Rockwell Automation Allen-Bradley AADvance T9110 Manual

AADvance Controller
Catalog Numbers T9110, T9300, T9310, T9401/2, T9431/2,
T9451, T9481/2
System Build Manual Original Instructions

2Rockwell Automation Publication ICSTT-RM448M-EN-P - February 2021
AADvance Controller System Build Manual
Important User Information
Read this document and the documents listed in the additional resources section about installation, configuration, and
operation of this equipment before you install, configure, operate, or maintain this product. Users are required to familiarize
themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws, and standards.
Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required to
be carried out by suitably trained personnel in accordance with applicable code of practice.
If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be
impaired.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use
or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for
actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software
described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is
prohibited.
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
Labels may also be on or inside the equipment to provide specific precautions.
WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment,
which may lead to personal injury or death, property damage, or economic loss.
ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property
damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.
IMPORTANT Identifies information that is critical for successful application and understanding of the product.
SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous
voltage may be present.
BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may
reach dangerous temperatures.
ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to
potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL
Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).

Rockwell Automation Publication ICSTT-RM448M-EN-P - February 2021 3
Preface
About This Publication This technical manual describes how to assemble a system, switch on and
validate the operation of your system.
In no event will Rockwell Automation be responsible or liable for indirect or
consequential damages resulting from the use or application of this
equipment. The examples given in this manual are included solely for
illustrative purposes. Because of the many variables and requirements related
to any particular installation, Rockwell Automation does not assume
responsibility or reliability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, with respect to use of
information, circuits, equipment, or software described in this manual.
All trademarks are acknowledged.
Disclaimer
It is not intended that the information in this publication covers every possible
detail about the construction, operation, or maintenance of a control system
installation. You should also refer to your own local (or supplied) system safety
manual, installation and operator/maintenance manuals.
Revision And Updating Policy
This document is based on information available at the time of its publication.
The document contents are subject to change from time to time. The latest
versions of the manuals are available at the Rockwell Automation Literature
Library under "Product Information" information "Critical Process Control &
Safety Systems".
Downloads
The product compatibility and download center is rok.auto/pcdc.
Select the Find Downloads option under Download
In the Product Search field enter "AADvance" and the AADvance® option is
displayed.
Double click on the AADvance option and the latest version is shown.
Select the latest version and download the latest version.
AADvance Release
This technical manual applies to AADvance system release 1.40 and these
software:
• AADvance® Workbench software version 1.4
• AADvance Workbench software version 2.1

4Rockwell Automation Publication ICSTT-RM448M-EN-P - February 2021
• AADvance®-Trusted® SIS Workstation software version 1.1
Latest Product Information
For the latest information about this product review the Product Notifications
and Technical Notes issued by technical support. Product Notifications and
product support are available at the Rockwell Automation Support Center at
rok.auto/knowledgebase.
At the Search Knowledgebase tab select the option "By Product" then scroll
down and select the ICS Triplex® product AADvance.
Some of the Answer IDs in the Knowledge Base require a TechConnectSM
Support Contract. For more information about TechConnect Support Contract
Access Level and Features, click this link: Knowledgebase Document ID: IP622
- TechConnect Support Contract - Access Level & Features.
This will get you to the login page where you must enter your login details.
Environmental Compliance
Rockwell Automation maintains current product environmental information
on its website at rok.auto/pec.
Download Firmware, AOP,
EDS, and Other Files
Download firmware, associated files (such as AOP, EDS, and DTM), and access
product release notes from the Product Compatibility and Download Center at
rok.auto/pcdc.
Summary of Changes This publication contains the following new or updated information. This list
includes substantive updates only and is not intended to reflect all changes.
Global Changes
This table identifies changes that apply to all information about a subject in the
manual and the reason for the change. For example, the addition of new
supported hardware, a software design change, or additional reference
material would result in changes to all of the topics that deal with that subject.
NOTE AADvance system release 1.40 identifies the product family
release. Each hardware, firmware and software component has
its own version within this family release and the details of those
versions can be found in the AADvance System Requirements
for version 1.40 in the PCDC Release Notes, which can be
accessed from the Product Compatibility and Download Center at
rok.auto/pcdc.
IMPORTANT A login is required to access the link. If you do not have an
account then you can create one using the "Sign Up" link at the
top right of the web page.

