Ur 0874

Advant® OCS Advant Controller 70
with Master software
User’s Guide
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.
DANGERHazards which could result in severe personal injury or death
WARNINGHazards which could result in personal injury
CAUTIONHazards which could result in equipment or property damage
NOTEAlerts 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, AdvaCommand, AdvaInform, AdvaBuild, and AdvaControl are registered trademarks of ABB Asea Brown Boveri Ltd.
Switzerland
NOTICE
The information in this document is subject to change without notice and should not be construed as a commitment by Industrial
Systems AB. Industrial Systems AB assumes no responsibility for any errors that may appear in this document.
In no event shall Industrial Systems 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 Industrial Systems 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 Industrial Systems AB 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.
3BUR 000 874R0201
CE-MARKING
The AC 70 meets the requirements specified in the EMC Directive 89/336/EEC.
Copyright © 1997 Industrial Systems AB. All rights reserved.

3BSE001264/D
Template: 3BSE001286/E
3BUR 000 874R0201

Advant Controller 70 User’s Guide
Table of Contents
TABLE OF CONTENTS
Chapter 1 - Introduction
1.1 General Information................................................................................................. 1-1
1.2 Equipment Requirements......................................................................................... 1-1
1.3 Manual Organization ............................................................................................... 1-2
1.4 Related Documentation............................................................................................ 1-3
1.5 Release History ........................................................................................................ 1-4
1.6 AC 70 Station Product Overview ............................................................................ 1-5
1.6.1 Processor Module 810 ............................................................................ 1-9
1.6.1.1 Electromagnetic Compatibility and CE-marking........... 1-10
1.6.2 Module Termination Units.................................................................... 1-10
1.6.2.1 TU810 Compact MTU for 50 Volt Applications ............1-11
1.6.2.2 TU811 Compact MTU for 250 Volt Applications ......... 1-12
1.6.2.3 TU830 Extended MTU for 50 Volt Applications........... 1-12
1.6.2.4 TU831 Extended MTU for 250 Volt Applications......... 1-13
1.6.2.5 Mounting ........................................................................ 1-15
1.6.3 I/O Modules .......................................................................................... 1-19
1.6.3.1 DI810 Digital Input Module .......................................... 1-19
1.6.3.2 DO810 Digital Output Module ...................................... 1-19
1.6.3.5 DO820 Digital Output Module ...................................... 1-20
1.6.3.6 AI810 Analog Input Module.......................................... 1-20
1.6.3.7 AI820 Analog Input Module.......................................... 1-20
1.6.3.8 AI830 Analog Input, RTD Module ................................ 1-20
1.6.3.9 AI835 Analog Input, Thermocouple/mV Module ......... 1-21
1.6.3.10 AO810 Analog Output Module...................................... 1-21
1.6.3.11 AO820 Analog Output Module...................................... 1-21
1.6.3.12 TB810 Modulebus Optical Port ..................................... 1-21
1.6.3.13 TB811 Modulebus Optical Port ..................................... 1-21
1.6.3.14 TB820 Modulebus Modem ............................................ 1-21
1.6.4 Power Supply........................................................................................ 1-22
1.6.5 ABB Master Programming Language (AMPL).................................... 1-23
1.6.6 System Software ................................................................................... 1-23
1.6.6.1 BASE System Software ................................................. 1-23
1.6.6.2 Option Extended PC Element Set .................................. 1-24
1.6.6.3 Option Event Handling .................................................. 1-24
1.6.6.4 Option MODBUS .......................................................... 1-24
1.6.6.5 Option EXT.................................................................... 1-25
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Table of Contents
CONTENTS (continued)
Chapter 2 - Installation
2.1 Site Planning Environment ...................................................................................... 2-1
2.1.1 AC 70 Layout.......................................................................................... 2-1
2.2 Setup......................................................................................................................... 2-1
2.2.1 Equipment Required................................................................................ 2-2
2.2.2 Checking the Input/Output System ......................................................... 2-2
2.2.2.1 General ............................................................................. 2-2
2.2.2.2 Testing Input Signals ........................................................ 2-3
2.2.2.3 Testing Output Signals ..................................................... 2-4
2.2.3 Functional Test and Correction of the PC Program ................................ 2-6
2.2.4 AC 70 ...................................................................................................... 2-6
2.3 Start-up Procedures .................................................................................................. 2-6
2.3.1 Controller Power Up ............................................................................... 2-7
2.3.2 Advant Station 100 Series Engineering Station ...................................... 2-7
2.3.2.1 Connecting Advant Station 100 Series ES ....................... 2-8
2.3.2.2 Load an Application Program .......................................... 2-8
2.3.2.3 Connect/Load Problems ................................................... 2-8
2.4 Product Verification ................................................................................................. 2-9
2.4.1 General .................................................................................................... 2-9
2.4.1.1 Procedure.......................................................................... 2-9
Chapter 3 - Configuration/Application Building

3.1 Design Considerations ............................................................................................. 3-1
3.1.1 PM810 ..................................................................................................... 3-1
3.1.1.1 Address Switches ............................................................. 3-2
3.1.1.2 AF 100 Fieldbus Connections .......................................... 3-3
3.1.1.3 Power Supply Connections .............................................. 3-4
3.1.1.4 Power Supply Configuration ............................................ 3-5
3.1.2 Mounting Termination Units (MTU) ...................................................... 3-5
3.1.3 I/O Modules ............................................................................................ 3-5
3.1.4 Power Supply Load Calculation.............................................................. 3-5
3.1.5 Communication ....................................................................................... 3-6
3.1.5.1 Provided Link Types......................................................... 3-6
3.1.5.2 Applied Communication .................................................. 3-7
3.1.5.3 MODBUS ......................................................................... 3-8
3.1.6 Operator’s Interface ................................................................................ 3-9
3.1.6.1 Local Operator.................................................................. 3-9
3.1.6.2 Central Operator ............................................................. 3-11
ii 3BUR 000 874R0201

Table of Contents
3.2 Capacity and Performance ......................................................................................3-11
3.2.1 Memory Demand ...................................................................................3-11
3.2.2 Calculation of Memory Demand in Advant Controller 70 ....................3-11
3.2.3 Calculation of Memory Demand for PCPGM ...................................... 3-12
3.2.4 Calculation of Memory Demand for DB Elements .............................. 3-13
3.2.5 Calculation of Memory Demand for CONTRM................................... 3-14
3.2.6 Formulas and References for Detailed Calculation .............................. 3-15
3.2.7 Rough Estimate of AC 70 Memory Demand (5-step Method)............. 3-17
3.2.8 Performance .......................................................................................... 3-18
3.2.9 CPU Load of Executable Units............................................................. 3-18
3.2.10 CPU Load of I/O Scanning ................................................................... 3-21
3.2.11 CPU Load of DataSet Communication................................................. 3-24
3.2.12 CPU Load of Event Detection .............................................................. 3-25
3.2.13 Calculation of Total CPU Load ............................................................ 3-27
3.2.14 Example ................................................................................................ 3-27
3.2.15 Operator’s Interface .............................................................................. 3-29
3.2.15.1 Local Operator Station ................................................... 3-29
3.2.15.2 Central Operator Station ................................................ 3-29
3.3 Power Supply Requirements.................................................................................. 3-29
3.4 Power and Cooling................................................................................................. 3-29
3.5 Application Start-up............................................................................................... 3-29
3.6 Configuration/Application Building Menus .......................................................... 3-29
Chapter 4 - Runtime Operation

4.1 Product Operation .................................................................................................... 4-1
4.1.1 Functions and Services of the PM810 .................................................... 4-1
4.1.1.1 PM810 Tasks.................................................................... 4-1
4.1.1.2 Block diagram .................................................................. 4-2
4.1.2 AF 100 Usage ......................................................................................... 4-3
4.1.2.1 Time Synchronization ...................................................... 4-3
4.1.2.2 DSP Transfer .................................................................... 4-3
4.1.2.3 Event Set .......................................................................... 4-3
4.1.3 Configuration and Programming ............................................................ 4-4
4.1.3.1 Processor Module Configuration ..................................... 4-4
4.1.3.2 I/O Module Configuration ............................................... 4-4
4.1.3.3 Drive Modules Configuration and Access ....................... 4-4
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Table of Contents
4.2 Operating Overview ................................................................................................. 4-5
4.2.1 Start-up of the AC 70 .............................................................................. 4-5
4.2.1.1 Treatment of Non-configured I/O Modules...................... 4-6
4.2.1.2 AF 100 Handling .............................................................. 4-6
4.2.2 Processor Module 810 Front Panel ......................................................... 4-7
Chapter 5 - Maintenance
5.1 Preventive Maintenance ........................................................................................... 5-1
5.1.1 Visual Inspection..................................................................................... 5-1
5.2 Hardware Indicators ................................................................................................. 5-1
5.2.1 PM810 LEDs........................................................................................... 5-2
5.2.1.1 Special Purpose LEDs ...................................................... 5-3
5.2.1.2 General Purpose LEDs ..................................................... 5-3
5.3 Fault Finding and User Repair ................................................................................. 5-5
5.3.1 Introduction ............................................................................................. 5-5
5.3.1.1 Fault Detection and Indication ......................................... 5-6
5.3.1.2 Fault Tracing Principles.................................................... 5-6
5.3.1.3 Fault Classification........................................................... 5-6
5.3.1.4 Start Up............................................................................. 5-7
5.3.2 Basic Fault Tracing ................................................................................. 5-7
5.3.2.1 Fault Tracing Procedure ................................................... 5-7
5.3.3 Advanced Fault Tracing .......................................................................... 5-9
5.3.3.1 Faults That Stop the System ............................................. 5-9
5.3.3.2 Faults Shown by the Error Report .................................. 5-12
5.3.4 User Repair............................................................................................ 5-18
5.3.4.1 Module Replacement...................................................... 5-18
Appendix A - General Specification

A.1 Processor Module PM810 ....................................................................................... A-1
A.1.1 Features .................................................................................................. A-2
A.1.2 Description ............................................................................................. A-2
A.1.3 Technical Data........................................................................................ A-3
A.1.3.1 Supply Requirements ...................................................... A-3
A.1.3.2 Interfaces ......................................................................... A-3
iv 3BUR 000 874R0201

Table of Contents
A.1.4 Connections ............................................................................................A-5
A.1.4.1 Connectors for Power Supply: X1A & X1B....................A-5
A.1.4.2 Connector for AF100 channel 1: X2................................A-6
A.1.4.3 Connector for AF100 channel 2: X3................................A-6
A.1.4.4 Connector for Service Port: X4........................................A-6
A.1.4.5 MODBUS Connection via TC801 and TK802 ................A-7
A.1.4.6 Connector for Electrical Modulebus: X9 .........................A-8
INDEX
3BUR 000 874R0201 v

Table of Contents
vi 3BUR 000 874R0201

Section 1.1 General Information
Chapter 1 Introduction
1.1 General Information

The Advant® Controller 70 (AC 70) is a modular programmable logic controller (PLC) for the
control and supervision of processes and equipment in industrial environments. It can be used as
a stand-alone station or it can be connected to an AF 100. The Advant Station 100 Series
Engineering Station (AS 100 Series ES) can connect to it for configuration. The PC-based MMI
(AdvaSoft® for Windows) can serve as the operator interface for the AC 70.
Function Block Programming Language (AMPL) is used for application programming.
Program entry, testing, documentation and fault tracing are supported by the AS 100 Series ES
programming unit. The Advant Station 100 Series Engineering Station is an IBM PC-based
programming and service tool. It featuring graphical function chart programming and a user
interface with windows, pull-down menus and “point and click” selection. Communication with
the AC 70 is accomplished via a standard serial interface from the personal computer.
This manual is intended primarily for plant designers and personnel who perform
commissioning and maintenance. In this manual, you will find information on the AC 70
system, its design and operation, its capabilities and its scope. This manual also contains
relevant information about the system hardware.
1.2 Equipment Requirements

The AC 70 uses S800 I/O modules as its I/O device.
3BUR 000 874R0201 1-1

1.3 Manual Organization

Chapter
Configuration/ Runtime
Introduction Installation Application Maintenance Appendices Index
Building Operation
General Site Planning Design Product Preventive Appendix A

Information Environment Considerations Operation Maintenance General
Specification
Equipment Setup Capacity & Operating Hardware
Requirements Performance Overview Indicators
Start-up
Manual Procedures
Organization Application Runtime Fault Finding
Start-up Tutorial & User Repair
Related Product
Documentation Verification Tutorial Operating
Instructions
Release Application
History Procedures Runtime Section
Operation
Product Configuration/ Menus
Overview Application
Building Menus
Introduction
Chapter 1 provides introductory and background information. This information includes:
• Guidelines on how you can find information in the manual.
• A product and functional overview that give you an idea of what the AC 70 can do and
how it works.
Installation
Chapter 2 describes different installation activities that include:
• Site Planning Environment
• Setup
• Start-up procedures for the controller are given
• Product Verification
1-2 3BUR 000 874R0201

Section 1.4 Related Documentation
Configuration Application Building

Chapter 3 will give you the information needed to obtain the desired function. The main
information is structured as follow:
• Design considerations and guidelines are given.
• Capacity and performance.
Operation
Chapter 4 discusses the different start modes and operating modes.
Maintenance
Chapter 5 focus is on fault finding supported by built in diagnostics and use of system status
displays in operator station and LEDs.
Appendices
Different information which does not belong in the main chapters of this manual is included. An
example is, Section A.1.4.1, Connectors for Power Supply: X1A & X1B.
Index
1.4 Related Documentation

Related documents for AC 70, including those referred to in this document, are listed below.
Table 1-1. AC 70 Related Documentation
Manual Description
AMPL Configuration Instructions for configuration and application
Advant Controller 110/70/55 programming, fault tracing and maintenance.
Reference Manual
PC Elements Data for all PC elements in
Advant Controller 70 Series Advant Controller 70.
Reference Manual
Data Base Elements Data for all data base elements in
Advant Controller 70 Series Advant Controller 70.
Reference Manual
Advant Fieldbus 100 Describes the Advant Fieldbus 100 equipment
User’s Guide and contains information required to install and
commission the system.
Advant Station 100 Series Describes the hardware and setup of
Engineering Station Advant Station 100 Series Engineering Stations,
AdvaBuild for Windows including the Advant Station 100 Series
Environment Engineering Board.
User’s Guide
3BUR 000 874R0201 1-3

Table 1-1. AC 70 Related Documentation (Continued)
Manual Description
AdvaBuild for Windows Describes installation of AdvaBuild for Windows
Application Builder components and contains the operating
User’s Guide instruction of Application Builder, Bus
Configuration Builder, On-line Builder and support
functions of AdvaBuild for Windows.
AdvaBuild for Windows Contains a description of the function chart
Function Chart Builder builder’s functions.
User’s Guide
Source Code Handling Contains descriptions and instructions for use of
User’s Guide AMPL source code for application programs and
data bases.
Chapter 3 Source Code Design is also valid for
Advant Controller 70.
Interference-free Electronics A description of the installation rules for the
MasterPiece and MasterView families to ensure
their correct function in environments where such
disturbances are present.
ABB Master Philosophy, theory, design and applications of
Environmental Immunity EMC on equipment and systems.
Valid for all ABB Process Automation systems.
Summary of the ABB Master environmental
factors.
S 800 I/O This book provides a physical and functional
User’s Guide description of the S800 I/O
Functional Units Part 8 This book provides functions to integrate Drives of
DRICONS ACS 600 type
User’s Guide
1.5 Release History

