24 System with redundant processor modules only. Restart the backup module which was stopped.
Indication on the backup module.
Error at changeover. Probably the system was
not fully synchronized when an attempt to
changeover was made.
2C System with redundant processor modules only. Replace the backup processor module.
Internal error.
32 System with redundant processor modules only. This means a serious shut down of a redundant
Indication on the “new” primary at changeover. system. Further detailed information of the possible
Error in changeover. Unexpected status. reason of the halt is stored in the system. This
information is accessible by ABB experts only.
Error in changeover. Unexpected status reason of the halt is stored in the system. This
information is accessible by ABB experts only.
38 System with redundant processor modules only. Restart with the same system program in both
Indication on the backup module. processor modules.
Internal error. System program in backup and
primary is not equal.
3BSE 002 414R601 Rev B I-3

Table I-1. List of Halt Codes (Continued)
Halt
Code
40 System with redundant processor modules only. Try again by depressing the ENTER button. If the
Error when initializing the backup module. same error occurs, replace the backup module.
41 System with redundant processor modules only. Replace the backup module.
Error detected in the initial diagnostic test. The
RCU-chip on the backup module may be
malfunctioning.
Internal error in the task-scheduler for the
backup module.
Hardware error on the RCU-chip.
Error in the communication between the backup
and primary modules.
Internal error concerning interrupts in the
backup module. Possibly malfunctioning RCU-
chip.
Error in changeover. Floating-point exception reason of the halt is stored in the system. This
pending. information is accessible by ABB experts only
Error in changeover. MOVEM instruction to/from reason of the halt is stored in the system. This
I/O during changeover. information is accessible by ABB experts only
Error in changeover. Status channel interrupt not reason of the halt is stored in the system. This
pending during changeover. information is accessible by ABB experts only
I-4 3BSE 002 414R601 Rev B

Section J.1 Message Coding
Appendix J System Messages
J.1 Message Coding

System and error messages are format coded as follows:
11 1 13:25:09 28 20 CXPC 800 A H’0000000F H’00080001 H’000A1500
Network Node Time Type Code Task Interrupted Address Data 1 Data 2
Interpretation can be found in Table J-1 below.
Table J-1. System Message Coding
Significance
Network Specifies within which communication network in the installation the message has been
generated.
Node Specifies the node in which the message was generated. If Network and Node are not
specified, the message is from an engineering station.
Time The time at which the message was generated.
Type The type of message i.e. the error category in the Advant Controller
Code Specifies the character of the change within the category, i.e. the nature of the fault.
Task Specifies the software task affected by the message.
Interrupted Specifies if the task has been interrupted.
Address Specifies the address associated with the change of status.
Data 1 Optional extra information, expressed in decimal or hexadecimal (H’) form.
Data 2 If data 2 contains no information, Data 1 only is presented. Data 2 can also be in decimal or
hexadecimal (H’) form.
3BSE 002 414R601 Rev B J-1

J.2 Message Types

The type number classifies faults in accordance with Table J-2.
Table J-2. System Message Types
Type Cause Notes

2 Overload
5 Task interrupted
10 Task killed
17 Master Net See also MasterNet User’s Guide
18 Console communication
20 Error on V24/ RS-232-C channel
22 PC-interpreter
23 Error in the controller data base MMC, operator station
24 Data transmission fault MMC, operator station
25 Fault in the operator station MMC, operator station
26 Other faults MMC, operator station
28 Process communication
incl Data Set (AF 100, PROFIBUS-DP,
LONWORKS, MasterFieldBus, RCOM)
29 Redundant processor modules, operating
system, kernel
30 MasterBus See also MasterNet User’s Guide
Data Set Communication
EXCOM
Clock synchronization
34 GCOM See MasterNet User’s Guide
39 Data Set Peripheral, Advant Fieldbus 100
40 VFI communication Internal errors. Please report to ABB
134 System/Node supervision
J-2 3BSE 002 414R601 Rev B

Section J.3 List of System Messages and Corrective Actions
J.3 List of System Messages and Corrective Actions

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.
Further fault finding and user repair is described in Chapter 5, Maintenance.
DANGER
You should carefully follow general safety instructions given in Chapter 5,
Maintenance when fault finding and operating an Advant Controller system
to minimize the risk of injury to personnel and damage to the equipment.
NOTE
In all situations when the controller has stopped you should carefully read all
halt codes and system messages available before you proceed. See Section
5.3.2.1, Reading of System Messages.
Type 2 Overload
11 1 12:16:30 2 46 CXKK220
Table J-3. Type 2, Code 46
Type Code Significance Task Comments/Actions

2 46 Overload CXKK220 The system is overloaded on a low priority
Type 5 Task interrupted

11 1 12:15:31 5 21 CXAF000 A H’00005982 H’00000004 H’00000000

5 21 Task interrupted CXAF000 for This message occurs before restart of EXCOM
EXCOM 1 tasks.
CXAF000 for
EXCOM 2
3BSE 002 414R601 Rev B J-3

Type 10 Task killed

11 1 12:23:44 10 19 CXAA 000 A H’000FF333 61000
Type Code Significance Data 1 Comments/Actions