Rockwell Automation Publication ICSTT-RM448M-EN-P - February 2021 5
New or Enhanced Features
This table contains a list of topics changed in this version, the reason for the
change, and a link to the topic that contains the changed information.
Subject Reason
Changed workstation to computer Technical improvement
Added AADvance®-Trusted® SIS Workstation
software information where applicable Enhancement
Changed
Workbench to software where applicable Technical improvement
Changed Workbench to AADvance Workbench
software
where applicable Technical improvement
Added reference to AADvance-Trusted SIS
Workstation Software User Guide, publication
ICSTT-UM002 Additional reference material
Applied latest publication template Marketing product change
Subject Reason
AADvance Release on page 3 Updated AADvance system release and software
information.
The AADvance Safety Controller on page 13 Added IMPORTANT and ATTENTION tables with
information on supported languages.
Safety Features on page 15 Removed information indicating that AADvance processor modules are designed to meet the
requirements for SIL 2 in a simplex configuration.
Scan Times on page 17 Removed footnote on
Minimum cycle time
overhead .
The AADvance Software Development Environment
on page 24
Changed The AADvance Workbench and Software
Development Environment section to The
AADvance Software Development Environment.
Updated section content.
Operating Systems on page 25 Updated with reference to the Product
Compatibility and Download Center (PCDC).
Importing and Exporting Data on page 26 Updated supported file formats.
Software Licenses on page 26 Updated section title and content. Added links to
software publications.
Ethernet Communication Protocols on page 48 Updated table.
Programming Language Support on page 49 Added IMPORTANT and ATTENTION tables with
information on supported languages.
Specify software requirements on page 66 Updated with reference to the Product
Compatibility and Download Center (PCDC).
System Security on page 85 Updated security steps.
Digital Input Field Loop Circuits on page 86 Updated suggested range of values
Software on page 130 Removed row for T9085. Added row for T9090.
Removed rows for T9901...T9906.
N on page 143 Removed NFPA 87.
proof test on page 144 Updated definition.

6Rockwell Automation Publication ICSTT-RM448M-EN-P - February 2021
Additional Resources These documents contain additional information concerning related products
from Rockwell Automation.
You can view or download publications at rok.auto/literature.
Resource Description
AADvance Controller Safety Manual, ICSTT-RM446
This technical manual defines how to safely apply AADvance controllers for a Safety
Instrumented Function. It sets out standards (which are mandatory) and makes
recommendations to make sure that installations satisfy and maintain their required safety
integrity level.
AADvance Controller Configuration Guide Workbench 1.x, ICSTT-RM405 This software technical manual defines how to configure an AADvance controller
using the AADvance Workbench software version 1.x to satisfy your system operation and
application requirements.
AADvance Controller Configuration Guide Workbench 2.x, ICSTT-RM458 This software technical manual defines how to configure an AADvance controller
using the AADvance Workbench software version 2.x to satisfy your system operation and
application requirements.
AADvance-Trusted SIS Workstation Software User Guide, ICSTT-UM002 This publication provides how-to instructions for AADvance-Trusted SIS Workstation
software configuration and use.
AADvance Controller OPC Portal Server User Manual, ICSTT-RM407 This manual describes how to install, configure and use the OPC Server for an AADvance
Controller.
AADvance Controller PFH and PFDavg Data, ICSTT-RM449 This document contains the PFH and PFDavg Data for the AADvance Controller. It includes
examples on how to calculate the final figures for different controller configurations.
AADvance Controller Solutions Handbook, ICSTT-RM447 This technical manual describes the features, performance and functionality of the
AADvance controller and systems. It gives guidance on how to design a system to satisfy
your application requirements.
AADvance Controller Troubleshooting and Maintenance Manual, ICSTT-RM406 This technical manual describes how to maintain, troubleshoot and repair an AADvance
Controller.
Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1 Provides general guidelines for installing a Rockwell Automation industrial system.
Product Certifications website, rok.auto/certifications. Provides declarations of conformity, certificates, and other certification details.