This is the first release for this product.
1-4 3BUR 000 874R0201

Section 1.6 AC 70 Station Product Overview
1.6 AC 70 Station Product Overview

The AC 70 station provides easy installation of the I/O modules and process cabling. It is highly
modularized and flexible so that the I/O modules can be combined to suit many applications. A
PM810, S800 I/O modules and a Fieldbus Communication Interface are combined to form an
AC 70 station. The equipment that is used as part of the AC 70 station is presented in Table 1-2.
Table 1-2. I/O Station with S800 I/O Components
Device Type
Function
Designator
AI810 8 AI channels (1*8), 0...20mA, 0...10V
AI820 4 AI channels (differential), -20...+20mA, -10...+10V, -5...+5V
AI830 8 AI channel for Resistance Measurements (e.g. Pt 100 sensors)
AI835 7+1 AI channels for Thermocouples or mV Inputs
AO810 8 AO channels (1*8), 0...20mA
AO820 4 AO channels (bipolar), -20...+20mA, -10...+10V
DI810 16 DI channels (2 *8), 24V d.c.
DI820 8 DI channels (8*1), 120V a.c.
DI821 8 DI channels, (8*1) 230V a.c.
DO810 16 DO channels (2*8), 24Vd.c.,0.5A
DO820 8 DO channels (8*1), Relay, 250V 3A a.c.
PM810 Processor Module for AC 70 Station
TB805 Cable adaptor out module (electrical ModuleBus)
TB806 Cable adaptor in module (electrical ModuleBus)
TB807 Terminator module for electrical ModuleBus
TB810 ModuleBus Optical Port Module 10 Mbit/s, fiber optic connection
on the CI810 for S800 I/O
TB811 ModuleBus Optical Port Module 5 Mbit/s, fiber optic connection
on the CI810 for drive equipment
TB820 ModuleBus Modem, fiber optic ModuleBus interface of an I/O
cluster.
TC501V150 Cable terminator for AF 100 twisted pairs, 150 ohms
TC505 Connector: AF 100 Trunk Tap to FCI
TC513 Modem for conversion
(twp --> coax) or (coax --> twp)
3BUR 000 874R0201 1-5

Table 1-2. I/O Station with S800 I/O Components (Continued)
Device Type
Function
Designator
(twp --> fiber optic) or (fiber optic --> twp)
(twp --> twp) or (twp --> twp)
TC801 + TK802 The D-sub 9 connector split TC801 with the cable TK802 is a
passive unit used for connection of two serial channels on PM810
TK801V003 Cable, ModuleBus Extension, 300 mm (11.8 inches)
TK801V006 Cable, ModuleBus Extension, 600 mm (23.6 inches)
TK801V012 Cable, ModuleBus Extension, 1.2 meters (47.25 inches)
TK811V015 Cable, Optical ModuleBus Extension, 1.5 meters (59 inches)
TK811V050 Cable, Optical ModuleBus Extension, 5 meters (16 feet)
TK811V150 Cable, Optical ModuleBus Extension, 15 meters (50 feet)
TU810 Compact MTU, 3*8 + 2*2 terminals, 50V.
TU830 Extended MTU, 3*16 + 2*4 terminals, 50V
TU835 Extended MTU, 2*4 groups + 2*2 power terminals, 50V,
individually fused per channel
TU836 Extended MTU, 2*4 groups + 2*2 power terminals, 250V,
individually fused per channel
TU811 Compact MTU, 2*8 terminals, 250V
TU831 Extended MTU, 2*8 terminals, 250V
SD811 Power supply, 120/230V ac to 24V dc @ 2.5A
SD812 Power supply, 120/230V ac to 24V dc @ 5.0A
RE810 Wall Cabinet, IP65, 800 x 1000 x 300mm (31.5 x 39.4 x 11.8)
The AC 70 station consists of a Processor Module 810 (PM810) and S800 I/O modules mounted
to a DIN-rail. It is a small, process station which performs logical control. The use of S800 I/O
modules as remote I/O is not supported. You can add up to 24 I/O modules to an AC 70. For
mounting, expansion and extension options for the I/O modules, refer to the S800 I/O User’s
Guide. In the S800 I/O User’s Guide, when reference is given to the Field Bus Control Interface
(FCI or CI810), assume this is the AC 70 (PM810).
You can freely combine S800 I/O modules and applications to obtain tailor-made solutions for
virtually any user application. The signals to and from the process are connected to the process
connectors on the S800 I/O modules. Process connectors are available with screw terminals.
1-6 3BUR 000 874R0201

Section 1.6 AC 70 Station Product Overview
The addresses of I/O modules are given by their position on the DIN-rail. The addresses of the
modules are automatically set when a module is plugged into it’s corresponding MTU.
You can use the AC 70 as a stand-alone station or it can communicate to an
Advant Controller 400/100 Series station through an AF 100 (refer to Figure 1-1).
Advant Controller 400
AC 70 Station
Fieldbus
AC 70 Station
Tool
Stand-alone
AC 110
Tool
Figure 1-1. AC 70 Overview
You can interconnect several Advant Controller 70 systems via the AF 100 (refer to Figure 1-2).
The AF 100 is a high-performance serial communications link featuring fast real-time exchange
of process data between the application programs in different controllers (e.g. AC 70, AC 110 or
AC 400 Series).
AC 400
Series
AF100
AC 110 AC 70 AC 70 AC 70
Figure 1-2. AC 70 Stations Connected Via the Fieldbus Network
3BUR 000 874R0201 1-7

The AC 70 offers the following wide range of functions, including analog signal processing and
feedback control:
• Logical operations and time delays
• Sequential control
• Feedback control
• Arithmetical operations
• Communication via Advant Fieldbus 100 (AF 100)
• Communication via serial interface using MODBUS I protocol
• Event handling.
The hardware and software of the AC 70 are entirely modular. AMPL is used for application
programming and a port is available for connecting an AS 100 Series ES. The AC 70 covers a
wide range of programmable functions (see Section 1.6, AC 70 Station Product Overview) and
is programmed using graphic symbols selected from menus via the AS 100 Series ES. Battery
backup of configuration and application data is incorporated.
1-8 3BUR 000 874R0201

Section 1.6.1 Processor Module 810
1.6.1 Processor Module 810
F R
B P
T1 T2
S7 S3
S6 S2
S5 S1
S4 S0
INIT
SERVICE
STN. ADDR.
4 5 6
3 7
x 10
2 8
1 0 9
4 5 6
3 7
x1
2 8
PM810 1 0 9
AF 100
L+ L+ SA 1 2
L- L- SB
+ + Tx
- -
SH SH
SH Rx
SH
Figure 1-3. PM810 Front Panel
A single +5V DC power supply is built into the PM810 and supplies power to itself and the I/O
modules. Single or redundant +24 V DC power is fed from an external source and fed to the I/O
modules via the PM810.
3BUR 000 874R0201 1-9

Two twisted-pair fieldbus ports allow configuration with redundant or non-redundant media.
The PM810 can be disconnected/connected without interrupting the fieldbus network.
There is one opto-isolated port (RS-232C) to connect the configuration and maintenance tool.
Diagnostic functions monitor system operation and report any faults detected. The monitoring
functions include a watchdog, bus supervision, memory checks and monitoring of the power
supply voltage. Faults are indicated on the PM810 module’s LED display. You can obtain more
detailed diagnostic information by connecting the AS 120 ES to the port on the PM810.
The system software is stored in 512 KB of flash Programmable Read-Only memory (flash
PROM). The user software is stored in 512 KB of flash PROM. There is also 512 KB of battery
back-up SRAM.
The PM810 includes a real-time clock. The real-time clock and memory are backed up for at
least 270 days.
1.6.1.1 Electromagnetic Compatibility and CE-marking

Grounding, cable selection and cable routing must be considered for electromagnetic
interference-free operation. Planning considerations are discussed in the S800 I/O User’s Guide.
The AC 70 meets requirements specified in EMC Directive 89/336/EEC. You should request
CE-marking and compliance when ordering the equipment.
For more information about environmental immunity, including EMC qualities with or without
CE-marking, refer to the ABB Master Environmental Immunity data sheet.
1.6.2 Module Termination Units

The Module Termination Units (MTU) are passive base units containing the process wiring
terminals and a section of the Modulebus. There are four MTUs used by the AC 70 with
S800 I/O:
• TU810 Compact MTU for 50 volt applications
• TU811 Compact MTU for 250 volt applications
• TU830 Extended MTU for 50 volt applications
• TU831 Extended MTU for 250 volt applications
• TU835 Extended MTU, individually fused per channel for 50 volt applications
• TU836 Extended MTU, individually fused per channel for 250 volt applications
An MTU can house one I/O module and contains bus connectors on each side for extension of
the Modulebus. The MTU interconnects between the PM810 and the I/O modules either directly
or by way of a Modulebus adaptor cable. The MTU mounts on a standard DIN rail and has a
mechanical latch that locks it to the rail.
1-10 3BUR 000 874R0201

Section 1.6.2 Module Termination Units
Two mechanical keys are used to set-up each MTU for a particular type I/O module. The
mechanical keys protect the I/O modules from being inserted on the wrong MTU and thereby
being damaged by excessive voltage or current. There are 36 different configurations that can be
set to match an I/O module type. There is also a mechanical locking tab that locks the I/O
module into position on the MTU. This module lock is connected to a switch that keeps the I/O
module in its initialization state until it is locked into position.
The MTUs are available in two versions (Compact and Extended). The Compact MTU version
typically provides for a compact installation of the I/O modules using 1 wire connections. The
Extended MTU version provides for a more complete installation on the MTU, including 3 wire
connection, fuses and field circuit power distribution. See Figure 1-4 and Figure 1-5 for an
illustration of the MTUs together with the I/O modules.
1.6.2.1 TU810 Compact MTU for 50 Volt Applications

The TU810 is a 16 channel compact module termination unit. It provides field terminations to
the I/O module and connection to the Modulebus of the PM810. The TU810 has three rows of
terminals for field signals and process power connections. The TU810 distributes the
Modulebus to the I/O module and to the next MTU. The correct Modulebus address of this
MTU is automatically configured when inserted into the previous MTU.
The TU810 is used with the following S800 I/O modules:
• DI810 Digital Input Module
• DO810 Digital Output Module
• AI810 Analog Input Module
• AI830 Analog Input, RTD Module
• AI835 Analog Input, Thermocouple Module
• AO810 Analog Output Module
3BUR 000 874R0201 1-11

122
7 (4.8)
(.27)
F
R
W
50
(1.97)
1
2
3
4
5
6
7
(6.37)
8
162
(4.68)
9
E
F
119
10 D
A
11
C
B
12
13
E
F
D
14
A
C
15
B
16
DI810
24V
31.5 (1.24)
7 58.5
(.27) (2.3)
Figure 1-4. Compact MTU with I/O Module, Dimensions in mm(in.)
1.6.2.2 TU811 Compact MTU for 250 Volt Applications

The TU811 is a 8 channel compact module termination unit. It provides field terminations to
terminals for field signals and process power connection. The TU811 distributes the Modulebus
to the I/O module and to the next MTU. The correct Modulebus address of this MTU is
automatically configured when inserted into the previous MTU.
1.6.2.3 TU830 Extended MTU for 50 Volt Applications

The TU830 is a 16 channel extended module termination unit. It provides field terminations to
1-12 3BUR 000 874R0201


• AI830 Analog Input, RTD Module
• AI835 Analog Input, Thermocouple Module
7 (.27) 122
(4.8)
A
F F
B B
E E
C C
(1.77)
D
DI810
45
24V
(4.3)
109
10
12
13
14
15
16
11
W
R
F
2
3
4
5
6
7
31.5 (1.24)
7 120.5
(.27) (4.74)
Figure 1-5. Extended MTU with I/O Module, Dimensions in mm(in.)
1.6.2.4 TU831 Extended MTU for 250 Volt Applications

The TU831 is a 8 channel extended module termination unit. It provides field terminations to
3BUR 000 874R0201 1-13

TU835 Extended MTU, Individually Fused per Channel for 50 Volt Applications
The TU835 is an 8 channel extended module termination unit. It provides field terminations to
the I/O module and connection to the ModuleBus of the communication interface (AC 70 or
ModuleBus Modem). The TU835 has two rows of terminals for field signals and process power
connection. Each channel has one fused (3A max.) transmitter power terminal and one signal
connection. Process voltage can be connected to 2 individually isolated groups. The TU835
distributes the ModuleBus to the I/O module and to the next MTU. The correct ModuleBus
address of this MTU is automatically configured when inserted into the previous MTU.
The TU835 is used with the following S800 I/O module:
TU836 Extended MTU, Individually Fused per Channel for 250 Volt Applications
The TU836 is an 8 channel extended module termination unit. It provides field terminations to
the I/O module and connection to the ModuleBus of the communication interface (AC 70 or
ModuleBus Modem). The TU836 has two rows of terminals for field signals and process power
connection. Each channel has one fused (3A max.) power outlet terminal and one signal return
connection. Process voltage can be connected to 2 individually isolated groups. The TU836
distributes the ModuleBus to the I/O module and to the next MTU. The correct ModuleBus
address of this MTU is automatically configured when inserted into the previous MTU.
The TU836 is used with the following S800 I/O module:
1-14 3BUR 000 874R0201

1.6.2.5 Mounting
The AC 70 station can be mounted horizontally (Figure 1-6 and Figure 1-7) and/or vertically
(Figure 1-8) or in combinations. Different MTUs (Compact or Extended version) can be used
depending on available space and preferred way of installing the field wiring (external
marshalling/power distribution or direct on Extended MTUs using built in 2/3 wire termination
and power distribution arrangements). Compact and extended MTUs can be mixed on the same
Modulebus and mounting rail.
816 (32.1)
20
(0.8)
10
(0.4)
84 58.5
(3.3) (2.3)
Figure 1-6. Horizontal Mounting of AC 70 with S800 I/O MTUs (Compact), Dimensions in mm(in.)
1560 (61.4)
20
10 84 120.5 (0.8)
(0.4) (3.3) (4.74)
Figure 1-7. Horizontal Mounting of AC 70 with S800 I/O MTUs (Extended), Dimensions in mm(in.)
3BUR 000 874R0201 1-15

10 10
(0.4) (0.4)
84 84
(3.3) (3.3)
58.5
120.5 (2.3)
(4.74)
816
(32.1)
1560
(61.4)
20
(0.8)
20
(0.8)
Figure 1-8. Vertical Mounting of AC 70 with S800 I/O MTUs, Dimensions in mm(in.)
1-16 3BUR 000 874R0201

Optical ModuleBus Expansion

The AC 70 provides fiber optic expansion of the ModuleBus for up to 7 additional I/O clusters.
The TB810 ModuleBus Optical Port must be inserted in to the PM810 to provide optical
ModuleBus expansion. See Figure 1-9 for location of the TB810.
SERVICE
STN. ADDR.
4 56
3 7 x 10
2 8
109
5
4 6
3 7 x1
2 8
PM810 109
TB810
AF100 Tx Rx
L+ L+ SA 1 2
L- L- SB
+ + Tx
- -
SH SH
SH SH Rx
Figure 1-9. Location of TB810 ModuleBus Optical Port in PM810
Each I/O cluster can have a maximum of 12 S800 I/O modules. The maximum number of
S800 I/O modules or other units connected to one AC 70 is 24. The optical ring connection
3BUR 000 874R0201 1-17

allows for a maximum distribution of 15m (49 ft.) (plastic fiber) or 200m (667 ft.) (HCS fiber)
between each I/O cluster on the ring, see example in Figure 1-10.
AC 70 AC 70
ModuleBus Optical Port TB810

Optical cable (single fiber)
15m (49 ft.)Max. (plastic fiber)
Optical cable (duplex fiber) ModuleBus Modem TB820