10 19 Task interrupted 61000 Gap in Data Set
61001 Dat referred to missing
61002 No RAM at initialization
61700 No Data Set or Dat
J-4 3BSE 002 414R601 Rev B

Type 17 MasterNet
11 1 12:23:44 17 1 CXNM540 A H’00000000 21 11
Table J-6. Type 17, Code 1, 2, 3, 7, 8, 9 and 11
Type Code Significance Data 1 Data 2 Comments/Actions

17 1 Configuration error 21 Node number More than one node with the same node
number or MB 300, GCOM.
Change node number!
22 Network and AC400 node has different node numbers.
node number Set the same node number on all busses on
the node!
23 Network and The node is connected to more than one
node number control network.
Make sure that the node is connected to one
control network, i.e. that all network numbers
are within the same decade!
24 Network and MB 300, GCOM interface incompatible with
node number system software.
25 Network and Incorrect (duplicate) network number.
node number Change the network number to the correct
number!
50 H’LRSNCPSP CS513 or CI547 config. error
LR Logical Record in the data base
SN Slave Number
CP Carrier Position in the subrack
SP Submodule Position on the carrier
51 H’LRSNCPSP CI532 config. error
SN Slave Number
52 H’LRSNCPSP CI532 config. error. Position already used
SN Slave Number
3BSE 002 414R601 Rev B J-5

Table J-6. Type 17, Code 1, 2, 3, 7, 8, 9 and 11 (Continued)

17 1 Configuration error 53 H’LRSNCPSP Config. error
SN Slave Number
54 H’LRSNCPSP The LAN channel is already used
SN Slave Number
2 Shortage of 18 Network number Too many nodes connected to the network
resources MB 300.
Reduce the number of nodes!
19 0=main processor Incorrect allocation of memory at start-up.
>0 = slave
processor
3 Disconnection 11 Data link level disconnected
2 Faulty communication board or wiring
3 Faulty communication board
13 Connection with node broken.
Faulty communication board or wiring.
H’RRAANENO
RR Disconnection cause, 00 = no contact with
slave node.
AA Slave channel number. 00 = all channels.
NE Network number
NO Node number
7 Reconnected 13 H’0000NENO Communication in working order
NE Network number
NO Node number
J-6 3BSE 002 414R601 Rev B


17 8 Hardware error 02 H’CCSSTT00 CS513 or CI547 error
CC Carrier position in the subrack
SS Submodule position on the carrier
TT Type of error:
- 03= Checksum error in received frame
- 04= CS513 missing/not accessible
- 0A= Late collision while transm. a frame
- 0B= Loss of carrier from transceiver
- 0D= Controller failed to transm. frame
- 44= Controller failed to initialize
- 48= Babble error. Frame > 1518 bytes
- 49= Transc. “heart beat error. Transc. is
not properly connected or the
SQE test is not working.
03 H’CC00EE00 SC520/530 error
CC Carrier position in the subrack
EE Type of error:
- 01= Failed to initialize
- 03= Board has halted
- 04= Board missing or not accessible
04 H’CCSSEE00 CI532/535 error
CC Carrier position in subrack
EE Type of error:
05 H’CCSSEE00 CI531 error
EE Type of error:
9 Hardware in 02 H’CCSS0000 CS513 or CI547 in working order
working order 03 SC520/530 in working order
04 CI532/535 in working order
05 CI531 in working order
SS Submodule position on the carrier (if relevant]
3BSE 002 414R601 Rev B J-7


17 11 Clock 02 0 No clock master node available.
synchronization
message 03 Backup node There might be more than one backup nodes
in the net. Set time again!
04 0 More than one clock master in the net. Set
time again!
J-8 3BSE 002 414R601 Rev B

Type 18 Console Communication

11 1 12:31:56 18 8 DECC100 H’00018580 5 H’00120000
Table J-7. Type 18, Code 8 and 11

18 8 Error code 0 - 5 indicates fault in 0 Status fault in system
the system, 6 - 10 indicates fault in 1 I/O fault in the system
the engineering station 2 Bus fault in the system
3 Time tripping (time-out) in the system
4 Memory fault in the system
5 Address fault in the system
6 Internal fault
7 Illegal instruction
8 Faulty address
9 Buffer overflow
10 Jump table index without limit
18 11 Communication failure between
Advant Controller and engineering
station
3BSE 002 414R601 Rev B J-9

Type 20 Error on V24 / RS-232-C Channel

11 1 06:03:54 20 1 CXBH260 H’000000B8 H’00020609 H’00000082

20 1 No contact with printer, CXBH260 Printer
terminal and external CXBH261 MasterView 320 no 1
computer
CXBH262 MasterView 320 no 2
Connected unit has the voltage disconnected.
Cable not connected.
XON-signal not generated from the unit connected.
Fault in signal transmission, e.g. modem or cable.
J-10 3BSE 002 414R601 Rev B

Type 22 PC interpreter
11 1 12:23:45 22 9 DAYIP30 109 34392
Table J-9. Type 22, Code 9, 12, 13 and 20