Rockwell Automation Publication ICSTT-RM448M-EN-P - February 2021 7
Table of Contents
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
About This Publication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Download Firmware, AOP, EDS, and Other Files . . . . . . . . . . . . . . . . . . . . 4
Summary of Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Chapter 1
The AADvance System Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Chapter 2
The AADvance Safety Controller Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Safety Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Safety System Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Performance and Electrical Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 17
Scan Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
System Installation Environment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Environment Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Installation Requirements for Non-Hazardous Environment . . . . . . . 20
Investigation File Number E341697 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Installation Requirements for Hazardous Environment . . . . . . . . . . . . 21
Installation Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
File Number E251761 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Certifications for Safety System Applications in Hazardous
Environments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
ATEX Certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
IECEx UL Certificate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Module Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
KCC-EMC Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
The AADvance Software Development Environment . . . . . . . . . . . . . . . 24
Operating Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Importing and Exporting Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Software Licenses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Corrective Maintenance and Module Replacement. . . . . . . . . . . . . . 26
TUV Approved Operating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Main Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Physical Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Environmental Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Product Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Compact Module Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Module Polarization Keying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Module Locking Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Field Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Processor Base Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

8Rockwell Automation Publication ICSTT-RM448M-EN-P - February 2021
External Ethernet, Serial Data and Power Connections. . . . . . . . . . 34
Serial Communications Ports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Processor Back-up Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Processor Maintenance Socket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
I/O Base Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Termination Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Backplane Electrical Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Expansion Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Technical Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Controller Internal Bus Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Internal Diagnostics and Fault Reset . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Remote Fault Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
On-line updates I/O Configuration Changes . . . . . . . . . . . . . . . . . . . 46
Hot Swap I/O for Business Critical Channels . . . . . . . . . . . . . . . . . . . 47
Processor Firmware Upgrades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Ethernet Communication Protocols . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Chapter 3
Application Development Programming Language Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Program Management Facilities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Support for Variable Types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
I/O Connection (Addressing of Physical I/O). . . . . . . . . . . . . . . . . . . . . . . 50
Off-line Simulation and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Application Program Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Aids to Software Development . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Chapter 4
Before You Begin Required Tools Standard AADvance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Specifying an Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Maximum Enclosure Air Temperature. . . . . . . . . . . . . . . . . . . . . . . . . 54
Enclosure Requirements for a Non-hazardous Environment. . . . . 54
Enclosure Requirements for a Hazardous Environment - Class I,
Division 2, Groups A, B, C and D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Controller Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Free Space around the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Base Units Rows and Expansion Cables. . . . . . . . . . . . . . . . . . . . . . . . 58
Adding Field Cable Management. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
System Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Power Supply and Power Distribution Requirements . . . . . . . . . . . 61
Controller Power Supply Requirements. . . . . . . . . . . . . . . . . . . . . . . . 61
Power Arrangements for Field Devices. . . . . . . . . . . . . . . . . . . . . . . . . 62
Estimating Power Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
System Design Considerations for Heat Dissipation and Cooling. . . . 63
Estimate Heat Dissipation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Estimate AADvance Controller Weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Estimating Center of Gravity Information. . . . . . . . . . . . . . . . . . . . . . . . . 65
Design Considerations for Electrical Grounding. . . . . . . . . . . . . . . . 65
Specify software requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Design Considerations for Maintenance Activities . . . . . . . . . . . . . . . . . 66