15m (49 ft.) Max. (plastic fiber)
Fiber Optic Simplex Configuration Fiber Optic Duplex Configuration
Figure 1-10. Optical ModuleBus Expansion, Simplex and Duplex Configurations
The TB820 can be used in both a simplex optical configuration as well as in a duplex optical
configuration. In a simplex optical configuration, the optical ModuleBus nodes are connected in
a ring. In a duplex optical configuration, the optical ModuleBus nodes are connected in a row.
The optical ModuleBus Extension fiber optic (plastic fiber) cable comes in three standard
lengths:
• TK811V015 - 1.5 meters (5 ft.)
• TK811V050 - 5 meters (16 ft.)
• TK811V150 - 15 meters (49 ft.)
1-18 3BUR 000 874R0201

Section 1.6.3 I/O Modules
As with the AC 70 (base cluster), the electrical ModuleBus length must not exceed 2 meters
from the ModuleBus Modem to the last MTU of each cluster. Each cluster requires a TB807
ModuleBus Terminator plugged into the last MTU.
1.6.3 I/O Modules

The S800 I/O modules have open ventilated plastic enclosures. On the front of each I/O module
there are three LEDs (FAULT, RUN and WARNING) indicating the module status. One
additional LED (OSP) is included on output modules. Refer to the S800 I/O User’s Guide for
the status indication of the LEDs.
I/O modules may be replaced in a fully operational I/O station. Mechanical keying on modules
and MTUs protect I/O modules from being inserted in positions where they would be damaged
by excessive voltage or current. An electronic type designation ID in each module keeps the I/O
module from being taken into operation by the system, if a module’s ID doesn’t match the
configured module type definition in the data base.
1.6.3.1 DI810 Digital Input Module

The DI810 Digital Input Module has 16 channels for 24 volt dc digital inputs. The inputs are
divided into two isolated groups of eight channels with a voltage supervision input for each
group. Each input channel provides current limiting, EMC protection, input state LED indicator
and optical isolation from the Modulebus. Please refer to the S800 I/O User’s Guide for more
information.
1.6.3.2 DO810 Digital Output Module

The DO810 Digital Output Module has 16 channels for 24 volt dc digital outputs. The outputs
are divided into two isolated groups of eight channels with a voltage supervision input for each
group. Each input channel provides protection against short circuits to ground, over-voltage,
over-temperature, EMC protection, output state LED indicator and optical isolation from the
Modulebus. State of outputs can be set to a predetermined (OSP) value if an error is detected.
Please refer to the S800 I/O User’s Guide for more information.

The DI820 Digital Input Module has 8 channels for 120 volt ac digital inputs. The inputs are
individually isolated. Channel 1 can be used to as voltage supervisor for channels 2 - 4, and
channel 8 can be used for channels 5 - 7. If voltage supervision is disabled, channels 1 and 8 can
be used as normal inputs. Each input channel provides current limiting, EMC protection, input
state LED indicator, analog filter and optical isolation from the Modulebus. Please refer to the
S800 I/O User’s Guide for more information.
3BUR 000 874R0201 1-19


The DI821 Digital Input Module has 8 channels for 230 volt ac digital inputs. The inputs are
individually isolated. Channel 1 can be used to as voltage supervisor for channels 2 - 4, and
channel 8 can be used for channels 5 - 7. If voltage supervision is disabled, channels 1 and 8 can
be used as normal inputs. Each input channel provides current limiting, EMC protection, input
state LED indicator, analog filter and optical isolation from the Modulebus. Please refer to the
S800 I/O User’s Guide for more information.
1.6.3.5 DO820 Digital Output Module

The DO820 Digital Output Module has 8 channels for 230 volt ac/dc relay outputs. The outputs
are individually isolated. Each input channel provides a relay contact (NO), EMC protection,
output state LED indicator and optical isolation from the Modulebus. State of outputs can be set
to a predetermined (OSP) value if an error is detected. Please refer to the S800 I/O User’s Guide
for more information.
1.6.3.6 AI810 Analog Input Module

The AI810 Analog Input Module has 4 current and voltage inputs. The inputs are independent
for each channel, in that either voltage or current can be measured.
The current input is able to handle a short circuit to the transmitter supply without damage.
Current limiting is performed with a PTC. Please refer to the S800 I/O User’s Guide for more
information.
1.6.3.7 AI820 Analog Input Module

The AI820 Analog Input Module has 4 differential, bipolar current/voltage inputs. Each channel
can be either a voltage or current input.
The current inputs can withstand an accidental maximum normal mode 30V dc connection. To
protect the current input circuit against dangerous input levels, i.e., by accidentally connecting a
24V source, the resistor rating of the 250Ω current sense resistors is about 4 Watts. This is
intended only to temporarily protect one channel at a time.
All 4 channels are isolated from the ModuleBus in one group. Power to the input stages is
converted from the 24V on the ModuleBus.Please refer to the S800 I/O User’s Guide for more
information.
1.6.3.8 AI830 Analog Input, RTD Module

The AI830 Analog Input, RTD Module has 8 RTD (Pt100, Cu100, Ni100 and Ni120 and
resistor) inputs. The inputs allow 3-wire connection to RTDs. Inputs are monitored for open-
circuit, short-circuit and a grounded sensor. Please refer to the S800 I/O User’s Guide for more
information.
1-20 3BUR 000 874R0201

Section 1.6.3 I/O Modules
1.6.3.9 AI835 Analog Input, Thermocouple/mV Module

The AI835 Analog Input, Thermocouple/mV Module has 8 differential inputs for TC/mV
measurements. One channel can be configured for “Cold Junction” (ambient) temperature
measurement, thus serving as the CJ-channel for the other channels on the module. All 8
channels can be used if no CJ-temperature measurement is needed. The inputs can be connected
to a variety of thermocouples with the following characteristics: B, C, E, J, K, N, R, S an T.
Please refer to the S800 I/O User’s Guide for more information.
1.6.3.10 AO810 Analog Output Module

The AO810 Analog Output Module has 8 current outputs. State of outputs can be set to a
predetermined (OSP) value if an error is detected Please refer to the S800 I/O User’s Guide for
more information.
1.6.3.11 AO820 Analog Output Module

The AO820 Analog Output Module has 4 bipolar analog output channels. The choice of current
or voltage output is configurable for each channel. There are separate sets of terminals for
voltage and current outputs, and it is up to the user to wire outputs properly. The only
differences between current or voltage channel configuration is in software settings. Please refer
to the S800 I/O User’s Guide for more information.
1.6.3.12 TB810 Modulebus Optical Port

The TB810 ModuleBus Optical Port is a communication interface between the PM810 and the
I/O cluster via the Optical ModuleBus.
configuration. In a simplex configuration, the optical Modulebus nodes are connected in a ring.
In a duplex configuration, the optical Modulebus nodes are connected in a row. Please refer to
the S800 I/O User’s Guide for more information.
1.6.3.13 TB811 Modulebus Optical Port

The TB811 ModuleBus Optical Port is a communication interface between the PM810 and the
drive modules via the Optical ModuleBus.
1.6.3.14 TB820 Modulebus Modem

The TB820 ModuleBus Modem is a communication interface between the PM810 and the S800
I/O modules via the optical and electrical ModuleBus.
3BUR 000 874R0201 1-21

1.6.4 Power Supply

The AC 70 station can be powered by a single or redundant supply voltage of 24 V dc, see
Figure 1-11 and Figure 1-12. A selection of power supplies (120/230V->24Vdc) is available to
supply the I/O station and its field circuits. The SD811 Power Supply provides 2.5A at 24Vdc
and the SD812 Power Supply provides 5A at 24Vdc. See Section 3.1.1.3, Power Supply
Connections for details.
PM810
Power
Supply 24V
A
B
I/O station
24V power supply

I/O modules
Figure 1-11. Installation Using Single Power Supply Unit
The PM810 is able to supervise the redundant voltage supply. The supervision function is
individually configurable for power supervision of each I/O station.
PM810
Power
Supply 24V
A
A
B
Power I/O station
Supply
B 24Vdc power supply
Supervision 24V A, 24V B
I/O modules
Figure 1-12. Installation Using Redundant Power Supply Units
1-22 3BUR 000 874R0201

Section 1.6.5 ABB Master Programming Language (AMPL)
1.6.5 ABB Master Programming Language (AMPL)

Application programs are written in the high-level language AMPL, a function block language,
which presents the basic functions as function elements with inputs and outputs. The function
element library includes an extensive set of elements ranging from a simple AND to a full PI
controller.
For further information, refer to AMPL Configuration - Advant Controller 110/70/55 Series
Reference Manual.
1.6.6 System Software

The AC 70 station contains the PC element library as part of its BASE system software.
Additionally, the following software options are available:
• Extended PC element set
• Event handling
• MODBUS
• EXT
1.6.6.1 BASE System Software

The BASE system software includes the PC element library shown in Table 1-3.
Table 1-3. PC Elements of the BASE System Software
Type Function PC element

Structure Structuring the PC program and sequential PCPGM, CONTRM, FUNCM, MASTER,
control SLAVEM, BLOCK, SEQ, STEP
Logic Combinational logic and Boolean memory AND, AND-O, AND-TRG, OR, OR-A,
OR-TRG, XOR, INV, TRESH-L, SR, SR-D,
SR-AA, SR-AO, SR-OA, SR-OO
Bit operations Read/Write a single bit. BGET, BSET
Time Timer for on- and off-delays, pulse functions, MONO, TON, TOFF, TONRET, TRIGG,
oscillator and calendar timing OSC-B, TIMER, SYSTIME
Register Shift and queue register FIFO, MOVE, REG, SHIFT
Switches Switching sets of data SW, SW-C
Multiplexer Select data from a group of data MUX-I, MUX-MI, MUX-MN
Code Convert data from one type to another, e.g., CONV, CONV-BI, CONV-IB, DRI-CNV
converter Boolean to integer
Counter Pulse counting COUNT
Comparators Basic arithmetic operations and square root, ADD, ADD-MR, SUB, MUL, MULDIV, DIV,
arithmetic absolute value and limit functions DIV-MR, ABS, SQRT, LIM-N
3BUR 000 874R0201 1-23

Table 1-3. PC Elements of the BASE System Software (Continued)

Comparators Comparison of two numbers, limit value COMP-B, COMP-I, COMP-R, MAX, MIN
monitoring and maximum or minimum selection
Miscellaneous Evaluate the load of an Advant Controller 70 SYSL
system
1.6.6.2 Option Extended PC Element Set

Table 1-4 shows the PC elements contained in the option ‘Extended PC element set’.
Table 1-4. PC Elements of the Option ‘Extended PC Element Set’

Function generator Generates an output from an input variable FUNG-1V
according to a function described by a data table.
Filter Single-pole low-pass filter. FILT-1P
Feedback control Various conventional P, I, and D functions and P-1, INT, DER, PI, PIP,
combinations thereof, a pulsed regulator and a PDP, CON-PU1, RAMP
ramp generator.
Register Register for assembling single data with a group REG-G
data.
1.6.6.3 Option Event Handling

The option ‘Event handling’ adds event handling capability to the AC 70's system software.
The following event-handling-specific DB elements, Table 1-5, are added when you enable this
option
Table 1-5. Added DB Element for Event Handling
EVS(S)
DIC
AIC
1.6.6.4 Option MODBUS

The optional program module OPT, MODBUS I extends the functionality of the controller with
the MODBUS I protocol (RTU, binary mode), which is intended for communication with an
IBM PC based MMI package. The Advant Controller 70 can be used only as a slave with the
fixed address 1 on the MODBUS.
1-24 3BUR 000 874R0201

Section 1.6.6 System Software
The separate serial interface on the MODBUS connection kit for PM810 is used for this
purpose.
1.6.6.5 Option EXT

With this option you can write your own AMPL PC elements.
A dedicated diskette includes all necessary items as extension loader, interface library and a
detailed descriptive manual to create and load application specific AMPL elements in addition
to the Advant Controller 70 system software. Commercially available tools as compiler, linker,
loader and assembler must be purchased separately.
3BUR 000 874R0201 1-25

1-26 3BUR 000 874R0201

Section 2.1 Site Planning Environment
Chapter 2 Installation
This chapter contains guidelines for planning the installation of the AC 70 station.
This chapter does not give the complete list of measures to be taken with respect to environment
and other conditions on site. The equipment should be adapted to the actual application by
thorough system definition and design.
Since each system is designed to meet a specific requirement, there is no standard configuration
that describes every system. Therefore, certain areas of the following instructions are meant
only as a guide for planning a specific installation. However, some of the information covers
specific requirements for proper system and equipment operation, and is not subject to
modification.
All information given in this chapter relates to standard equipment.
2.1 Site Planning Environment

The following sections contain recommendations and instructions for the installation and
connection of the AC 70.
WARNING
All electrical installation work must be performed in accordance with national
safety regulations and the safety rules for the Advant OCS.
2.1.1 AC 70 Layout
For a complete description of the AC 70 with S800 I/O layout, refer to the S800 I/O User’s
Guide
2.2 Setup
In this section, you will find procedures for checking an AC 70’s installation and for starting up
an AC 70. The procedures and the order in which you should carry them out is as follows:
1. Check that the documentation is complete and that the specified test equipment is at hand
(refer to Section 2.2.1, Equipment Required).
2. Check I/O modules to and from the application program
(refer to Section 2.2.2, Checking the Input/Output System).
3. Check the PC program
(refer to Section 2.2.3, Functional Test and Correction of the PC Program).
3BUR 000 874R0201 2-1

2.2.1 Equipment Required

The following are minimum requirements:
• Standard hand tools
• Universal instruments, e.g., a multimeter, a buzzer
• AS 100 Series ES with options ‘Extended PC element set’ and ‘Events handling’
• Spare modules and fuses.q
The necessary parts of the product documentation should also be available, e.g.:
• S800 I/O User’s Guide
• AMPL Configuration - Advant Controller 110/70/55 Reference Manual
• Data Base elements - Advant Controller 70 Series Reference Manual
• PC elements - Advant Controller 70 Series Reference Manual
• Advant Fieldbus 100 - Users Guide
The specific project documentation should also be available, e.g.,
• Hardware configuration
• Signal lists and connection diagrams
• Documentation of application programs.
2.2.2 Checking the Input/Output System
2.2.2.1 General
The I/O modules are now inserted and the channels are tested one by one. The output channels
are tested from the PC program to the actuators in the process, and the input channels are tested
from the transducers to the application software. In both cases, the operation of the hardware
functions is observed on the signals on the modules and the operation of the software functions
is observed on the screen of the Advant Station 100 Series ES.
It may be necessary to simulate digital and analog input signals which are normally generated
by the process. Suitable methods to do this are:
Digital Input Signals

Activate the input by applying a voltage, corresponding to the rated input signal voltage, as
close as possible to the process transducer, in order to test as much of the process wiring as
possible. You can also generate a test input signal by operating transducers manually, e.g., by
actuating limit switches.
Analog Input Signals

Use a signal generator to generate analog signals. A simple test circuit to generate a voltage
consists of a potentiometer connected across a suitable voltage source capable of producing a
positive and a negative output. You need a current source capable of at least 20 mA to generate
current signals. Analog test signals should also be injected as close as possible to the signal
transducer to test as much as possible of the process wiring.
2-2 3BUR 000 874R0201

Section 2.2.2 Checking the Input/Output System
You can show on-line updating of input signal values on the Advant Station 100 Series ES in the
function “Test.”
For a detailed description of how to operate the function “Test,” see the AC 70 manuals AMPL
Configuration Advant Controller 110/70/55 Reference Manual and AdvaBuild Function Chart
Builder.
2.2.2.2 Testing Input Signals