22 9 100 Correct again after overload.
101 Overload.
109 Insufficient memory or memory error.
110 Clock change or overload.
113 Interpreter task begun before INIT of the process
communication has been completed. This message
needs no corrective action during the initialization.
12 This type of fault affects the 100 The address jumpering of the positioning board and the
pulse counter and I/O address given on the PC element POS-A are
positioning board different. The positioning board is inactive.
DSDP 140A and DSDP 150 101 The I/O address given on the PC element POS-A is
Address = board address odd.
102 The address jumpering of the positioning board and the
I/O address given on the PC element POS-O are
different. The positioning board is inactive.
103 The I/O address given on the PC element POS-O is
odd.
I/O address given on the PC element POS-L are
different. The positioning board is inactive.
105 The I/O address given on the PC element POS-L is
odd.
I/O address given on the PC element PULSE-S are
different.
107 The I/O address given on the PC element PULSE-S is
odd.
I/O address given on the PC element FREQ-SP are
different.
109 The I/O address of the PC element FREQ-SP is odd.
Continue
3BSE 002 414R601 Rev B J-11

Table J-9. Type 22, Code 9, 12, 13 and 20

22 12 110 The address jumpering of the positioning board and the
I/O address given on the PC element FREQ-MP are
different.
111 The I/O address given on the PC element FREQ-MP is
odd.
112 POS-A reactivated
113 POS-O reactivated
114 POS-L reactivated
115 PULSE-S reactivated
116 FREQ-SP-reactivated
117 FREQ-MP reactivated
118 DSDP board reactivated
119 DSDP out of order
120 Incorrect address in PC element, the address is too
high or too low (POS-A, POS-L, POS-O, FREQ-SP,
FREQ-MP, COUNT-DP).
121 Incorrect address in the PC element
122 Incorrect address to MV 100 unit
127 MV 100 controller out of order
128 MV 100 controller in order
129 MV 100 unit out of order
130 MV 100 unit in order
131 DSDC board out of order
132 Fault on DSDC board
133 Fault on DSDC board
134 DSDC board reactivated
137 DSXW board out of order
138 DSXW board reactivated
139 Fault on DSXW board
141 DSDP 170 board in working order
142 DSDP 170 board out of order
13 100 Free-programmable module out of order
101 Free-programmable module active
20 102 Item designation pointed out by data base element
START is not a CONTRM.
J-12 3BSE 002 414R601 Rev B

Type 26 Other Faults (System Messages from Printer and operator station)
11 1 16:23:54 26 12 DCCA910 H’04900010 1 2
Type Code Address Comments/Actions

26 12 H’04900010 Text too long to be printed
H’04900020 PC element PRINT with LAST missing.
Set LAST = 1 in the last PRINT element!
3BSE 002 414R601 Rev B J-13

Type 28 Process Communication

11 1 16:23:54 28 20 CXPC800 H’0000003C H’011E0002
Data 1 contains concepts and instance numbers which can be used to locate incorrect data base
elements with the help of the command MDB. Do MDB “Concept”. Instance.
Example:
A system message includes Data 1 = H’ 011E0002. The most significant word 011E represents
the concept while the least significant word 0002 represents the instance number. Convert with
the help of Table J-11 to decimal form. Apply the decimal form and do MDB 286.2 to see the
corresponding data base.
From a more general viewpoint the command LCT is used to list all types of data base elements
in the system and all its concepts (LOF FILE). If the logical file for a certain data base element
is required, search for it in the UCONCSTR column and follow the line out to LOGFILE. An S
has been added for channels, e.g.: DI-channel is designated DIS. DI-channel has logical file 8.
DI-boards have logical file 4.
Table J-11. List of Common Concept Numbers in System Messages
Hex Dec DB Element (Concerning)

2 2 AI, Analog input boards
3 3 AO, Analog output boards
4 4 DI, Digital input boards
5 5 DO, Digital output boards
6 6 Analog input signals
7 7 Analog output signals
8 8 Digital input signals
9 9 Digital output signals
B5 181 MFb (S400 I/O) Units
11E 286 AXR (Analog object board)
14D 333 Advant Fieldbus 100 (CI52x), PROFIBUS-DP, CI541 or
LONCHAN
14E 334 Advant Fieldbus 100 units, Profibus slaves or LONDEV
14F 335 DataSet Peripheral
151 337 Processor module
15D 349 MasterFieldbus (CI570)
15F 351 Event Set
J-14 3BSE 002 414R601 Rev B

Table J-11. List of Common Concept Numbers in System Messages (Continued)
Hex Dec DB Element (Concerning)

16B 363 LONNV, LONWORKS Network Variables
16C 364 LONMNVI, LONWORKS Multiple Network Variables
16E 366 LON, LONWORKS Interface
Table J-12. Type 28
Type Code Data 1 Data 2 Comments/Actions