Rockwell Automation Publication ICSTT-RM448M-EN-P - February 2021 9
Maintenance Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Design Provisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Connecting the AADvance Controller to the Network . . . . . . . . . . . . . . . 70
Chapter 5
Install the AADvance System Unpacking and Preassembly Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Install Base Units and Termination Assemblies: Enclosure DIN Rail
Assembly Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Fitting Termination Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Allocations of Coding Pegs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Connect the AC Safety Ground Connection. . . . . . . . . . . . . . . . . . . . . . . . 77
Connect the 24 Vdc System Power to an AADvance Controller . . . . . . . 78
Procedure to Connect Serial Communications Cabling . . . . . . . . . . . . . 79
Connecting MODBUS Slave Devices to Serial Ports . . . . . . . . . . . . . 81
Connect a Slave Device, Full Duplex . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Connect Multiple Slave Devices, Full Duplex . . . . . . . . . . . . . . . . . . . 82
Connect a Slave Device, Half Duplex. . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Connect Multiple Slave Devices, Half Duplex . . . . . . . . . . . . . . . . . . . 84
System Security. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Connecting Field Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Digital Input Field Loop Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Analogue Input Field loop Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Recommended Field Circuit for Digital Outputs . . . . . . . . . . . . . . . . 96
Recommended Circuit for Analogue Outputs. . . . . . . . . . . . . . . . . . . 99
Install Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Install a T9110 Processor Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Replace a Faulty Processor Back-up Battery . . . . . . . . . . . . . . . . . . . 103
Set the Real Time Clock Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Install I/O Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Install T9310 Expansion Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Fault Reporting Reference Information . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Status Indicators on the T94xx Series Input and Output Module 110
Status Indicators on the T9110 Processor Module . . . . . . . . . . . . . . . 111
Chapter 6
System Startup Recommendations to Manage Test Documentation . . . . . . . . . . . . . . . 113
System Physical Design Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Procedure to Verify Build State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Procedure to Conduct the Mechanical Inspection . . . . . . . . . . . . . . . . . 114
Procedure to Check Ground Bonding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Procedure to Check Power Distribution Integrity . . . . . . . . . . . . . . . . . 114
Power Distribution and First Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Startup Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Processor Module Startup Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
I/O Module Startup Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Processor Firmware Upgrades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Setting the Controller IP Address for Communications . . . . . . . . . . . . 120
Controller IP Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

10 Rockwell Automation Publication ICSTT-RM448M-EN-P - February 2021
Troubleshooting AADvance Discover Communications . . . . . . . . . . . . 120
Configure the Controller Resource Number in the Controller . . . . . . 121
Configure the IP Address in the Controller . . . . . . . . . . . . . . . . . . . . . . . 122
Chapter 7
Functional Acceptance Testing Devising tests for Functional Acceptance . . . . . . . . . . . . . . . . . . . . . . . . . 125
Test Environment for Functional Acceptance . . . . . . . . . . . . . . . . . . . . . 125
Managing Functional Acceptance Testing . . . . . . . . . . . . . . . . . . . . . . . . 125
Chapter 8
Dismantling the AADvance
System
About Dismantling a System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Chapter 9
Parts List Base Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Special Application Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Termination Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Expansion Cable Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Blanking Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Spares and Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Demonstration Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Miscellaneous Items. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Appendix A
History of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

Rockwell Automation Publication ICSTT-RM448M-EN-P - February 2021 11
Chapter 1
The AADvance System
Introduction An AADvance® system consists of an AADvance controller, an external
operator's computer, field connections, power sources and external network
connections. The flexibility of the design means that a system can meet a wide
variety of business needs. An AADvance system is assembled to a scale and
configuration that is applicable to your initial requirements and can be easily
changed to meet your changing business requirements in the future. A system
is built from an approved range of modules and assemblies.

12 Rockwell Automation Publication ICSTT-RM448M-EN-P - February 2021
Chapter 1 The AADvance System
Notes:

Rockwell Automation Publication ICSTT-RM448M-EN-P - February 2021 13
Chapter 2
The AADvance Safety Controller
The AADvance®controller is specifically designed for functional safety and
critical control applications; it gives a flexible solution for smaller scale
requirements. The system can also be used for safety implemented functions
as well as applications that are not related to safety but are nevertheless critical
to a business process. This AADvance controller offers the ability to make a
cost-effective system to a customer's specification for any of the following
applications:
• Emergency shutdown system
• Fire and gas installation protection system
• Critical process control
• Burner management
• Boiler and furnace control
• Distributed process monitoring and control
An AADvance controller is particularly useful for emergency shut down and
fire and gas detection protection applications as it offers a system solution
with integrated and distributed fault tolerance. It is designed and validated to
international standards and is certified by independent certifying bodies for
functional safety control installations and UL for use in hazardous
environments.
This chapter introduces the primary components that can be used to assemble
an AADvance controller.
A controller is built from a range of compact plug-in modules (see illustration)
that are straightforward to assemble into a system. A system can have just one
or more controllers, a combination of I/O modules, power sources,
communications networks and computers. It can operate as a stand-alone
system or as a distributed node of a larger control system.