Test a digital input channel as shown in Figure 2-1. The procedure is very similar for analog
signals (refer to Figure 2-2). Test digital and analog input channels as follows:
• Select a PC element terminal connected to the related DB element in the
Advant Station 100 Series ES function “Test.”
• Select the menu item for display on the Advant Station 100 Series ES.
• Activate the signal input by activating the signal transducer or by simulating the signal.
• Check that the corresponding yellow LED on the input module lights up (only digital
modules). For analog inputs, measure the signal with a multimeter at the terminal of the
process connector of the corresponding channel. Check that the change appears at the
terminal “VALUE” of the DB element on the Advant Station 100 Series ES screen.
• Switch the test signal for a digital input to logical “zero” and check that the yellow LED on
the input module extinguishes and that the signal at the “VALUE” terminal goes to “zero”.
PROCESS AC 70 HARDWARE AC 70 SOFTWARE
Application program
UP
Digital
input
module
Process
element DB elements PC elements
ZP
Process Yellow
Simulated digital input signal
connector LED
AS 100 Series ES
Digital Input
NAME VALUE
ERR
Figure 2-1. Testing Digital Input Signals
3BUR 000 874R0201 2-3

PROCESS AC 70 HARDWARE AC 70 SOFTWARE
Simulated Application program

analog
input
Analog
Process input
module DB elements PC elements
element
Process
connector
AS 100 Series ES
Analog Input
NAME VALUE
ACT ERR
CONV PAR
Limit control
Figure 2-2. Testing Analog Input Signals
2.2.2.3 Testing Output Signals

Test a digital output channel as shown in Figure 2-3. The procedure is very similar for analog
signals (refer to Figure 2-4). Test digital and analog output channels as follows:
• Select a PC element terminal connected to the related DB element in the
Advant Station 100 Series ES function “Test.”
• Select the menu item for forcing output signal values.
• Select the “VALUE” terminal on the DB element and enter the desired output value.
• Check that the corresponding yellow LED on the output module lights up (only digital
modules). For analog outputs, measure the signal with a multimeter at the terminal of the
process connector or at the actuator.
• Reset the desired output value to a low value and check that the yellow LED on the module
extinguishes and that the signal value changes.
NOTE
The yellow LEDs on the module DO, which indicate the status, light only if the
process voltage “UP” (24 V DC) is connected.
2-4 3BUR 000 874R0201

Section 2.2.2 Checking the Input/Output System
AC 70 SOFTWARE AC 70 HARDWARE PROCESS
Application program
Digital
output
module UP
PC elements DB elements Actuator
ZP
Yellow Process
LED connector
AS 100 Series ES Test point for

digital output
signal
Digital Output
NAME VALUE
ERR
Figure 2-3. Testing Digital Output Signals
3BUR 000 874R0201 2-5

AC 70 SOFTWARE AC 70 HARDWARE PROCESS
Application program
Analog
output
module
PC elements DB elements Actuator
Process
connector
Test point for

AS 100 Series analog output
signal
Analog Output
NAME VALUE
ERR
Figure 2-4. Testing Analog Output Signals
2.2.3 Functional Test and Correction of the PC Program

Since the test requirements vary considerably from one installation to another, the design
engineer is responsible for determining the limits within which the functional requirements
apply and any other parameters which must be observed. The program is normally checked one
execution unit at a time.
The testing and debugging facilities and the on-line modification of an application program are
described in AMPL Configuration Advant Controller 110 Series Reference Manual and
AdvaBuild for Windows - Function Chart Builder.
2.2.4 AC 70
2.3 Start-up Procedures

This section includes power up for the very first definition/configuration of the system
resources.
2-6 3BUR 000 874R0201

Section 2.3.1 Controller Power Up
2.3.1 Controller Power Up

You can power up an AC 70 as follows:
1. Check that the circuit breakers on the Power Switch units are switched off.
2. Switch on the mains power 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 with the equipment.
3. Switch on the circuit breaker S1 on the Power Switch unit(s).
4. Check for the following positive indications of a successful power up:
– PM810
Operating OK green LED R
Power OK green LED P
Battery OK green LED BAT
AF 100 active - blinking (If AF 100 is connected) yellow LED CH1 & CH2
One of the status states P1 to P6 displayed (Table 5-1) 8 yellow LEDs
5. There are also some negative indications, for example,:
– PM810
Fault red LED F (Fault)
System Status 8 yellow LEDs
– I/O modules red LED F (Fault)
(Indicating that the modules are not implemented)
NOTE
Length of time for this to occur depends on the size of the data base being loaded.
2.3.2 Advant Station 100 Series Engineering Station

The AS 100 Series ES is used for program entry, testing, fault tracing and documentation of the
AC 70 application program.
The following functions are provided:
• Off-line generation and downloading of complete application programs (refer to the
Function Chart Builder User’s Guide)
• On-line modification of application programs
• Testing and fault tracing
• Tree editor for editing program structure
• PC diagram editor
• DB editor to configure DB elements
• Reading/setting of clock and calendar
• Generation and backtranslation of the AMPL source code
• Graphical documentation of application programs
3BUR 000 874R0201 2-7

• Display of detailed diagnostic information.

The AS 100 Series ES is connected to the AC 70 via the serial interface on the PM810.
An AS 100 Series ES can be connected to an AC 70 with equal success locally or remotely.
2.3.2.1 Connecting Advant Station 100 Series ES

For a detailed description of how to connect the AS 100 Series ES to an AC 70 and how to start
up and operate the Advant Station 100 Series ES, see “Advant Station 100 Series Engineering
Station User’s Guide”.
The AC 70 has its own diagnostic test routines, which run not only upon starting up the system,
but also during normal operation. If an error is detected, an error message is generated and
displayed on the Advant Station 100 Series ES screen. In case of a severe fault, the error status
is also signaled by LEDs (FAULT) and presented on the diagnostic display (error code) on the
CPU module.
For interpretations of these error codes and their indications, see Chapter 5, Maintenance.
2.3.2.2 Load an Application Program

You can load an application program by connecting an AS 100 Series ES. An application
program for an AC 70 system consists of a DB part and a PC program. The DB part and
PC program cannot be loaded separately.
The following must be done before you can load an application program from the AS 100 Series
ES:
1. Create an AC 70 node with the correct node address on the AS 100 Series ES.
2. Create a DB part on the AS 100 Series ES.
3. Create a PC program on the AS 100 Series ES.
4. Generate target code for the application program of this target by selecting the related menu
point item on the AS100 Series ES.
5. Connect the AS 100 Series ES to the AC 70.
You can now load the application program. Do items 1 - 4 only once; do item 5 every time you
load the application program.
2.3.2.3 Connect/Load Problems

Always use the values of the BUSNO and STNNO terminals of the PM810 DB element in the
FCB connect dialog.
If loading of the application leads to the error message:
AF 100 address on target differs from AF100 address in
application
the BUSNO and/or the STTNO terminals of the current PM810 database element differ from
those that are currently defined on the target.
2-8 3BUR 000 874R0201

Section 2.4 Product Verification
1. Application loaded to PM810.

The BUSNO and/or the STTNO terminals of the current PM810 database element differ
from those that are currently loaded on the target.
Loading this application would re-configure the bus and station number of the target.
2. No application loaded.
The BUSNO and/or the STTNO terminals of the current PM810 database element differ
from those used in the connect dialog.
If there is no application loaded to the AC70, the bus number used in the first connect
dialog defines the bus number on the AC70.
Solution
To enable loading of the application, reset the target without any application by either
pressing the INIT button until P3 is shown, or by executing Clear PROM. Restart the target
via the FCB menu Target Control.
2.4 Product Verification
2.4.1 General
A general description of how to set the controller in operation and start the execution of
application program is presented in the Advant Controller manuals. Once the system is started
and ready for operation the I/O can be checked.
General information for some functional tests, which can be made to verify the AC 70 are
presented in the following sections.
2.4.1.1 Procedure
The application program is normally checked, one unit at a time. For example, first check that a
flow valve functions and then verify that the start sequence for a pump motor functions and so
on.
After each sub-function has been tested, a comprehensive function control is performed to
verify that all operational 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.
During a test of the application program, the control system can be prevented from affecting the
process by disconnecting field wiring from the terminals on the MTUs or physically isolating
output signals from the process.
3BUR 000 874R0201 2-9

2-10 3BUR 000 874R0201

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

This section provides guidelines and other information that you need to know before designing
and configuring an AC 70. This information includes an overview of the hardware configuration
guidelines.
3.1.1 PM810
Memory requirements and loading factors are important information which must be considered
for each application when assigning functions to a PM810 Module. Refer to Section 3.2,
Capacity and Performance, for information on how to estimate memory and loading.
3BUR 000 874R0201 3-1

3.1.1.1 Address Switches

The PM810 is equipped with two rotary switches used as station address selectors for the AF 100
connection. If the station address is not in the range of 1 to 79, the PM810 is not reachable via
the AF 100. There can be up to 79 stations per AF 100 Fieldbus. Figure 3-1 shows the front panel
of the PM810.
F R
B P
T1 T2
S7 S3
S6 S2
S5 S1
S4 S0
INIT
SERVICE
STN. ADDR.
4 56
3 7 x 10 Address
2 8 Switch #1
109
4 56
3 7x1 Address
PM810 2 8 Switch #2
109
AF 100
L+ L+ SA 1 2
L- L- SB
+ + Tx
Power Supply - -
Connections SH SH
SH SH Rx
Fieldbus
Connections
Figure 3-1. AC 70 Front Panel
3-2 3BUR 000 874R0201

Section 3.1.1 PM810
3.1.1.2 AF 100 Fieldbus Connections

The PM810 connects to the AF 100 via the 8 terminals on its front. The fieldbus wires are
connected to a removable terminal header. This allows the PM810 to be removed from the
AF 100 without disconnecting the other nodes of the fieldbus. The AF 100 can have redundant
media which will be connected to channel 1 and 2 of the PM810. See Figure 3-2 for connection
details.
4 6
3 7 x1
2 8
PM810 10 9
AF 100
L+ L+ SA 1 2
L- L- SB Channel 2
PM810 + + Tx
X3
- -
SH SH
SH SH Rx
Terminal
Channel 1 Headers
X2
1
2
3
4 1
Fieldbus #1 3
2
4
Fieldbus #2 Shield Jumper
Figure 3-2. PM810 Fieldbus Terminal Connections
Table 3-1 shows the fieldbus connection assignments.
Table 3-1. PM810 Fieldbus Connections, Channel 1 X2, Channel 2 X3
Pin Designation Description

1 + + Signal
2 - - Signal
3 SH Shield(1)
4 SN Shield
(1) Should be jumpered to Pin 4 Shield
3BUR 000 874R0201 3-3

3.1.1.3 Power Supply Connections

The PM810 requires 24V dc (+20%) with a maximum current requirement of 1 A. It can be feed
by either a single or redundant power supply. If a redundant power supply is used, the PM810
can monitor the status of each supply. See Figure 3-3 for power supply connections.
4 56
3 7 x1
2 8
PM810 109
AF 100
L+ L+ SA 1 2
L- L- SB
+ + Tx
- -
SH SH
PM810 SH SH Rx
Terminal
Headers
Power Supply “B”

monitor
3
2
Power Supply “A” 1
+24V dc
monitor To MTUs
+24V dc 0V dc
3
2
1
From power supply
0V dc
Jumper
Figure 3-3. PM810 Power Supply Connections
Power comes into the PM810 from a single or redundant power supply. The power supplies of a
redundant pair can be monitored by the PM810. The incoming power can then be distributed to
other PM810s or the I/O modules if desired.
Power supply connections are presented in Table 3-2 and Table 3-3.
Table 3-2. PM810 Power Connection Terminal X1A

1 L+ +24V dc Supply In (can be jumpered to pin 2)
2 L+ +24V dc Supply Out
3 SA Redundant Power Supply Monitoring Input
3-4 3BUR 000 874R0201

Section 3.1.2 Mounting Termination Units (MTU)
Table 3-3. PM810 Power Connection Terminal X1B

1 L- 0V dc Supply In
2 L- 0V dc Supply Out
3 SB Redundant Power Supply Monitoring Input
3.1.1.4 Power Supply Configuration

For information on the power supply configuration, refer to the S800 I/O User’s Guide.
3.1.2 Mounting Termination Units (MTU)

For information on the MTUs, refer to the S800 I/O User’s Guide.
3.1.3 I/O Modules

For information on the I/O modules, refer to the S800 I/O User’s Guide.
3.1.4 Power Supply Load Calculation

For information on power supply load calculations, refer to the S800 I/O User’s Guide.
3BUR 000 874R0201 3-5

3.1.5 Communication
3.1.5.1 Provided Link Types
Communication Survey
The table below shows the communication links available for Advant Controller 70 and the
systems you can connect with. You can find more detailed information for each link in the
following subsections.
Table 3-4. Communication Survey
Functionality
Equipment Used link(s)
(explanations below)
Advant Controller 410/450 Advant Fieldbus 100 R I B E
Advant Controller 110 Advant Fieldbus 100 R I B E
Advant Controller 70 Advant Fieldbus 100 R I B
S800 I/O Modulebus R I B
Drive modules Modulebus R I
Advant Station 100 Series Serial interface of CPU, 1)
Engineering Station Advant Fieldbus 100
AdvaSoft for Windows Advant Fieldbus 100 R I B E
Local Operator Station / MMI MODBUS I R I B
Other manufacturers’ MODBUS I R I B
equipment
Explanations
1) Configuration data transfer, application program loading and commissioning functions
R, I, B indicates Real, Integer and Boolean data, respectively. Bi-directional information flow is
possible.
E indicates handling of time-stamped events.
Data Set Peripherals

Information is exchanged between separate controllers (and between controllers and AdvaSoft
for Windows) by means of “Data Set Peripherals” (DSP), i.e., messages containing aggregates
of data base information. Data Set Peripherals are explicitly specified in the communicating
controllers, as part of the application programming.
With a Data Set Peripheral, the communication normally transmits data cyclically between the
nodes. The cycle time is selectable from 1 ms upwards.
3-6 3BUR 000 874R0201

Section 3.1.5 Communication
For a detailed description of Data Set Peripheral, see the manual AMPL Configuration Advant
Controller 100 Series Reference Manual.
Appropriate Hardware and Software
Table 3-5. Link Types, Hardware and Software
Communication Interface
Link Type Software Option Comments
Module
Advant Fieldbus 100 PM810 -
MODBUS I MODBUS connection kit OPT MODBUS I
(slave function only) processor module PM810
3.1.5.2 Applied Communication
Interface to Application Program
Table 3-6. 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 Advant Fieldbus 100 PM810 DataSet Peripheral, DAT
Advant Controller 110 Advant Fieldbus 100 PM810 DataSet Peripheral, DAT
S800 I/O I/O element
Advant Station 100 Series Serial interface of PM810 Not needed Set of commands
Engineering Station Configuration data
AdvaSoft for Windows Advant Fieldbus 100 PM810 DataSet Peripheral, DAT
Local Operator Station / MMI MODBUS (slave function) PARDAT
at second serial interface of
MODBUS connection kit for
PM810
(1) Generally data base elements are given for establishing the link and the interface to the application program. PC: denotes PC element.
3BUR 000 874R0201 3-7