28 20 Concept, Bus fault. No board responds at the address used.
instance No. The board is extracted, faulty or incorrect jumpered.
H’011E H’xxxxyyyy Redundant S100 boards.
(286), x yyyy = 0 The unit (board 1 and board 2) has failed
yyyy = 1 Board 1 has failed
H’015D H’xxxxyyyy MasterFieldBus
(349),x xxxx = Bus number
yyyy = Not used.
H’00B5 H’xxxxyyyy MasterFieldBus nodes
yyyy = Node number
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)
H’014E H’xxxxyyyy AF100 stations and PROFIBUS slaves
yyyy = Station number
H’0145 H’wwxxyyzz S800 I/O modules
(325),x ww = Bus number
xx = Station number
yy = Cluster number
zz = Position number
H’0167 H’0000xxxx Single DSBC176 or redundant DSBC174 bus
(359),x extender
xxxx = 1 Left board has failed
xxxx = 2 Right board has failed.
3BSE 002 414R601 Rev B J-15

Table J-12. Type 28 (Continued)

28 21 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.
H’011E H’xxxxyyyy Redundant S100 boards. Internal hardware status.
(286),x xxxx = H’0000 Undefined error.
xxxx = H’00C9 = Fault bit set.
xxxx = H’00CA = Toggle error.
xxxx = H’00CB = ADC reference error.
xxxx = H’00D2 = Checksum error.
xxxx = H’00D3 = Error in DPM.
xxxx = H’00D4 = Error in internal memory.
xxxx = H’00D5 = Error in external memory.
xxxx = H’00D6 = Watch dog error.
xxxx = H’00D7 = Interval clock error.
xxxx = H’00D8 = ADC reference error, 0 V.
xxxx =H’00D9 = ADC reference error, 10 V.
xxxx = H’00DA = ADC reference error, 5 V.
xxxx = H’00DB = Gain error.
xxxx = H’00DC = AO supervision error.
yyyy = 0 Board 1 and board 2 has failed.

yyyy = Not used
yyyy = Node number
J-16 3BSE 002 414R601 Rev B


28 21 H’014D H’xxxxyyzz AF100 and PROFIBUS
yy = 0 No redundant CI52x
yy = 1 CI52x sub module 1
or
xxxxyyzz = 32-bit device error diagnostics.
H’016E H’xxxxyyyy LON device error bits
(366),x xxxx = 0001 Error command
xxxx = 0002 EEPROM access error
xxxx = 0008 RAM Defective
xxxx = 0010 Parameter Checksum error
xxxx = 0030 Self test failed
xxxx = 0040 Watch dog time-out
xxxx = 0080 Runtime error
xx = Station number
yy = Cluster number
H’0167 H’xxxxyyyy Single DSBC176 or redundant DSBC174 bus
(359),x extender
xxxx = Status from DSBC174 or DSBC176.
yyyy = 1 Left DSBC17x connected to left CPU.
yyyy = 2 Right DSBC174 connected to right CPU.
23 A measurement range not permitted for pulse
counter.
24 6,x An analog input has a value outside the working
range of the AD converter.
25 H’xxxxyyyy Interrupted communication on the distributed I/O
bus. See manual MasterFieldbus and S400 I/O
xxxx = Bus number
yyyy = Node number
26 H’xxxxyyyy Fault at one of the nodes of the distributed I/O bus.
xxxx = Bus number
yyyy = Node number
28 Channel fault in supervised AO channel.
3BSE 002 414R601 Rev B J-17


28 29 H’xxxxyyyy MasterFieldbus cable A fault
xxxx = Bus number
yyyy = Node number
30 H’xxxxyyyy MasterFieldbus cable A in operation
xxxx = Bus number
yyyy = Node number
31 H’xxxxyyyy MasterFieldbus cable B fault
xxxx = Bus number
yyyy = Node number
32 H’xxxxyyyy MasterFieldbus cable B in operation
xxxx = Bus number
yyyy = Node number
33 AO channel external fault
34 AI channel overflow
J-18 3BSE 002 414R601 Rev B


28 39 Concept, A previous hardware error has vanished. The board
instance No. or node is taken into operation again.
yyyy = Not used.
yyyy = Node number
H’014D H’xxxxyyzz AF100 and PROFIBUS
yy= 0 No redundant CI52x
yy= 1 CI52x sub module 1
yy= 2 CI52x sub module 2
xx = Station number
yy = Cluster number
H’0167 H’xxxxyyyy Single DSBC176 or redundant DSBC174 bus
(359),x extender.
xxxx = 400 Status word from DSBC17x
yyyy = 1 Left DSBC17x connected to left CPU.
yyyy = 2 Right DSBC174 connected to right CPU
55 Concept, Gain factor for linearization of Pt 100 outside
instance No. permissible value
56 Time interval or accumulated time for pulse counter
outside permitted value.
3BSE 002 414R601 Rev B J-19