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Chapter 2 The AADvance Safety Controller
A Key benefit of the AADvance system is its flexibility. All of the configurations
are readily achieved by combining modules and assemblies without using
special cables or interface units. System architectures are user configurable
and can be changed without major system modifications. Processor and I/O
redundancy is configurable so you can make a decision between fail safe and
fault tolerant solutions. There is no change to the complexity of operations or
programming that the controller can handle if you add redundant capacity to
create a fault tolerant solution.
They can be mounted onto DIN rails in a cabinet or directly mounted onto a
wall in a control room. Forced air cooling or special environmental control
NOTE The printed circuit boards of all AADvance modules, termination
assemblies and backplanes are coated during manufacture. The
coating meets defense and aerospace requirements, is approved
to US MIL-1-46058C standard and meets IPC-CC-830. The coating
is also UL approved.

Rockwell Automation Publication ICSTT-RM448M-EN-P - February 2021 15
Chapter 2 The AADvance Safety Controller
equipment is not necessary. However, important consideration must be given
to the choice of cabinet or when the controller is installed in a hazardous
environment.
Specific guidelines are given in this user documentation to help you choose an
enclosure that will make sure that the system operates to its full capability and
reliability and that it also complies with the ATEX and UL certification
requirements for use in hazardous environments.
The Ethernet and serial ports are configurable for a number of protocols in
both simplex and redundant configurations for connection to other AADvance
controllers or external third party equipment. Communications internally
between the processors and I/O modules uses a proprietary communications
protocol over a custom wired harness. The AADvance system supports
transport layer communication protocols such as TCP and UDP for MODBUS,
CIP, SNCP, Telnet and SNTP services.
A secure network communications protocol (SNCP), developed by Rockwell
Automation for the AADvance system, permits distributed control and safety
using new or existing network infrastructure while ensuring the security and
integrity of the data. Individual sensors and actuators can connect to a local
controller, minimizing the lengths of dedicated field cabling. There is no need
for a large central equipment room; rather, the complete distributed system
can be administered from one or more computers placed at convenient
locations.
The AADvance controller is developed and built for IEC 61131 compliance and
includes support for all five programming languages.
Program access is secured by a "Program Enable" key that you can remove.
Simulation software lets you prove a new application before reprogramming
and downloading, again maximizing system uptime. Additional security
functions are also included to help prevent unauthorized access.
Safety Features The AADvance controller meets non-safety business requirements and SIL 2
and SIL 3 safety related system requirements. The system has comprehensive
built-in redundant capabilities that improve system availability.
The AADvance safety system features are:
• Easily transformed from a simplex non-safety system to a fault tolerant
safety related system.
IMPORTANT AADvance® Workbench software version 1.4 supports the
Instruction List (IL) language.
AADvance Workbench software version 2.x and AADvance®-
Trusted®SIS Workstation software do not support the IL
language.
ATTENTION: The AADvance Workbench software and AADvance-Trusted
SIS Workstation software do not support the Sequential Function Chart
(SFC) language for safety-related applications.