Guidelines - DataSet Peripheral Communication

Designation of DataSet Peripheral
Data Set Peripherals (DSP) are used with signal exchange between, for example, controllers. A
DataSet Peripheral is defined by a data base element which states if it is a transmitting or
receiving DataSet Peripheral, the cycle time and from where the information is received or to
where it is transmitted. The data base element for a DataSet Peripheral also refers to a number
of DAT elements. These DAT elements contain, in turn, the values which are to be
transmitted/received.
When a DSP and associated DAT elements are allocated names, it is important to be able to
trace the origin of the data, i.e., where the data originates. One way is to give a DataSet Periph-
eral a name in accordance with DSP “from node number” - “to node number”. If a DataSet
Peripheral is transmitted from node 12 to node 11, it is given the name DSP12-11. Associated
DAT elements can be given the name DSP12-11.R1 (which is obtained automatically if a real
DAT element is created with the help of DSP).
As an alternative, you can give DAT elements function-describing names (of up to 12 charac-
ters).
Performance Considerations
Information given in Section 3.2, Capacity and Performance shows that increasing the number
of DataSet Peripherals causes more load than increasing the number of DATs. Thus you should
minimize especially the number of DataSet Peripherals.
3.1.5.3 MODBUS
Outline Description
The Gould Electronics protocol MODBUS I is available as standard. You can use it for
communication with, for example, other manufacturers’ control systems (PLCs). You can install
MODBUS I in AC 70 using MODBUS I SW Driver on the second serial interface of MODBUS
connection kit for AC 70 CPU module and AC 70 OPT MODBUS I.
Only the slave function is supported in this case. That means Advant Controller 70 is a
MODBUS I slave with a fixed slave number 1. See Section 3.1.6.1, Local Operator for
calculation of MODBUS I data address.
Performance Considerations
In AC70 1.1/0 the MODBUS communication task has lower priority than the AS100 ES
communication task. Therefore, during actions started via AS100ES, e.g. cyclic display, the
response times for MODBUS telegrams will increase.
In AC70 1.1/1 the MODBUS communication task has higher priority than the AS100 ES
communication task. Therefore, during actions started via AS100ES, e.g. Save in PROM,
MODBUS communication will be available.
3-8 3BUR 000 874R0201

Section 3.1.6 Operator’s Interface
3.1.6 Operator’s Interface
3.1.6.1 Local Operator

Communication with a local operator station / MMI is an application of MODBUS I. See
Section 3.1.5, Communication.
You can connect panels or a personal-computer-based operator station directly with a cable via
an RS-232-C serial interface at connector 2 of the MODBUS connection kit for PM810.
No additional communication interface modules are necessary.
You need software option OPT MODBUS I which provides MODBUS protocol on the serial
interface of the PM810 module.
Physical Connection
You can use following serial interface for connection with local operator station, MMI or panel:
• Connector:
– Connector 2 (RS-232-C) on the MODBUS connection kit for PM810
• The LINE characteristics:
– 9600 baud rate
– 1 start-bit, 1 stop-bit
– no parity
Communication with Local Operator Station

The local operator station communicates with the Advant Controller 70 via the MODBUS I
protocol (binary). With Advant Controller 70, it can only be used as a point-to-point network
(because of the RS-232-C). The master of this communication link is on the operator station /
MMI side.
The Advant Controller 70 is the slave with a fixed slave node number 1.
Access
The following DB elements are accessible by the local operator station:
• Boolean Parameters PARDAT(B), PARDAT(NB)
• Integer Parameter PARDAT(I), PARDAT(II), PARDAT(NI)
• Integer Long Parameter PARDAT(IL)
• Real Parameter PARDAT(R)
3BUR 000 874R0201 3-9

All signals of an application on an Advant Controller 70 to be accessed by the operator station

must be reflected as PARDAT. On an Advant Controller 70, it is only possible to read or write to
and from memory. Direct access to input or output is not supported.
The MODBUS I address can be calculated as follows:
Bit addresses: ADDR = (n • 32)-k
Integer addresses: ADDR = (n-1) • 2 +l
Where ADDR is the MODBUS address to be entered in the MODBUS telegram
n is the item designation of the PARDAT element
(example: n = 3 for PD3),
k is the bit offset in the PARDAT(B) element, starting with 0
(example: k = 8 for bit number 9 in a PARDAT (B)),
l is the offset in the PARDAT(II) element, starting with 0
(example: l = 1 for value number 2 in a PARDAT (II)),
Communication Protocol
The communication protocol for data exchange between the Advant Controller 70 and local
operator station / MMI is the standardized MODBUS I protocol.
The following MODBUS functions are supported:
Table 3-7. MODBUS Functions
Func. MODBUS Function Data Access in AC70

Code
01 Read coil status One bit in a PARDAT(B)
02 Read input status One bit in a PARDAT(B)
03 Read holding register One word in a PARDAT(I), PARDAT(IL) or PARDAT(R)
04 Read input register One word in a PARDAT(I), PARDAT(IL) or PARDAT(R)
05 Force single coil One bit in a PARDAT(B)
06 Force single register One word in a PARDAT(I), PARDAT(IL) or PARDAT(R)
07 Read exception status Get AC 70 status
08 Read diagnostic counter Get internal counters on AC 70
15 Force multiple coils Bits in a PARDAT(B)
16 Force multiple registers A number of word in a PARDAT(I), PARDAT(IL) or PARDAT(R)
The function codes 1 and 2, as well as 3 and 4, work identically when reading from the internal
memory. The function codes 1, 2, 3, 4, 7 and 8 are not allowed for broadcasting when the
Advant Controller 70 is a slave.
3-10 3BUR 000 874R0201

Section 3.2 Capacity and Performance
3.1.6.2 Central Operator

Communication with a central operator’s station, AdvaSoft for Windows, is possible via Advant
Fieldbus 100. See Section 3.1.5, Communication.
To support AdvaSoft for Windows you need Advant Controller 70 software option OPT Events
which is part of the AC 70 Basic Unit.
The operation station products are described separately.
For information about AdvaSoft for Windows, see AdvaSoft for Windows, User’s Guide.
For information about Advant Fieldbus 100, see Advant Fieldbus 100 User’s Guide.
3.2 Capacity and Performance
3.2.1 Memory Demand
3.2.2 Calculation of Memory Demand in Advant Controller 70

The CPU Advant Controller 70 module PM810 provides 256 KB of PROM for storage of the
application code and 512 KB RAM for executing the application.
The amount of free RAM is dependent on the number and type of options actually loaded into
the system. Typically, the free RAM size is about 256 KB.
You can determine the exact free memory size by calling the Function Chart Builder command
Target | Report Status.
During the execution of an on-line change, extra RAM space is needed. If the memory is
already consumed by loading a big application, you are alerted by the Function Chart Builder
running on the engineering station with the warning, “Not enough memory on target available”.
NOTE
The following calculations are difficult and time-consuming; however, they are
necessary to get an accurate result. For a quick but rough overview, see
Section 3.2.7, Rough Estimate of AC 70 Memory Demand (5-step Method).
Once the application is prepared and downloaded to the target, you can obtain an exact report
about free memory resources on the target via the Status Report.
3BUR 000 874R0201 3-11

3.2.3 Calculation of Memory Demand for PCPGM

The following calculation must be made for the PCPGM once per application.
Table 3-8. Calculation of Memory Demand for PCPGM
Calculated
Calculation Rounded
Memory Comments
Formula to Use Result
Size
Constant 2000 bytes
M = m1 + m2 +.. N=number of CONTRMs
mN(1) “connection to other
CONTRMs” below
Sum -> -> RAM only
(1) See Table 3-15 for calculation of m.
3-12 3BUR 000 874R0201

Section 3.2.4 Calculation of Memory Demand for DB Elements
3.2.4 Calculation of Memory Demand for DB Elements

The following calculation must be made for every DB element.
Table 3-9. Calculation of Memory Demand for DB Elements
Calculation Calculated
Rounded
Formula to Memory Comments
Result
Use(1) Size
Sum -> -> RAM only
Constant 130 bytes
Sum -> -> PROM and RAM
Constant 130 bytes
Sum -> -> PROM and RAM
Sum -> -> RAM only
Sum -> -> RAM only
Const 6 bytes
Sum -> -> RAM only

(1) See Table 3-16.
Round up the results in the framed fields to the next 256 Bytes boarder and add to the final
result.
3BUR 000 874R0201 3-13

3.2.5 Calculation of Memory Demand for CONTRM

The following calculations must be repeated for each of the CONTRMs the application consists
of.
Table 3-10. Calculation of Memory Demand for CONTRMs
Calculated
Calculation Rounded
Memory Comments
Formula to Use Result
Size
Const 130 bytes
(1)
+A
(2)
+C
(3)
+D
(4)
+G
(5)
+I
(6)
+K
Sum -> -> RAM and PROM
Const 264 bytes

(7)
+B
(8)
+E
(9)
+F
(10)
+H
(11)
+J
(12)
+L
Sum -> -> RAM and PROM
(1) See Table 3-11.

(2) See Table 3-12.
(3) See Table 3-12.
(4) See Table 3-13.
(5) See Table 3-14.
(6) See Table 3-15.
(7) See Table 3-11.
(8) See Table 3-12.
(9) See Table 3-12.
(10) See Table 3-13.
3-14 3BUR 000 874R0201

Section 3.2.6 Formulas and References for Detailed Calculation
Round up the result in the framed fields to the next 256 Bytes boarder and add to the final result
which determines the required RAM space.
Only those parts explicitly marked in the comments contribute to the required PROM space.
You can use the results from Calculated Memory Size field (not rounded up) plus 1500 bytes to
find the total amount of required PROM.
3.2.6 Formulas and References for Detailed Calculation

The following sections give formulas and references for the detailed calculation of all
memory-consuming parts of the application. Use the results to fill in the sheets above
accordingly.
Table 3-11. References of PC Elements
Component PC Elements
A Sum of “PC Statement (byte)” according to PC-Elements
Advant Controller 70 Reference Manual, Chapter 6
B Sum of “Local Data Area (byte)” according to PC-Elements
Advant Controller 70 Reference Manual, Chapter 6
Table 3-12. References and Formulas of Connections to I/O
Component Connections to I/O

C Sum of connections to “Module DB Elements” (byte) according to
Data Base Elements Advant Controller 70 Reference Manual Memory
Requirements (Get/Put) (bytes)
E Sum of “Module DB Elements” * 2 bytes
D d1 + d2 + d3 + ... dN
d1..dN sum of “Channel DB Elements” (bytes) according to
Data Base Elements Advant Controller 70 Reference Manual Memory
Requirements (Get/Put) (bytes).
N= number of boards connected to this CONTRM
F Sum of Input Channel DB Elements (connected terminals only)
2 bytes for each B,I input channel
4 bytes for each IL,R input channel
3BUR 000 874R0201 3-15

Table 3-13. Formulas of Connections to Common Data
Component Connections to Common Data

G 4 bytes for each DAT, PARDAT, DSP
6 + 6 * N bytes for each DAT(B)
N = number of connected terminals of this DAT
H 2 bytes for each B,I input
4 bytes for each IL,R input
Table 3-14. Formulas of Connections to Constants
Component Connections to Constants

I 4 bytes for each B,I
6 bytes for each IL,R,T,TR
6 +2 * N bytes for each A (N=length of array
J 2 bytes for each B,I
4 bytes for each I,R,TR
N+3 bytes for each A (N=length of array)
Table 3-15. Formulas of Connections to Other CONTRMs
Component Connections to Other CONTRMs

K 4 bytes for each B,I,IL,R,T,TR
6 bytes for each A,G
L For all inputs from other CONTRMs
2 bytes for each B,I
4 bytes for each IL,R,TR
N+3 bytes for each A
2*N for G of type B,I
4*N for G of type IL,R,T,TR
M For all outputs to other CONTRMs
2 bytes for each B,I
4 bytes for each IL,R,TR
N+3 bytes for each A
2*N for G of type B,I
4*N for G of type IL,R,T,TR
3-16 3BUR 000 874R0201

Section 3.2.7 Rough Estimate of AC 70 Memory Demand (5-step Method)
Table 3-16. References of DB Elements
Component DB Elements
N Sum of “Common Data” according to Data Base Elements
Advant Controller 70 Reference Manual Memory Requirements
O Sum of “Common Data Description” according to Data Base Elements
P Sum of “Common Data Extended” according to Data Base Elements
Advant Controller 70 Reference Manual Memory requirements
Q Sum of “Common Data Event Queue” according to Data Base Elements
R Sum of “Configuration Data” according to Data Base Elements
S Sum of “Common Configuration Addresses” according to Data Base
Elements Advant Controller 70 Reference Manual Memory Requirements
NOTES
Calculations must be made for each of the CONTRMs in the application program.
The calculations for SEQ are exactly the same as those for the CONTRM.
The calculations for MASTER and SLAVE must be made as follows:
1. Calculate separately the memory demand for the MASTER and all
subordinated SLAVEs according to the rules given for the CONTRM.
2. The resulting memory need is the sum of all calculated parts.
3.2.7 Rough Estimate of AC 70 Memory Demand (5-step Method)

NOTE
The result of this method is only a rough estimate which can be made in a
reasonable amount of time and before your real application programming is
ready.
Step 1
Calculate the required “PC element statement” size and “local data” size for your CONTRMs
according to the formulas and data given in the PC-Elements Advant Controller 70 Reference
Manual.
3BUR 000 874R0201 3-17

Step 2
Calculate the memory demand for the connections in your application. For each CONTRM, the
signals into the CONTRM must be respected. Use 2 bytes for each B or I signal, use 4 bytes for
each IL,R,T or TR signal.
Step 3
Calculate the required amount of “configuration data,” “common data description,” “common
data,” “common data extended” and “common data event queue” according to the formulas and
data given in the Data Base Elements Advant Controller 70 Reference Manual.
Step 4
Reserve 10 bytes extra for each signal into or from the CONTRM.
Step 5
Calculate the total memory from the sum of the values from step 1 through 4.
3.2.8 Performance
The performance of an Advant Controller 70 depends on the CPU load of the application
program. The CPU load of an application program is determined by
• CPU load of all executable units (PCPGM, CONTRM, MASTER, SEQ)
• CPU load of I/O Scanning
• CPU load of DataSet communication (DSP) on the Advant Fieldbus 100
(refer to the AF 100 User’s Guide)
• CPU load of event detection
3.2.9 CPU Load of Executable Units

The CPU load of executable units (PCPGM, CONTRM, MASTER, SEQ) is determined by the
execution time of the executable units and their cycle time.
The execution time of an executable unit of type PCPGM is 1000 µs. The cycle time of a
PCPGM is defined by the first call parameter (C1).
The execution time of an executable unit of type CONTRM, MASTER or SEQ consists of
• Execution time of the module header element CONTRM, MASTER or SEQ
• Execution time of all PC elements included in this executable unit
• Execution time of GET and PUT elements for the input and output phases
The execution time of the module header elements CONTRM, MASTER and SEQ is 1000 µs.
3-18 3BUR 000 874R0201