28 74 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 type.
Example: REF5 in EVS(S) is a DIC but REF5 in
EVS(R) is an AIEV.
x = 9 Reference is neither AIEV nor DIEV, probably
missing.
x = A Reference is AIEV instead of DIEV or vice
versa.
x = B Reference is not AIEV or DIEV or is not
active.
76 Concept, H’0000000x EVS(R) has been removed. Reconfiguration will be
instance No. done.
H’015F x = 0 Removed EVS(R) belonged to AF 100
(351),x x = 1 - 9 Removed EVS(R) belonged to RCOM
network ‘x‘.
-1 Concept, H’xxxxxxxx Process error diagnostics from remote device
instance No. AF100, 32-bit process error diagnostic.
H’014D xxxxxxxx = H’20000000, More than 50 errors
(333),x xxxxxxxx = H’40000000, Simultaneous bus masters
xxxxxxxx = H’80000000, Redundant line failed
-2 Concept, H’xxxxyyzz AF100 device.error

instance No xxxx = Bus number
H’014D yy = 0 No redundant CI52x
(333),x yy = 1CI52x sub module
zz = Station number (of CI52x)
J-20 3BSE 002 414R601 Rev B


28 -4 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
H’00400000 No station configured
H’00800000 Ba version conflict
H’01000000 Invalid configuration table
H’02000000 Invalid telegram detected
H’04000000 Multiple devices (station number conflict)
H’08000000 Permenent sender detected
H’10000000 Too many signal addresses
H’20000000 Bus master synchronization lost
H’40000000 Simultaneous time masters
H’80000000 Invalid bus length
H’014D H’40000000 PROFIBUS address conflict
(333),x
H’014D LONWORKS channel error bits:

(333),x H’00000002 Parameter not correct
H’00000008 Can not open LONWORKS driver
H’00000010 Location mismatch
H’00000020 Supervision time-out
H’00000040 Runtime error
H’00000080 Subnet/node mismatch
H’00010000 Error command received
H’014E LONWORKS device error bits:
(334),x H’00000002 Device error bits
H’00000004 Parameters not correct
H’00000010 Device not responding
H’00000020 Location mismatch
H’00000040 Supervision time-out
H’00000080 Runtime error
H’00010000 Error command received
3BSE 002 414R601 Rev B J-21


28 -5 Concept, Minor Device/Station Error or I/O S800 Module
instance No warning. Nonfatal hardware error.
xx = Station number
yy = Cluster number
H’014E H’xxxxyyyy CI810 or CI820
H’014D LONWORKS channel
(333),x The configured location, subnet or/and node for the
channel does not match the actual values in the
device.
-6 Concept, Communication error
instance No
H’014D H’xxxxyyzz AF100 and PROFIBUS. Communication Error.
(333),x Reason: No contact with device
xxxx = Bus number
yy = 0 No redundant CI52x
zz = Station number (of CI52x or CI541V1)
-8 Concept, Bus controller CI52x halted
instance No.
-9 Diagnostics info Fatal bus error in CI52x, modem or cable
H’014D
-10 (333),x H’xxxxyyzz Redundant communication media error
xxxx = Bus number
yy = 0 Non-redundant
yy = 1 CI522 module I
yy = 2 CI522 module II
zz = Cable number
-11 H’xxxxyyzz Redundant communication media in working order
xxxx = Bus number
yy= 0 Non-redundant
yy = 1 CI522 module I
yy = 2 CI522 module II
zz = Cable number
-14 H’xxxxyyyy Redundant board changeover
xxxx= Internal information
yyyy= New primary CI522 module number
J-22 3BSE 002 414R601 Rev B

Type 29 Redundant Processor Modules, Operating System, Kernel

11 1 18:33:55 29 2 CXKK600 H’00000012 1 5
Table J-13. Type 29, Code 1,2, 3 and 4
Type Code Significance Address Comments/Actions

29 1 Message from redundant 1 Changeover has been performed automatically.
processor module 3 Fault in backup processor module.
diagnostics
4 Diagnostics fault.
2 Memory error in processor 1 The frequency of corrected bit-errors has exceeded a
module RAM certain limit. Data 1 = processor module position.
2 The total number of corrected bit errors has exceeded
a certain limit. Data 1 = processor module position.
Program card supervision H’10 Correct program card (PCMCIA 2.0) replaced.
H’11 Program card memory checksum error.
H’12 Program card removed (missing card).
H’13 Wrong program card.
For the addresses H’10 - H’13 data 1 and data 2 give
the position and subposition respectively.
3 Incorrect backup voltage for 1 Check battery backup.
RAM
4 Message from minute pulse 1 No minute pulse available (≥ 3 pulses missing)
handler 2 Minute pulse outside time range. Data 1 gives the
difference in units of 0.1 ms.
3BSE 002 414R601 Rev B J-23

Type 30 MasterBus (Data Set, EXCOM)

11 1 13:25:09 30 21 CXAA000 H’EEAC H’1010002 H118100FF
Table J-14. Type 30, Code 21, 23
Type Code Significance Address Data 1 Data 2 Comments/Actions