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Chapter 2 The AADvance Safety Controller
• An AADvance system provides a set of components that can be
configured to meet a range of safety and fault tolerance user
requirements within a single system such as - fault tolerant topologies
1oo1, 1oo2D and 2oo3.
• IEC 61508 certified, reviewed and approved for safety systems up to SIL 3
by independent certifying bodies.
• The scalable characteristics of the system enables independent safety
functions within the same system to be configured with different
architectures to meet a user specific safety and availability requirements.
• The main components that provide the safety architecture are the
processor and I/O modules; the remaining components provide secure
external interfaces and connectivity between the field elements and the
main components and add to the safety functionality.
• AADvance processor modules are designed to meet the requirements for
SIL 3 in a dual or triplicated configuration.
• Individual input modules are designed to meet the requirements for SIL
3 in simplex, dual or triple configurations.
• Individual output modules have been designed to meet the requirements
for SIL 3 in a simplex or dual configurations.
• Safe SIL 3 rated 'Black Channel' external communication over Ethernet.
Safety Configurations An AADvance system supports the following safety configurations:
Fail-safe
I/O modules fail-safe in the most basic simplex system.
SIL 2
SIL 2 architectures for fail-safe low demand applications. All SIL 2
architectures can be used for energize or de-energize to trip applications.
• SIL 2 low demand architectures
• SIL 2 fail safe architectures
• SIL 2 fault tolerant input architectures
• SIL 2 triplicated input architectures
• SIL 2 fault tolerant output architectures
• SIL 2 fault tolerant input/output architectures
SIL 3
SIL 3 architectures:
• SIL 3 de-energize to trip applications.
• SIL 3 energize to action applications when fitted with dual digital output
modules.
• SIL 3 simplex or dual output module architectures
• SIL 3 fail safe I/O fault tolerant processor architecture
• SIL 3 fault tolerant architecture
• SIL 3 fault tolerant simplex, dual and triple input architectures
• SIL 3 dual or triple processor architectures
• SIL 3 high demand applications where the required safe state is greater
than 4 mA, when fitted with dual analogue output modules (A ‘safe state’

Rockwell Automation Publication ICSTT-RM448M-EN-P - February 2021 17
Chapter 2 The AADvance Safety Controller
is an output configured to go to a specific value, or configured to hold last
state)
Safety System Certification The AADvance Controller is certified by independent certifying bodies. Refer
to the certificate for details of the standards included in the certification.
Performance and Electrical
Specifications
Scan Times
The controller processing scan times listed in the table are taken from a test
system which used only production modules. The tests which were used to
measure the scan times did not measure the effects of logic complexity and
communications loading.
Table 1 - Controller Performance and Electrical Specifications
Attribute Value
Performance Characteristics
Safety Integrity Level IEC 61508 SIL 2 IEC 61508 SIL 3
(depending on processor and I/O module configuration)
Safety level Degradation 1oo1D, 1oo2D, 2oo3D
Processor Modules supported Three
I/O Modules supported 48 (8 or 16 channels modules)
Safety Accuracy Limit:
Digital inputs
Analogue inputs 1.0 Vdc 200 µA
Sequence of Event Resolution
Processor Module (for internal Variables):
Event Resolution
Time Stamp Accuracy
Digital Input Module:
Event Resolution
Time Stamp Accuracy
1 ms
Application Scan
1 ms
10 ms
Electrical Characteristics
Supply voltage Redundant 24 Vdc nominal, 18 Vdc to 32 Vdc range
Channel isolation (channel to channel and channel
to chassis
Maximum withstanding ± 1.5 kVdc withstand for 1 minute.
IMPORTANT Overall system power consumption, heat dissipation and weight
can be estimated using the values given in the heat dissipation
and weight data tables shown in this manual.

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Chapter 2 The AADvance Safety Controller
The scan time is:
Scan time = 39.3 ms (minimum cycle time overhead)
+ Sync time
+ Total number of modules * 0.04 ms
+ (Number of module groups x scan time shown above)
Where:
Sync time is a function of the total number of modules defined according
to the following table:
Though the average scan time will be within 1 ms of the scan time calculated
above the calculation does not take into account the effects of application logic
and network communication, and individual scans can vary by up to +/- 4 ms
around the average scan time.
Throughput time is the time from input change to output action. For
asynchronous inputs the throughput times can be derived from the Scan time
calculated above according to the following formula:
• Minimum throughput time = Scan period + 7 ms
• Maximum throughput time = 2 x Scan time + 13 ms
EXAMPLE: An example configuration scan time:
System configuration includes T9432 Analogue input simplex modules x 30
and T9451 Digital output simplex modules x 18.
Table 2 - Typical Module Scan Times
Module Scan
T9402
Digital input module, 24 Vdc, 16 channel
Simplex
Dual
Triple
0.924 ms
1.676 ms
2.453 ms
T9432
Analogue input module 24 Vdc, 16 channel
Simplex
Dual
Triple
1.170 ms
1.965 ms
2.656 ms
T9451 Digital output module, 24 Vdc, 8 channel Simplex
Dual 1.174 ms 2.202 ms
T9482 Analogue output module, 24 Vdc, 8 channel Simplex
Dual 0.981 ms 1.761 ms
Minimum cycle time overhead 39.3 ms
Scan overhead for each module 0.04 ms
0..10 modules 20 ms
11..20 modules 22 ms
21..30 modules 24 ms
31..40 modules 27 ms
41..48 modules 32 ms.