Section 3.2.9 CPU Load of Executable Units
You can find the execution time of all PC elements in the PC Elements - Advant Controller 70
Reference Manual. If PC elements AND, OR, SR or XOR are executed in in-line code, you can
find their execution time in Table 3-17. Note that for every in-line code sequence, the execution
time of the in-line begin and end statements must be added.
Table 3-17. Execution Times for In-Line Coded PC Elements
Execution Time
Element
(in µs)
AND 2.12 + 0.94*C1
OR 2.12 + 0.94*C1
XOR 5
SR 4.4
In-line begin+end 10
The execution time for a single PC element or for all PC elements within a module or block can
be automatically computed by the PC-Section | Computing Time | Unit and PC-Section |
Computing Time | Element commands of the Function Chart Builder running on the
engineering station. Reduction of execution time due to in-line coding of PC elements AND,
OR, SR and XOR is not taken into account by these Function Chart Builder commands.
Every connection of a PC element terminal to any of the following terminals causes the
execution of a GET or PUT element:
• DB element terminal
• Terminal of a PC element within another executable unit
If more than one PC element terminal within a certain executable unit is connected to the same
DB element, only one GET or PUT element is executed.
The execution times of GET and PUT elements for connections to all kinds of DB element
terminals are listed in the DB Elements Advant Controller 70 Reference Manual. The execution
times of GET and PUT elements for connections between PC element terminals in different
executable units are listed in Table 3-18.
Table 3-18. Execution Times of GET and PUT Elements for Connection Between
Different Executable Units
Execution Time
Element Data Type Notes
(in µs)
GET B, I, IL, R, T, TR 20 * n n = number of connections of
specified data type
PUT B, I, IL, R, T, TR 17 * n n = number of connections of
specified data type
3BUR 000 874R0201 3-19

Table 3-18. Execution Times of GET and PUT Elements for Connection Between
Different Executable Units (Continued)
Execution Time
Element Data Type Notes
(in µs)
GET A, G (16 + 3*k) * n n = number of arrays or groups
k = number of elements in array
or group
PUT A, G (16 + 3*k) * n n = number of arrays or groups
k = number of elements in array
or group
An executable unit including the module header element, PC elements, and GET and PUT
elements is executed with the cycle time specified by the first call parameter (C1) of the module
header element (CONTRM, MASTER or SEQ).
The CPU load L exec (in%) of all executable units can be calculated by the following formula:
N ⋅T
Lexec = ∑ -------------
i
Ci
-i ⋅ 100%
i
where
T i = execution time of function i (in ms)
N i = number of function i
C i = cycle time of function i (in ms)
The functions are:
• PCPGM
• Module header elements CONTRM, MASTER, SEQ
• PC elements
• GET and PUT elements
The cycle time Tc depends on the element:
• PCPGM Own cycle time (call parameter C1)
• Module header element Own cycle time (call parameter C1)
(CONTRM, MASTER or SEQ)
• PC element Cycle time of the executable unit including
this PC element
• GET or PUT element Cycle time of the executable unit including this element.
3-20 3BUR 000 874R0201

Section 3.2.10 CPU Load of I/O Scanning
3.2.10 CPU Load of I/O Scanning

The scanning of I/O modules is done asynchronously to the execution of the control modules.
I/O modules are scanned cyclically, where the cycle time is selectable at the input terminal IOS-
CANT at the PM810 element in the range of 0..100ms in steps of 2ms. The minimum cycle time
depends on the number and type of I/O modules to be scanned. The actual cycle time can be
read from the output terminal ACTSCANT at the PM810 element. The I/O values are stored in
an internal memory of the AC 70 which is written/read by the control modules (CONTRMs).
Each execution module reads its inputs before executing its AMPL elements. This guarantees a
consistent image of the process signals. After execution of the AMPL elements, the module
writes the calculated results to the outputs.
To optimize the load from I/O scanning some modules are not scanned in every scan cycle. A
scanning ratio 10 means that this module is scanned in every 10th scan cycle, i.e. if
ACTSCANT = 8 an AI810 is scanned every 32ms.
Table 3-19. Scanning ratio values
Module Type Scanning Ratio

AI810, AI820 4
AI830, AI835 10
AO810, AO820 4
DI810, DI820, DI821 1
DO810, DO820 0.645 ms
DRISTD 1
DRIENG (see DRIDS below)
DRIDS at REF1or REF2 1
DRIDS at REF3 to REF5 4
DRIDS at REF6 or REF7 10
DRIDS at REF8 to REF10 40
PM810 1
3BUR 000 874R0201 3-21

Table 3-20. Execution Times
Module Type Ti = Execution Time

Digital inputs 0.230 ms
Digital outputs 0.250 ms
Analog inputs (AI810, AI820) 0.225 ms x number active channels
Analog inputs (AI830, AI835) 0.003 ms x number active channels
Analog outputs (AO810, AO820) 0.090 ms x number active channels
DRIDS at REF1or REF2 0.250 ms
DRIDS at REF3 to REF5 0.070 ms
DRIDS at REF6 to REF10 0.025 ms
PM810 0.840 ms
The sum of all Execution times, T IO (in ms) is given by:
T IO = ∑ Ti
i
where
T i = execution time of I/O scanning (Table 3-20)
Table 3-21. Scan Times
Module Type Si = Scan Time (1)

AI810 4.500 ms
AI820 2.250 ms
AI830, 835 0.600 ms
AO810 1.800 ms
AO820 0.900 ms
DI810, 820, 821 0.645 ms
DO810, 820 0.645 ms
DRISTD 1.300 ms
3-22 3BUR 000 874R0201

Section 3.2.10 CPU Load of I/O Scanning
Table 3-21. Scan Times
Module Type Si = Scan Time (1)

DRIENG 2.600 ms
PM810 2.100 ms
(1) Si is the time which each module contributes to the total I/O
Scanning cycle time
The smallest possible I/O Scanning cycletime S min (in ms) can be calculated from the
following formula:
S min = ∑ Si
i
where
S i = scan time of I/O scanning, (Table 3-21)
S min = rounded up to the next multiple of 2 ms
Example:
A station with two AI810s, one AO810, one DI810 and two DO820s will give the following I/O
scanning cycle time:
2 AI810 = 2*4.500 = 9.000

1 AO810 = 1*1.800 = 1.800
1 DI810 = 1*0.645 = 0.645
2 DO810 = 2*0.645 = 1.290
1 PM810 = 1*2.100 = 2.100
Sum of S,i = 14.835
S, min = 16
If the time specified at PM810:IOSCANT is greater than S min , 16ms, the user specified time
will be used. The value of PM810:IOSCANT is typically chosen in accordance with the
application.
The load from I/O Scanning, L IO (in ms), can be calculated from the following formula:
3BUR 000 874R0201 3-23

where
T IO
L IO =  -------- • 100%
S IO
TIO = execution time of I/O scanning (Table 3-20)

S IO = The larger number of either S min or the value of PM810:IOSCANT
Note that the load calculation considers the worst case. The worst case appears depending on the
configuration the analog modules when analog signal values are changing rapidly.
3.2.11 CPU Load of DataSet Communication

The CPU load L DSP of DataSet communication depends on the number of DataSet elements
(DSP), their cycle time and the number of DAT elements referenced by those DataSet elements.
The execution time T DSP of a DataSet (in ms) can be calculated by following formula:
0,287 + n DAT ⋅ 0,053

where
n DAT = number of DAT elements (1..8) referenced by DataSet
The CPU load L DSP (in %) of DataSet communication can be calculated by the following
formula:
2⋅T
 ------------i + ----------------
0,02 
L DSP = ∑  Ci C PCPGM 
- ⋅ 100%
i
where
Ti = execution time of DSP i (in ms)
C i = cycle time of DSP i (in ms), see terminal CYCLETIM
C PCPGM = cycle time of executable unit PCPGM
In addition to the load limitation, the following constraint must be fulfilled:
∑ Ti < Cmin
i
3-24 3BUR 000 874R0201

Section 3.2.12 CPU Load of Event Detection
where
Ti = execution time of DSP i (in ms)
C min = smallest cycle time of all DSP i (in ms), see terminals CYCLETIM
CAUTION
If this constraint is not fulfilled, the CPU can be overloaded no matter what the
calculated CPU load is! Overloading means that your Advant Controller 70 stalls.
You can find some examples of CPU load calculations for DataSet communication in
Table 3-22 and Table 3-23.
Table 3-22. CPU Load from DataSet Communication, Example 1
Number of Cycle Time Constraint

Number of Cycle Time Execution
DATs per of PCPGM Load L DSP
DSP
Elements
DSP
of DSP
C i (in ms)
Time T DSP
(in ms)
C PCPG M (in %) ∑ Ti < Cmin
n DAT (in ms) i
4 4 32 0.5 32 12.7
10 8 128 0.71 11.7
Sum 24.4 9.1 < 32
Table 3-23. CPU Load from DataSet Communication, Example 2
Number of Cycle Time Constraint

Number of Cycle Time Execution
DATs per of PCPGM Load L DSP
DSP
Elements
DSP
of DSP
C i (in ms)
Time T DSP
(in ms)
C PCPG M (in %) ∑ Ti < Cmin
n DAT (in ms) i
50 8 512 0.71 512 14 35.5 < 512
3.2.12 CPU Load of Event Detection

Data base elements AIC and DIC, configure event detection for PC signals connected to the
terminal VALUE of these data base elements.
To every data base element AIC and DIC, a system function is assigned which executes event
detection. The CPU load of these event detection functions is determined by their execution
time and cycle time.
The execution time of the event detection functions, depending on the kind of data base element,
is listed in the DB Elements Advant Controller 70 Reference Manual. The cycle time of these
functions equals the scan time for event detection (specified by the terminal SCANT).
The CPU load Le ve nt (in%) of event detection can be calculated by the following formula:
3BUR 000 874R0201 3-25

Si
T i + 0,2ms •  ---------- – 1
= ∑ -------------------------------------------------------
S min
L eve nt - ⋅ 100%
i
S i
where
Ti = execution time of event detection function i (in ms)
S i = scan time of event detection function i (in ms), see terminal SCANT of the
corresponding AIC and DIC elements
S min = smallest scan time of all event detection function i (in ms), see terminals SCANT
of all AIC and DIC elements
In addition to the load limitation, following constraint must be fulfilled:
∑ Ti < Smin
i
where
Ti = execution time of event detection function i (in ms)
S min = smallest scan time of all event detection function i (in ms),
see terminals SCANT of all AIC and DIC elements
CAUTION
If this constraint is not fulfilled, the CPU can be overloaded no matter what the
calculated CPU load is! Overloading means that your Advant Controller 70 stalls.
To lower the CPU load enter, at the terminal IOSCANT (0..100ms) a big scan time.
Consider that one event detection function with a very small scan time increases the load for all
other event detection functions drastically (see examples 1 and 2 in Table 3-24).
3-26 3BUR 000 874R0201

Section 3.2.13 Calculation of Total CPU Load
You can find some examples of CPU load calculations for event detection in Table 3-24.
Table 3-24. CPU Load of Event Detection, Examples
CPU Load Constraint

Event Detection Functions L event
∑ Ti < Smin
(in %) i
32 DIC, 5 32 < 640

SCANT=640ms
31 DIC, 1 DIC, 22 32 < 40
SCANT=640ms SCANT=40ms
16 AIC, 16 DIC, 10.5 67.2 < 640
SCANT=640ms SCANT=640ms
32 AIC, 16 DIC, 16 DIC, 33 134 < 160
SCANT=640ms SCANT=640ms SCANT=160ms
Note that the load calculation considers the worst case. The worst case appears when all event
detection functions detect an event or even several events (AIC element) at the same time. While
no events are detected, the CPU load is much lower but you must not rely on that. Otherwise an
event shower might overload your Advant Controller 70 and, hence, stall it.
3.2.13 Calculation of Total CPU Load

The total CPU load L can be calculated by the following formula:
L = L ex ec + L IO + LDS + Le ve nt
where
L ex ec = CPU load of executable units (in%)
LIO = CPU load of I/O Scanning (in %)
LDSP = CPU load of DSP (in%)
Le ven t = CPU load of event detection (in%)
CAUTION
Twenty percent (25%) of the CPU load must be reserved for basic system
functions. The remaining 75% of the CPU load is available for the application
program. The load reported by PC element SYSL is smaller than the actual load,
as it does not measure the total load from I/O Scanning. Therefore PC element
SYSL should not report more than 60% load.
3.2.14 Example
As an example, the CPU load is calculated. The calculation of the load for I/O Scanning,
executable unit PC1 and PC1.1 are shown in the following tables.
3BUR 000 874R0201 3-27

Table 3-25. Calculation of CPU Load of I/O Scanning
I/O Scan
Execution
Number of Cycle Load L
Module Time Te
Functions N Time Tc (in%)
(in µs)
(in ms)
DI810 1 230 0.645
DO810 1 250 0.645
PM810 1 700 2.100
Sum 1180 4 29.5
Table 3-26. Calculation of CPU Load for Executable Unit PC1
Execution Cycle
Number of Load L
Function Time Te Time Tc
Functions N (in%)
(in µs) (in ms)
PCPGM 1 950 20 4.75
Table 3-27. Calculation of CPU Load for Executable Unit PC1.1
Execution Cycle
Number of Load L
Function Time Te Time Tc
Functions N (in%)
(in µs) (in ms)
CONTRM 1 950 20
AND 1 11.7 + 3.4*3
(1)
GET 1 17 + 11.2*4
PUT(2) 1 19 + 6.2*2
1065.1 20 5.33
(1) Four connections to DI810 channel elements (see DB Elements Advant Controller 70
Series Reference Manual)
(2) Two connections to DO810 channel elements DB Elements Advant Controller 70 Series
Reference Manual)
The CPU load of the whole application is 29.5 + 4.75+5.33=39.6%.
3-28 3BUR 000 874R0201

Section 3.2.15 Operator’s Interface
3.2.15 Operator’s Interface
3.2.15.1 Local Operator Station
General Technical Data, Capacity

The number of local operator stations which are communicating via serial interface at processor
module using MODBUS protocol is limited to 1.
3.2.15.2 Central Operator Station

General Technical Data, Capacity
The number of operator stations of the type AdvaSoft for Windows communicating with one
Advant Controller 70 is limited to 10.
3.3 Power Supply Requirements

For current consumption information, refer to the S800 I/O User’s Guide.
3.4 Power and Cooling

For information about power and cooling of the PM810, refer to Appendix A, General
Specification. For information about power and cooling of the I/O modules, refer to the
S800 I/O User’s Guide.
3.5 Application Start-up

Please see the AMPL Configuration manual for application start-up procedures.
3.6 Configuration/Application Building Menus

Please see the AMPL Configuration manual for configuration and application building menus.
3BUR 000 874R0201 3-29

3-30 3BUR 000 874R0201

Section 4.1 Product Operation
Chapter 4 Runtime Operation
4.1 Product Operation
4.1.1 Functions and Services of the PM810

The PM810 controls the I/O modules by execution of a user-defined application program. This
includes connectivity to the Advant Station series that serves as the user interface and
configuration tool and it also includes configuration and supervision of I/O modules. The
PM810 offers DSP (data set peripheral) transfer via AF 100 to which it is connected as a pure
slave station.
4.1.1.1 PM810 Tasks

During normal operation the PM810 will perform the following tasks.
Execution of Applications
A user-defined application consists of a PC part with executable function blocks (PC elements)
and a DB part with configuration data for the processor module (PM810) and I/O modules.
The PM810 is able to execute one PCPGM with a total number of 31 structure elements
(i.e. CONTRM or SEQ). Both allow cycle times between 4 milliseconds and 20 seconds with
different task priorities.
Scanning of I/O Modules

The I/O scanner works cyclically but asynchronously to the execution of the application. The
main task of the scanner is to transfer process values between application data domain(s) and the
I/O modules. In case of drive modules to be scanned refer to Section 4.1.3.3, Drive Modules
Configuration and Access
Processor Module Supervision

Cyclic background supervision tasks perform checks on:
• backup battery
• redundant power supply
• AF 100 interface
• redundant AF 100 line
• RAM content (CRC)
3BUR 000 874R0201 4-1