30 21 Overload in receiving end. H’EEAC 1 H’XXYY0000 Routine:
(=61100) (channel CXAA000 DS (MV 300)
full) CXAM000 DS [MVI, RCOM)
CXAT000 TS (MV 300)
XX = Destination network
YY = Destination node
Overload in receiving end. Message Dest. Destination Routine:
ident. netw. node CXAF00x (EXCOM)
number
23 Fault in the data base H’EB28 4 DS, MS, Routine:
element (DS, MS, TS). (=60200) TS number CXAA000 DS (MV 300)
There are no data CXAM000 DS [MVI, RCOM)
references. CXAT000 TS (MV 300)
DS or MS has been
blocked.
Incorrect polling time at H’ED1D 4 DS, Routine:
receiving data base (=60701) MS number CXAA000 DS (MV 300)
element (DS or MS). CXAM000 DS [MVI, RCOM)
DS or MS blocked.
Transmitting and receiving H’ED80 4 H’XXXXYYYY Routine:
data base elements (DS, (=60800) CXAA000 DS (MV 300)
MS, TS) have different data CXAM000 DS [MVI, RCOM)
references. CXAT000 S (MV 300)
XXXX = Number of data
references in DS,
MS or TS
YYYY = DS, MS or TS
number
J-24 3BSE 002 414R601 Rev B

Table J-14. Type 30, Code 21, 23 (Continued)
Type Code Significance Address Data 1 Data 2 Comments/Actions

30 23 The data reference of the H’EE49 4 H’XXXXYYYY Routine:
data base element (DS, MS (=61001) CXAA000 DS (MV 300)
or TS) does not exist. CXAM000 DS [MVI, RCOM)
CXAT000 TS (MV 300)
XXXX = Number of dat
references in DS,
MS or TS
YYYY = DS, MS or TS
number
The receiving reference in H’EEAD 4 DS, MS, Routine:
the data base element (DS, (=61101) TS number CXAA000 DS (MV 300)
MS or TS) is not CXAM000 DS [MVI, RCOM)
addressable. CXAT000 TS (MV 300)
The data base element H’FICC 3 H’XXYYZZVV XX = Destination network
(DS, MS or TS) addressed (=61900) YY = Destination node
does not exist. ZZ = DS, MS or TS number
VV = 1: transmitting type
VV = 2: receiving type
3BSE 002 414R601 Rev B J-25

Type 39 Data Set Peripheral, Advant Fieldbus 100

11 1 13:25:10 39 6 CXAP000 H’00230011 H’014F0001
Table J-15. Type 39

39 1 Configuration of DSPs on Concept, Result from Command time out or hardware
the communication instance of board operation error
interface or changing the first DSP
DSP state has failed. concerned
2 DSPs exist which are Basic cycle time One or several DSPs are defined for
scanned slower than used in HEX a CYCLETIM< basic cycle time. The
definition. DSPs concerned are updated with
the basic cycle time. The basic cycle
time is changed with the APP
command.
5 Unconfigured DSPs exist No data 1. One or several unconfigured
DSPs have been found after
configuration at start-up. The
DSPs might automatically be
configured at reconfiguration.
2. Previous configuration failed.
6 Communication to the See See Comments The communication interface is
communication interface Comments removed or does not function
is lost. properly.
For messages with address:
00230011, 00240011, 00240012
Data 1: DSP data base concept,
instance number
Data 2: No data
For messages with address:
00040012
Data 1: 0
Data 2: Logical bus number
J-26 3BSE 002 414R601 Rev B


39 7 Illegal bus or bad See See Comments The DSP is defined for a non
definition of Advant Comments existing bus or the bus is badly
Fieldbus 100 defined.
In case the DSP bus number is
badly defined:
Data 1: DSP data base concept,
instance number
Otherwise:
Data 1: 0
9 The DSP has badly Concept, No data The DSP references e.g. a non
defined references. instance of existing DAT.
the DSP
14 Illegal definition of DSP Internal error The DSP is badly defined and by
concerned
code this not configured, The bad
definition concerns: IDENT,
STATION or no DATs are
referenced.
3BSE 002 414R601 Rev B J-27

Type 134 System/Node Supervision

11 1 13:25:10 134 20 H’ H’ H’
Table J-16. Type 134, Code

134 20 AC 410/AC450, 24 V error Concept, MSW: Direction H’EEEE ⇒ Error coming
instance No. H’2222 ⇒ Equip. in working order
LSW: Channel 1 ⇒ Channel 1
2 ⇒ Channel 2
21 AC 410/AC450, MSW: Direction H’EEEE ⇒ Error coming
regulator error H’2222 ⇒ Equip. in working order
LSW: Regulator AC450
0 ⇒ Common reg. error (any/none
of 1 - 4 erroneous).
1 ⇒ Regulator 1 error.
AC410
101⇒ Regulator missing.
102⇒ Regulator error.
22 AC 410/450, MSW: Direction H’EEEE ⇒ Error coming
battery error H’2222 ⇒ Equip. in working order
LSW: Battery 1 ⇒ Battery A (Only AC 450)
2 ⇒ Battery B (Only AC 450)
backup power supply error H’2222 ⇒ Equip. in working order
LSW: Backup 1 ⇒ Unit A (Only AC 450)
power supply 2 ⇒ Unit B (Only AC 450)
fan error H’2222 ⇒ Equip. in working order
LSW: Not used
25 AC 450, MSW: Direction H’EEEE ⇒ Error coming
I/O 24 V error H’2222 ⇒ Equip. in working order
LSW: Channel 1 ⇒ Channel A
2 ⇒ Channel B
J-28 3BSE 002 414R601 Rev B

Table J-16. Type 134, Code (Continued)