Rockwell Automation Publication ICSTT-RM448M-EN-P - February 2021 19
Chapter 2 The AADvance Safety Controller
Total I/O modules = 48
Sync time = 32 ms
Scan time = 39.3 ms + 32 ms + (48 x 0.04) ms + (30 x 1.170) ms + (18 x 1.174) ms =>
129.5 ms
Minimum throughput time = 129.5 ms + 7 ms => 136.5 ms
Maximum throughput time = (2 x 129.5) ms + 13 ms = 272.0 ms.
System Installation
Environment
The installation environment can be a source of common cause failure so it is
necessary that the installation assessment covers the environmental
specification for the AADvance system and includes the following:
•theprevailingclimatic conditions
• type of area, e.g. is it a hazardous or non-hazardous area
• location of power sources
• earthing and EMC conditions
In some customer installations parts of the system can be installed in differing
locations; in these cases the assessment must include each location.
Power Sources and Heat Dissipation Calculations
It is highly recommended that module supply power and field loop power
consumption calculations are done to find out the heat dissipation before
designing a suitable enclosure and making a decision about the installation
environment (see topic "System Design for Heat Dissipation").
Safety Related System Installation Process
For a Safety Related System the installation process must also be in line with
the following:
Environment Standards The AADvance system has been investigated to United States National
Standard (s) UL508, 17th Edition and Canadian National Standard (s) C22.2 No
142, 1st Edition. The investigation covers the following modules and provides
WARNING: You must use the installation guidelines given in this manual
and any installation and commissioning procedures that comply with
applicable international or local codes and standards.
CAUTION: AADvance modules are suitable for use in Class I, Division 2,
Groups A, B, C and D Hazardous locations or Non-hazardous locations only or
equivalent.
ATTENTION: Pour les modules AADvance sont utilisables dans Class I,
Division 2, A, B, C et D pour un environnement dangereux ou pour un
environnement non dangereux ou équivalente.

20 Rockwell Automation Publication ICSTT-RM448M-EN-P - February 2021
Chapter 2 The AADvance Safety Controller
requirements for compliance to the standards for use in a non-hazardous and
hazardous environments.
The AADvance controller has been investigated and approved by UL for use as
Industrial Control Equipment in hazardous locations, Class I, Division 2,
Groups A, B, C and D in North America.
The AADvance controller has been assessed for ATEX compliance. The UL
Certification No. is DEMKO 11 ATEX 1129711X. The ATEX marking is Ex nA IIC
T4 Gc.
Additionally the AADvance controller is approved under the IECEx
certification scheme. The certificate number is IECEx UL 12.0032X
Installation Requirements
for Non-Hazardous
Environment
Investigation File Number E341697
Products Covered
The products investigated and approved:
Programmable Logic Controller Models:
• T9110 Processor Module
• T9401 Digital Input Module
• T9402 Digital Input Module, 16 Channel
• T9431 Analogue Input Module
• T9432 Analogue Input Module, 16 Channel
• T9451 Digital Output Module
• T9481 Analog Output Module
• T9482 Analogue Output Module, 8 Channel.
Listed Accessories for use with PLCs:
• T9100 Processor Backplane
•T9300I/OBackplane
• T9801 Digital Input Termination Assembly, Simplex
• T9802 Digital Input Termination Assembly, Dual
• T9803 Digital Input Termination Assembly, TMR
• T9831 Analogue input Termination Assembly, Simplex
• T9832, Analogue Input Termination Assembly, Dual
• T9833 Analogue Input Termination Assembly, TMR
• T9851 Digital Output Termination Assembly, Simplex and
T9852 Digital Output Termination Assembly, Dual
• T9892 Digital Output Termination Assembly, Dual
• T9881 Analogue Output Termination Assembly, Simplex
• T9882 Analogue Output Termination Assembly, Dual.