I/O Module Supervision

After configuration of all I/O modules, the module supervision starts. The supervision
distinguishes between following module states:
• Module is missing
The supervision makes an entry in the error buffer.
• Module is passive or re-inserted and of correct type
The supervision configures and activates this module, and makes an entry in the error
buffer.
• Module has wrong type
The supervision deactivates the module and enters this information in the error buffer.
• Module has minor faults (e.g. due to process connections)
The supervision enters this information in the error buffer.
Diagnostics
Diagnostics means detailed information that is provided from the PM810 on request from the
Engineering Station.
A summary error report gives an overview about all configured and erroneous I/O modules with
following information:
• position of the module
• type of module
• current state of module
• time of error detection by supervision
• and the error message itself (e.g. “Wrong module”)
Time Tagged Events (SOE)

The transportation mechanism applies a time stamp to events and distributes them on AF 100 to
specified supervisor stations. This applies only if the option ‘Event handling’ is enabled.
4.1.1.2 Block diagram

Data exchange on the AF 100 is maintained by the DB element DSP. Please refer to the manual
Data Base Elements Advant Controller 70 for further description of this element.
4-2 3BUR 000 874R0201

Section 4.1.2 AF 100 Usage
AC 70 Software AC 400 / AC 110

Software
DB part DB part
DSP Communication Communication DSP

Send Interface Interface Receive
PM810 CI520/CI626
AF 100
DSP DSP
Receive Send
Figure 4-1. Block Diagram of Communication Interfaces
The total number of DSP (sent and received) is up to 50 for the PM810 communication
interface.
4.1.2 AF 100 Usage
4.1.2.1 Time Synchronization

The PM810 is able to act as a time synchronization slave on the AF 100. Once enabled, it will
update the internal clock every second with data from the time synchronization master, e.g
AC 400 or AC 110.
4.1.2.2 DSP Transfer

Exchange of process data via the AF 100, is realized by DSP transfer.
The station status is also cyclically distributed on the AF 100.
4.1.2.3 Event Set

The AC 70 can create events from digital and analog values. For specific information on Event
Set, refer to the book, AMPL Configuration - Advant Controller 110 Series Reference Manual.
3BUR 000 874R0201 4-3

4.1.3 Configuration and Programming
4.1.3.1 Processor Module Configuration

The processor module DB element offers some parameters belonging to the PM810, which are
adjustable by the user. Possible parameters are listed below.
Start Mode
Setting up “STOP mode” prevents the system from loading and starting the application. Setting
up CLEAR (cold start) configures I/O modules and loads and starts the application stored in
FPROM. Setting up AUTO (warm start) allows the system software to continue the application
at interruption point (e.g. in case of power failure) after configuration of I/O modules.
Battery Supervision
This setting only enables or disables generation of error messages if the battery voltage is too
low or the battery is missing.
Redundant Power Supply Supervision

This setting only enables or disables generation of error messages if one of the two power
supply monitoring lines are not activated.
Time Synchronization
Enables or disables time synchronization via AF 100.
Redundant AF 100 Line Supervision

This setting only enables or disables generation of error messages if the redundant AF 100 line
fails.
4.1.3.2 I/O Module Configuration

You can set up I/O module configuration data at DB elements (refer to the AC 70 DB Elements
Reference Manual) with the AS 100ES. Properties and parameters are converted to internal code
and loaded to the PLC.
4.1.3.3 Drive Modules Configuration and Access

You can set up I/O module configuration data at DB elements (refer to the AC 70 DB Elements
Reference Manual) with the AS 100ES.
The drive data sets which are exchanged with the drives are defined by the DB elements DRIDS.
A Standard Drive Module is represented by a DB element DRISTD, which can reference up to 2
DRIDS elements, an Engineered Drive Module is represented by a DataBaseElement DRIENG,
which can reference up to 10 DRIDS elements.
4-4 3BUR 000 874R0201

Section 4.2 Operating Overview
The DRIDS:WR_ENA terminal defines the direction of the drive data set:
• DRIDS_WR_ENA == TRUE
– data set with number DRIDS:DS_NO is sent
– data set with number DRIDS:DS_NO + 1 is received
• DRIDS_WR_ENA == FALSE
– data set with number DRIDS:DS_NO is received
A transmit request for a drive data set is signalled to the IOScanner each time the
DRIDS:WR_ENA terminal is accessed by the application.
For further information on the drive data sets contents, refer to Functional Units Part 8
DRICONS User’s Guide.
4.2 Operating Overview

The process operator interface for the AC 70 is connected via the AF 100. Refer to the
Adva Command for Windows User’s Guide.
4.2.1 Start-up of the AC 70

When the AC 70 is started, it will perform some general self tests. Start up can be done in three
ways: Stop, Clear (cold start) or Auto (warm start). This depends on how the settings on the PM
DB element are chosen.
Stop
The AC 70 tries to install the connection to AF 100 and configures the station status DSP. No
application will be activated. It waits for commands from a connected Engineering Station.
Clear (Cold Start)

The AC 70 performs its self tests, checks the user flash PROM for containing a valid application
and activates this application. Next, complete initialization and I/O module configuration are
performed.
Auto (Warm Start)

In case of a power failure and valid RAM content, the AC 70 checks the parameters of I/O
modules, configures the modules if necessary, and continues execution of the application from
the point of interruption.
A restart, caused by pressing the INIT button, always leads to a cold start.
Fatal Error Occurred

If the application or a user option generates a fatal error, and the start mode is “Clear” or “Auto”,
this causes an endless restart loop since it is not possible to change the start mode without
connecting an Engineering Station. In this case you must be able to force a “Stop” mode start
3BUR 000 874R0201 4-5

without using an Engineering Station. This is possible by pressing the INIT button for at least
five seconds. When doing so, the AC 70 only performs self tests. No user options and no
application will be activated.
4.2.1.1 Treatment of Non-configured I/O Modules

In addition to supervision of I/O modules, there are some special cases:
Non-configured I/O Module Inserted

The supervision will not treat any I/O modules that are not configured. Therefore, no error
message will be generated.
Non-configured I/O Module Removed

The supervision does not care about such a module and generates no messages.
4.2.1.2 AF 100 Handling
Number of DSPs
The maximum number of DSPs configured is up to 50 (total sum for DSPs with direction
“source” and/or “receive”).
Time Synchronization Slave

When setting the PLC to time synchronization slave, the internal software real time clock will
be updated cyclically with reception of the time synchronization signal on AF 100. In this case,
the PLC will not allow setting of time by an Engineering Station.
4-6 3BUR 000 874R0201

Section 4.2.2 Processor Module 810 Front Panel
4.2.2 Processor Module 810 Front Panel
F R
B P
T1 T2
S7 S3
S6 S2
S5 S1
S4 S0
INIT
SERVICE
STN. ADDR.
4 5 6
3 7
x 10
2 8
1 0 9
4 5 6
3 7
x1
2 8
PM810 1 0 9
AF 100
L+ L+ SA 1 2
L- L- SB
+ + Tx
- -
SH SH
SH Rx
SH
Figure 4-2. PM810 Front Panel
The Processor Module 810, see Figure 4-2, has an INIT button, a service port, 2 rotary station
address switches and LED indicators.
3BUR 000 874R0201 4-7

LED Indicators
The PM810 has indicators for FAULT, RUN, POWER OK and one for each fieldbus
communication cable. It also has indicators for battery, status and mode. A more detailed
description will be given in Section 5.2.1, PM810 LEDs.
The colors and functions of the LEDs are shown in Table 4-1. For the location of the LED’s, see
Figure 4-2.
Table 4-1. Description and Colors of the LEDs on the PM810
Marking Color Description

F (Fault) Red Fault in the module (1)
R (Run) Green Operational state
P (Power ok) Green Internal power ok
B (Battery ok) Green Internal battery ok
T1 (Traffic 1) Yellow Traffic on AF 100 cable 1
T2 (Traffic 2) Yellow Traffic on AF 100 cable 2
S0 - S7 Yellow Status and mode indicators
(1) The F-LED will switch on at power up, restart of the module, or when the module goes to an Error
state. At start up, the module will do a self test.If the self test fails, the F-LED will switch on.
Init Button
Pushing the INIT button for a short time will cold start the PM810.
Pressing the INIT button until P3 is displayed makes the AC 70 perform only a self test without
activating the application and user options.
RS232 Port
The RS232 port can be used to connect an AS 100 series ES via a serial cable for software
configuration.
Station Address Switches

Screw driver slots are used to turn the switches to the correct station address.
4-8 3BUR 000 874R0201

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 AC 70.
5.1.1 Visual Inspection

For a description of the AC 70 visual inspection, refer to the S800 I/O User’s Guide
Battery
A sufficient battery voltage is indicated by the B LED to be on. If the B LED is off the battery
has to be changed.
5.2 Hardware Indicators

Various indicators (LEDs) are used in the AC 70. The indication LEDs inform you about the
status or fault in the system. They are intended to be simple and easy to use. They should allow
you to spot faults in the station easily.
3BUR 000 874R0201 5-1

5.2.1 PM810 LEDs

The PM810 status is displayed by 14 LEDs, 8 general purpose and 6 special purpose LEDs.
Figure 5-1 shows how they are arranged on the front panel.
F R
B P
LED Status
T1 T2
Indicators
S7 S3
S6 S2
S5 S1
S4 S0
INIT
SERVICE
STN. ADDR.
4 5 6
3 7
x 10
2 8
1 0 9
4 5 6
3 7
x1
2 8
PM810 1 0 9
AF 100
L+ L+ SA 1 2
L- L- SB
+ + Tx
- -
SH SH
Rx
SH SH
Figure 5-1. PM810 Status Indication LEDs
5-2 3BUR 000 874R0201

Section 5.2.1 PM810 LEDs
5.2.1.1 Special Purpose LEDs
F (FAULT)
The red FAULT LED is automatically switched on directly after power-up of the PM810. The
system software turns on this LED when the self test fails.
In case of serious hardware or software errors, this LED is switched on, indicating that the value
displayed with general purpose LEDs (see Section 5.2.1.2, General Purpose LEDs) is an error
value.
R (RUN)
The green RUN LED is active when the system software starts to run. It turns off in case of
serious hardware or software errors.
P (POWER)
The green POW LED indicates that the power supply to the PM810 is good. It is independent of
the system software status.
B (BATTERY)
The green BAT LED indicates that the voltage level of an inserted battery is sufficient for
backup of the internal Real Time Clock and buffered read/write memory.
If no battery is plugged in, or the voltage is too low, this LED will turn off.
T1/T2
The yellow T1 and T2 LEDs indicate that the I/O station is receiving data on the two AF 100
channels respectively.
5.2.1.2 General Purpose LEDs

The 8 yellow LEDs labeled 0 - 7, indicate the current status of the PM810.
Status Display
The status of the PM810 is indicated when LED 7 is on, and the FAULT LED is off. In this case,
LEDs S0 thru S3 display the binary (hexadecimal) state value, and LEDs S4 thru S6 are not yet
used.
3BUR 000 874R0201 5-3

Table 5-1 gives an overview about possible status states.
Table 5-1. PM810 Status States
LED LED LED LED LED LED LED LED LED

State State Description
P 7 6 5 4 3 2 1 0
P- on on CPU unit is in initial phase
P1 on on on CPU unit is in operational mode
P3 on on on on CPU has stopped after initialization;
START MODE attribute at PM810 DB-
element has been set to STOP
P4 on on on CPU is not running an application
program.
P5 on on on on CPU is loading an application program
from the internal PROM
P6 on on on on The programming tool is connected
(CPU is in the on-line mode)
Figure 5-2 shows an example of the LEDs for state P1, the normal operational state.
F R
B P
T1 T2
S7 S3
S6 S2
S5 S1
S4 S0
Figure 5-2. Example: LEDs for State P1, Normal Operational Mode
Error Display
An error code is indicated when LED 7 is off and the FAULT LED is on. In this case, LEDs
S0 thru S3 display the lower nibble of the error code and LEDs S4 thru S6 display the higher
nibble. All values are represented in binary (hexadecimal).
5-4 3BUR 000 874R0201

Section 5.3 Fault Finding and User Repair
As an example, Figure 5-3 shows the PM810 in an error condition. In this example, LEDs S4
thru S6 display the value 0‘h, and LEDs S0 thru S3 display the value 5‘h. Therefore, the error
code is 05‘h, “Bus Error”, which can be translated from Table 5-2 in Section 5.3.3.1, Faults That
Stop the System.
F R
B P
T1 T2
S7 S3
S6 S2
S5 S1
S4 S0
Figure 5-3. Example: LED Error Code Indication for “Bus Error”
5.3 Fault Finding and User Repair
5.3.1 Introduction
Diagnostics are available in different forms for rapid localization of the source of the equipment
malfunction. The AC 70 has built-in supervision facilities for hardware modules and programs.
Diagnostic aids are available in different forms to rapidly locate the cause of equipment
malfunction.
Disturbances and system halt caused by software error is commonly solved by a manual system
restart. Sometimes the application program has to be loaded from backup copies. In such
situations, you are strongly recommended to carefully note all available stored error codes and
system messages before attempting program loading and new initialization.
External faults in process wiring and transducers can also affect the operation of the AC 70. This
type of fault is not discussed in this manual. See the manuals AMPL Configuration Advant
Controller 110/70/55 Reference Manual and AdvaBuild Function Chart Builder User’s Guide
for a description of debugging PC programs.
Hardware error is usually corrected by replacing the faulty unit which is returned to
ABB Service for repairs. The smallest replaceable unit is normally a module or an apparatus
like a power supply unit.
This section, which covers fault tracing, is divided into two sub-sections:
• Basic fault tracing
• Advanced fault tracing.
Simple tools such as LEDs on the modules and a voltmeter are used for basic fault tracing.
Advanced fault tracing requires an Advant Station 100 Series ES in addition to these tools.
3BUR 000 874R0201 5-5

5.3.1.1 Fault Detection and Indication

Both hardware modules and system software in the AC 70 incorporate fault detection facilities.
These include both LEDs on the modules, and error reports on the AS 100 Series ES, which
gives error text about the probable cause of a malfunction.
5.3.1.2 Fault Tracing Principles

Fault tracing must be performed in a systematic and logical manner. Before starting up a system,
which has not been in operation, always check that:
• The mains voltage is connected
• All modules are installed properly
• All modules are in the correct position
• All connections are made correctly.
If these checks do not reveal the cause of a malfunction, continue with the procedure described
in Section 5.3.1.3, Fault Classification, and then continue to Section 5.3.3, Advanced Fault
Tracing. See Section 5.3.1.4, Start Up for instructions on how to restart a system after a fault has
been revised.
A fast and simple method of fault tracing is to reduce the system to a minimum by withdrawing
all modules except the PM810. Then reinsert them, one by one, to their positions until the fault
recurs.
5.3.1.3 Fault Classification

Faults can be divided into the following four groups.
• Faults in the power supply
This fault is indicated by the yellow POW LED on the PM810. If the LED is not
illuminated, the fault is in the power supply and you must locate it according to the
procedure ‘Checking the Power Supply’ in Section 5.3.2.1, Fault Tracing Procedure.
• Faults which do not stop the system
If the green LED RUN on the PM810 is illuminated, the system is probably still
operational and you must locate the fault as described in Section 5.3.2, Basic Fault
Tracing.
• Faults which stop the system
If the red LED FAULT on the PM810 is illuminated, refer to Section 5.3.3.1, Faults
That Stop the System.
• Faults which give no indications
Refer to Section 5.3.3, Advanced Fault Tracing.
5-6 3BUR 000 874R0201

Section 5.3.2 Basic Fault Tracing
5.3.1.4 Start Up
The AC 70 must be restarted after the system is forced to shut down by a severe fault.
You can do this by pressing the reset button which results in a cold start.
Attempt to diagnose the fault before restarting any system displaying error codes. This can
consist, for example, of noting error indications and error codes, or starting up the system and
reading out the error report with the Advant Station 100 Series ES.
5.3.2 Basic Fault Tracing
5.3.2.1 Fault Tracing Procedure