134 26 AC450, Concept, MSW: Direction H’EEEE ⇒ Error coming
I/O regulator error instance No. H’2222 ⇒ Equip. in working order
LSW: Regulator 1⇒ Regulator missing.
2⇒ Regulator error.
27 AC450, MSW: Direction H’EEEE ⇒ Error coming
I/O fan error H’2222 ⇒ Equip. in working order
LSW: Not used
user defined error H’2222 ⇒ Equip. in working order
LSW: Which 1⇒ F1.
error 2⇒ F2. (Only AC 450)
3⇒ F3. (Only AC 450)
4⇒ F4. (Only AC 450)
29 AC 450, Status of
TC520 communication operation
error
31 AC 450, Status of
TC520 communication operation
error
3BSE 002 414R601 Rev B J-29

J-30 3BSE 002 414R601 Rev B

Section K.1 Conversion Guide
Appendix K Hexadecimal to Decimal Representation
K.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. The decimal notation system uses the digits 0 - 9, the binary system 0 -
1, the hexadecimal system 0 - 9 and the letters A - F where A represents 10, B represents 11, C
represents 12, D represents 13, E represents 14 and F represents 15. The examples below are
intended to explain the structure of the notation systems.
Decimal Notation:
1090 = 1 * 103 + 0 * 102 + 9 * 101 + 0* 100 = 1090
Binary Notation:
1010 = 1 * 23 + 0 * 22 + 1* 21 + 0* 20 = 10 (dec)
Hexadecimal Notation:
1099 = 1 * 163 + 0 * 162 + 9 * 161 + 9 * 160 = 4249 (dec)
A09B = 10 * 163 + 0 * 162 + 9 * 161 + 11* 160 = 41115 (dec)
From the examples above, it is seen that each position in a number corresponds to the value
times the base (2, 10, 16) raised to the power corresponding to its position in the number.
In the Advant Controller 400 Series, numbers in hexadecimal notation are identified by an
introductory H’. Decimal notation is used otherwise.
Examples: H’0000357A Hexadecimal
00003578 Decimal
The following shows a table for rapid conversion of up to four-figure hexadecimal numbers.
If the number contains more figures, the value can be calculated in accordance with the
examples above.
For example: H’257E = 8192 + 1280 + 112 + 14
3BSE 002 414R601 Rev B K-1

Appendix K Hexadecimal to Decimal Representation
Table K-1. Conversion of up to Four Figure Hexadecimal Numbers
HEX DEC HEX DEC HEX DEC HEX DEC

0 0 0 0 0 0 0 0
1 4096 1 256 1 16 1 1
2 8192 2 512 2 32 2 2
3 12288 3 768 3 48 3 3
4 16384 4 1024 4 64 4 4
5 20480 5 1280 5 80 5 5
6 24576 6 1536 6 96 6 6
7 28672 7 1792 7 112 7 7
8 32768 8 2048 8 128 8 8
9 36864 9 2304 9 144 9 9
A 40960 A 2560 A 160 A 10
B 45056 B 2816 B 176 B 11
C 49152 C 3072 C 192 C 12
D 53248 D 3328 D 208 D 13
E 57344 E 3584 E 224 E 14
F 61440 F 3840 F 240 F 15
K-2 3BSE 002 414R601 Rev B

Index
INDEX
A D
Address D-4 Data and Text Handling 1-94
Advant Station 500 Series 1-103 Data entry 2-51
AI810 1-73 Data Set 1-88
AI830 1-73 to 1-74 Delivered Version Specification C-1
AI835 1-73 Delivery Specification C-1
AO810 1-73 DI810 1-71
AO820 1-74 DI811 1-71 to 1-72
Application Program Backup DI820 1-71
Appropriate Hardware and Software 3-3 DI821 1-71 to 1-72
Overview 1-25 Dimensioning 2-51
Working procedures 5-70 Distributed Connection Units 2-31
AUTO 4-2 DO810 1-72
DO820 1-72
B E
Backup power supply for RAM EAF, Estimated Application Function 3-37
Description 1-42 EMC, Electro Magnetic Compatibility, data 3-64
Battery Backup Time 3-53 Enter button
Safety aspects 5-1
Environmental Adaptation 1-114
C Environmental Considerations 2-2
Calendar Time Functions 1-94 Event Handling
CI810V1 1-70 Technical Data 3-55
CI820 1-70 extended MTUs 1-75
CLEAR 4-2 External clock synchronization
Compact MTUs 1-75 Description 1-33
Configuration mode 4-1 Electrical data A-21
Configuration/Application Building 3-66 Installation 2-28
Connection Unit 1-46
Controller block diagram 1-21 F
Controller System Configuration 3-66 Feedback Control 1-98
CPU-load Functional interfaces 1-22
Base load 3-40 Functional modularization 1-23
Calculation principles 3-36 Functional units 1-93
Data Set 3-46 Fusing in Distribution Board 3-5
Logging 3-48 Fusing within the system 1-42
MasterView 320 3-47
Others 3-49 H
PC and process I/O 3-41 Hardware structure 1-19
Performance-General 3-39 HART Interface 1-50 to 1-51
Reduction of load 3-37 Heating Element 2-16
Subscription, command, events 3-44
Creating 2-51 I
Current Consumption 3-5 Inspection and Test Record C-1
Intrinsic Safety Barriers 1-50
3BSE 002 414R601 Rev B i

Index
L S
License Certificate C-1 Safety Switch 2-8
Lifting instructions 2-16 Safety system aspects 1-106
Location of components D-1 SD811 1-77
Location-Oriented Item Designations D-3 SD812 1-77
Logic and Time Delays 1-94 Sequence Control 1-94
Shut-down
M Automatic 2-47
Masterview 320 1-101 Emergency 2-45
MasterView 800/1 1-103 Manual 2-46
MasterView 800/1 Series 1-103 Safety 2-45
Measuring 1-97 Software structure 4-13
Memory STOP 4-2
Application Program Backup 1-25 SU-modules D-3
Power Supply Backup 1-25 Supervision 1-97
Size 3-53 Supervisory input
System Program Backup 1-24 Description 1-109
Mimic Panel 1-101 Supervisory inputs
Module Termination Units 1-75 Electrical data A-21
Modulebus 1-68 Installation 2-28
Motor and Valve Control, Group Start 1-99 Support and Problem Reporting C-1
Mounting planes D-1 Swing frame D-1
MTUs 1-67, 1-75 System Definition 3-66
System Log C-1
N
Naming 3-68 T
TB815 1-70
O Terminal Diagram C-1
Object oriented connection 1-47 termination Units 1-67
OFFLINE 4-2 TU810 1-75
Offline mode 4-1 TU811 1-75
Operation mode 4-1 TU830 1-75
Order Reference Sheet C-1 TU831 1-75
Outputs behavior at Interrupts 1-105 TU835 1-76
TU836 1-76
TU837 1-76
P
Type Circuits 3-69
P1, P2, -3, -4 4-1
PC element 1-89
Positioning 1-94 U
Priority system 3-34 UPS, Uninterrupted power supply 3-8
Product variants 1-23 User Defined PC Elements
Protective Earth 2-6 Application 1-91
Pulse Counting and Frequency Measurement 1-95 Program module 1-33
R V
Release Notes C-1 VT 100 terminal 1-101
Reports 1-96 VT100 terminal 1-102
Run/Alarm relay
Description 1-107
Electrical data A-21
Installation 2-28
ii 3BSE 002 414R601 Rev B

3BSE 002 414R601 Rev B
April, 2001

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Advant® OCS Advant® Controller 410

with Master software

3BSE 002 414R601 Rev B

3BSE 002 414R601 Rev B i

ii 3BSE 002 414R601 Rev B

3BSE 002 414R601 Rev B iii

iv 3BSE 002 414R601 Rev B

3BSE 002 414R601 Rev B v

Chapter 4 - Runtime Operation

vi 3BSE 002 414R601 Rev B

3BSE 002 414R601 Rev B vii

viii 3BSE 002 414R601 Rev B

Appendix A - Hardware Modules

Appendix B - RM500 Cabinet - Data Sheet

3BSE 002 414R601 Rev B ix

Appendix C - Delivery Documentation

Appendix D - Item Designations

Appendix E - Current Consumption and Heat Dissipation

Appendix F - Load Calculation

Appendix G - Memory Calculation

Appendix H - Product Variants

Appendix I - Halt Codes

Appendix J - System Messages

Appendix K - Hexadecimal to Decimal Representation

x 3BSE 002 414R601 Rev B

3BSE 002 414R601 Rev B xi

xii 3BSE 002 414R601 Rev B

3BSE 002 414R601 Rev B xiii

xiv 3BSE 002 414R601 Rev B

3BSE 002 414R601 Rev B xv

xvi 3BSE 002 414R601 Rev B

3BSE 002 414R601 Rev B xvii

xviii 3BSE 002 414R601 Rev B

1.1 General Information

IMS Station Operator Station Eng.Station Batch Station

Remote Terminal Process I/O

3BSE 002 414R601 Rev B 1-1

1.2 Manual Organization

General Site Planning Design Product Preventive

Figure 1-2. Basic Documentation Structure

1-2 3BSE 002 414R601 Rev B

3BSE 002 414R601 Rev B 1-3

Chapter 3, Configuration/Application Building

Chapter 4, Runtime Operation

1-4 3BSE 002 414R601 Rev B

1.4 Related Documentation

3BSE 002 414R601 Rev B 1-5

Table 1-1. Related Documentation - Configuration/Application Building

1-6 3BSE 002 414R601 Rev B

Table 1-2. Related Documentation - Installation

Table 1-3. Related Documentation - Optional Functions

3BSE 002 414R601 Rev B 1-7

Table 1-3. Related Documentation - Optional Functions (Continued)

1-8 3BSE 002 414R601 Rev B

Table 1-4. Related Documentation - Tools

1.5 Release History

3BSE 002 414R601 Rev B 1-9

• Communication including event handling with Advant Controller 110 on:

1-10 3BSE 002 414R601 Rev B

• New appearance of RE500 cabinets

QC01-BAS11 7.0/0 02/01/01