You will find helpful information about each step of basic fault tracing below:
1. Locating the cause of a malfunction
Information displayed on the operator’s panel and from the process can give some
indication as to where a fault is located.
Experience shows that approximately 85 percent of all faults occur in the process itself,
10 percent in the application program, and 5 percent in the control system hardware.
It is always advisable to follow this procedure to locate the cause of a malfunction to
minimize downtime.
2. External influences
In an electronic system which has been operating satisfactorily, most malfunctions have
external causes. Therefore, it is important when you trace a fault, to determine if any
external factor such as incorrect handling of equipment, welding work, lightning and/or
power failure has caused the malfunction.
3. Safety when starting up and shutting down
The AC 70 can only perform its control functions when in normal operation.
Voltage failure, a component fault or restarting manually usually affect the operation of the
control system. Control system failure affects the process in different ways of varying
gravity:
– In a control system with a monitoring character, changes of process status are not
registered, but there is no immediate danger to the process.
– Control of continuous processes demands a high degree of availability from the
control system. Restarting the AC70 in such situations can have very serious
consequences.
Therefore, it is important to be aware of the local conditions and safety requirements when
you start and stop the AC 70.
4. Checking the power supply
The AC 70 power is supplied with 5 V DC internally and 24 V DC externally from an
external power source.
3BUR 000 874R0201 5-7

Illumination of the LEDs marked P on the PM810 indicates the presence of station
voltage. The station voltage can be measured on the terminals L+ and L-.
The station voltage must be in the range 19.2 - 28.8 V DC. If it is too low, the modules
probably will not function correctly.
5. Checking the PM810 module.
Check the following signals on the PM810:
– The green LED R indicates that the PM810 is operational.
– If the red LED F is illuminated, this indicates a severe fault.
– The green LED B indicates that the inserted battery is sufficient to back up the RAM
and the real-time clock. Should this LED go out, the battery must be replaced.
– The green LED P indicates the presence of the internal 5 V DC and the incoming
24 V DC.
6. Checking the process I/O
Please check the S800 I/O User’s Guide for information on checking the process I/O.
7. Checking the installation
Open-circuits, short-circuits, and loose connections can occur. Therefore, check as
necessary:
– External fuses
– Station and PCB connectors
– Wiring, screwed terminals
– Mechanical installation.
8. Replacement of defective modules
All modules can be replaced during operation while the voltage supply is switched on.
The diagnosis software reconfigures the new module.
Do the following when replacing modules:
– Follow the requirements of Section 5.3.4.1, Module Replacement.
– Check that the new module is of the correct type.
– Transfer any labels indicating the position, etc., from the original, to the new module.
– Note any symptoms observed and other useful information, and attach this
information to the module returned for repair.
9. Restart the control system
After replacement of the defective modules, restart the control system.
10. System restart
If no diagnostic information is available, attempt to restart the system. To restart the
system, press the reset push button, which results in a cold start.
11. Fault tracing by interpretation of fault symptoms
5-8 3BUR 000 874R0201

Section 5.3.3 Advanced Fault Tracing
Refer to Section 5.3.3, Advanced Fault Tracing.

If the diagnostic information presented is insufficient, contact a suitable service workshop
to assist you in interpreting the symptoms, or attempt to obtain more details with the aid of
the usual service equipment.
12. Checking process functions
– Compare with the original performance to check that the correct action has been
taken.
– Check that the original operating parameters, etc., have not been changed by the fault
tracing action.
– Utilize any checklist which may be available on site.
13. Log symptoms and corrective action or repairs in a fault report
Information regarding previous malfunctioning can be of great assistance for subsequent
maintenance of the equipment. Keep a record of all faults and corrective action taken.
5.3.3 Advanced Fault Tracing

Advanced fault tracing is the detection of errors in application and system software when the
system does not operate at all. Advanced fault tracing is accomplished with the help of:
• LEDs on the modules
• Error reports using the Advant Station 100 Series ES
• Fault tracing by interpretation of fault symptoms.
The Advant Station 100 Series ES should be available in addition to the equipment necessary
for basic fault tracing.
5.3.3.1 Faults That Stop the System

Faults which completely stop the system can be caused by a defective PM810.
In the case of a severe fault, which stops the PM810, an error code is indicated by the LEDs on
the front panel. Should the LED FAULT light, the CPU itself is most probably defective.
Fatal errors are stored in the PM810 and can be read by the Advant Station 100 Series ES using
the error report function (see Section 5.3.3.2, Faults Shown by the Error Report).
After the occurrence of a fatal error, the Error Report is readable if the PM810 is restarted in
STOP MODE. To restart the PM810 in STOP MODE, you must press the INIT button until P3
is displayed.
3BUR 000 874R0201 5-9

The following table defines all error codes, their names and their significance. It also gives hints
on what action you should take.
Table 5-2. Error Codes on PM810 Display
Error
code Significance Corrective Action
(Hex.)
05 Bus error - memory Restart CPU and run application again. If error occurs again,
The processor tried to access a replace the CPU module PM810.
nonexistent memory location. This
indicates a serious system software
error or defective hardware.
09 Stall alarm Restart the system in STOP MODE.
This is a software problem and indicates Extend the cycle times of execution units in the PC program or
that the CPU is not working correctly. It remove one or more execution units, e.g., control modules,
is probably caused by a CPU overload. and load and deblock the application again.
0A Memory test error Replace the CPU module PM810.
The error code appears during the RAM
test, which is performed during system
initialization.
0C Instruction set fault Replace the CPU module PM810
0D Interval timer test failed Replace the CPU module PM810.
0F Bus error test failed Replace the CPU module PM810.
This is a hardware problem and
indicates a CPU internal bus error.
22 START MODE selector in the STOP Restart the system with START MODE selector in either the
position CLEAR or AUTO position.
The START MODE selector on the
PM810 DB element was in STOP
position when the system attempted to
restart.
27 Insufficient memory Restart the system in STOP MODE. Then remove all loaded
The CPU could not start the application but unused options which may consume memory by loading
due to lack of memory. BASE software. Enable only necessary options and restart the
system by pressing the INIT push button with the START
MODE selector in CLEAR position.
42 Overload Restart the system in STOP MODE. Then reduce the load by
The CPU was not able to run the extending the cycle times, for example, of control modules in
specified control module. The control the PC program or remove one or more execution units, e.g.,
module could not be completed within control modules. Load and deblock the application again.
the specified cycle time and was
aborted.
5-10 3BUR 000 874R0201

Table 5-2. Error Codes on PM810 Display (Continued)
Error
(Hex.)
43 User PROM error Restart the system in STOP MODE. Then reload the
This indicates that the memory used for application program and try to save it again in PROM.
storing the application program could Replace the CPU module PM810.
be defective.
44 System PROM error Reload the system software and try again.
This indicates that the memory used for Replace the CPU module PM810.
storing the system software could be
defective.
45 Stall timer defect Replace the CPU module PM810.
This is a hardware problem.
46 UART defect Replace the CPU module PM810.
This is a hardware problem.
47 RAM check failed Restart the system by pressing the INIT push button with the
This is a memory problem and indicates START MODE selector in either the CLEAR or AUTO position.
inconsistencies of the data stored in the Replace the CPU module PM810.
RAM.
49 Internal error Restart the system by pressing the INIT push button with the
Indicates an unexpected state, usually START MODE selector in either the CLEAR or AUTO position.
due to a system error. Reload the application program and try again.
Replace the CPU module PM810.
4A Power failure Check the power supply for AC 70.
Indicates that the AC 70 was switched
off or that there was a power failure.
4C Address error Restart the system by pressing the INIT push button with the
This is a software problem and indicates START MODE selector in either the CLEAR or AUTO position.
that the CPU is not working correctly. Reload the system software.
4D Processor generated exception Restart the system by pressing the INIT push button with the
This is a software problem and indicates START MODE selector in either the CLEAR or AUTO position.
that the CPU is not working correctly. Reload the system software.
4F Battery buffered memory error Replace the battery and set the time and date using
This indicates that the contents of the Advant Station 120ES.
battery buffered RAM and real-time
clock have been lost. This may happen
if the battery was run down or not
installed during a power failure.
3BUR 000 874R0201 5-11

Table 5-2. Error Codes on PM810 Display (Continued)
Error
(Hex.)
51 Not available function block Restart the system in STOP MODE.
Indicates that a function block (i.e., PC Load the correct system software and options or reduce the
element or DB element) has been called application program to match current system software.
which the current system software does Load and deblock application again.
not recognize.
55 BOOT PROM error Replace the CPU module PM810.
This is a hardware error.
5D Application in PROM generated for Restart the system in STOP MODE. Then generate new target
another system software release. code with a matching release of the AS 120 ES, download to
This may occur after loading of a new PM810 and save it in PROM.
system software.
63 Missing option Restart the system in STOP MODE. Then install the missing
Indicates that the application in PROM option and restart the system with the START MODE selector
needs an option that is not part of the in either the CLEAR or AUTO position.
system software (probably due to
download of new BASE system
software).
5.3.3.2 Faults Shown by the Error Report

You can obtain an error report from the system using the Advant Station 100 Series ES. The
error report indicates whether the system’s diagnostic function has detected any fault or
abnormal condition.
Apart from messages of non-fatal errors, such as I/O module errors, the error report also
includes messages for errors which lead to a system stop.
For tracing module or system errors, you can delete older error entries when leaving the error
report. Errors that are permanently present in the system are inserted again with an updated time
stamp.
Error reports generated by the AC 70 have the following format (see also the following figure).
• Error text: Name and significance of the error without the codes.
• State: ‘A’ indicates that the module is still active, ‘P’ indicates that the
module is in the passive state.
• Date and time: Date and time the error first occurred.
• Position: For I/O module errors, the position of the related module is split in “bus,”
“substation,” and “position”:
bus
Always zero, since the error report is performed locally on CPU.
5-12 3BUR 000 874R0201

station
Always zero, since the I/O modules are only used locally by the PM810.
position
Describes the position number on which the faulty module is placed.
One error entry is reserved in the report per position, i.e., the first error detected on
this position is reported.
Error Report
position state date time error text
0, 0, 1 A 94. 3.22 6:23:22 No battery plugged

0, 0, 8 A 94. 3.23 8:35:17 System error detected
0, 0, 9 A 94. 3.23 12:45:33 Module error detected
0, 5, 1 P 94. 3.22 9:55:35 Process error detected
0, 0, 4 P 94. 3.23 21:15:45 Activate module failed
Figure 5-4. Example of an Error Report by Advant Station 100 Series ES
A list of possible error texts and actions to take to correct those faults is shown in the Table 5-3
below. Errors that lead to a system stop have references to corresponding error codes on the
display of PM810. For information about those errors, see Table 5-2.
Table 5-3. Error Texts in Error Report
Error Text Corrective Action

AC 70 restart Check other error messages which may have
The CPU performed a restart due to another occurred a short time before.
error.
Activate channel failed Check process connections to all module
It was not possible to activate an I/O channel channels and validate configuration data.
during configuration or diagnosis. Exchange I/O module.
Activate module failed Check process connections and power supply for
It was not possible to activate the I/O module itself specified I/O module.
(green RUN LED is probably off). Exchange I/O module.
Add-on installation error Reduce the amount of installed Add-on options.
An Add-on option could not be installed during
start up of CPU due to its system requirements.
Address error See error code 4C in Table 5-2.
3BUR 000 874R0201 5-13

Table 5-3. Error Texts in Error Report (Continued)

AF 100 internal error ## Check configuration of AF 100 and
A non-expected communication error occurred on communication interfaces connected to the bus.
AF 100. Report this error to support line.
Battery buffered memory error See error code 4F in Table 5-2.
Battery supervision Check voltage of the installed back-up battery
Voltage of the installed battery is too low. and exchange it.
If no battery is needed, suppression of this error
message is possible by setting the attribute
SUP_BAT on PM810 DB element to zero.
Boot PROM error See error code 55 in Table 5-2.
Bus error - memory See error code 05 in Table 5-2.
Bus error test failed See error code 0F in Table 5-2.
Configuration of module failed Check the specified I/O.
An error occurred during configuration of Check configuration data in DB part.
specified I/O module. Exchange I/O module.
Event handler error Check the configuration of all EVS(T) and
An Event Set EVS(R) or EVS(T) located on EVS(R) in the network.
another station in the network requested events
from a local Event Set.
Event queue overflow Check why events are generated faster than they
The event queue of an Event Set EVS(S) or are transferred to the event receiver. An
EVS(T) has overflowed. extended event queue (terminal
QUEUE=EXTENDED) may help.
Event receiver error This error may occur after changes in the Event
An Event Set EVS(S) or EVS(T) has received Set configuration. In that case, ignore this
events from an event source which is not message, otherwise report to support line.
referenced by this Event Set.
Finish of configuration failed Load application again.
It was not possible to write configuration data to Exchange the specified I/O module.
the specified I/O module or to save them therein.
Illegal station address Select the same station address in the Advant
A difference between station address on station Station 100 Series ES.
address selector at PM810 and that in
configuration data was detected.
The station address has been changed during
operation.
Instruction set fault See error code 0C in Table 5-2.
Internal error See error code 49 in Table 5-2.
Interval timer test failed See error code 0D in Table 5-2.
5-14 3BUR 000 874R0201


I/O module error Check I/O module and configuration in DB part.
The diagnosis detected an error on specified I/O Get additional information with diagnosis tool.
module.
I/O module has wrong type Use the same type in station and in DB
There is a difference in types between the I/O configuration.
module on specified position in the station and
that configured in DB part.
I/O module is passive Check process connections to all channels.
The diagnosis detected a passive I/O module. Exchange I/O module.
I/O module timeout Exchange module.
The module did not respond.
Memory test error See error code 0A in Table 5-2.
Module error detected Exchange I/O module.
The specified I/O module has a fatal device error.
No battery plugged Plug lithium backup battery or select zero for
Back up battery is missing although specified in attribute SUP_BAT at DB element for PM810 to
configuration data for PM810. suppress this error message.
Not available function block See error code 51 in Table 5-2.
Not enough memory on PM810 Avoid online changes on CPU.
The system software needs more memory than Reduce size of application.
available. See also error code 27 in Table 5-2.
OSP watchdog See error code 54 in Table 5-2.
Passivate channel failed Ignore this message if the I/O device has been
Internal error: it was not possible to passivate reported as a defective module previously and
unused channels. exchange that module if it is to be used further on.
Otherwise, report this error to support line.
Passivate module failed Ignore this message if the I/O device has been
Internal error: it was not possible to passivate the reported as a defective module previously and
I/O module. exchange that module if it is to be used further on.
Otherwise, report this error to support line.
Power failure See error code 4A in Table 5-2.
Process error detected Check process connections to each channel.
The diagnosis detected a process error on Validate configuration data for the I/O module
specified I/O module. and configured channels.
Exchange I/O module.
Processor generated exception See error code 4D in Table 5-2.
RAM check failed See error code 47 in Table 5-2.
3BUR 000 874R0201 5-15


Read module parameter failed Exchange the specified I/O module.
Internal error: Configuration data could not be
read from specified module.
Read object map failed Exchange the specified I/O module.
Internal error: It was not possible to read
information from the specified I/O module.
Read signal parameter failed Exchange the specified I/O module.
Internal error: It was not possible to access data
from specified I/O module.
Run time library error Remove the option (if not needed) by reloading
An option tried to call a not existing function of the BASE system software.
system software, probably this option needs a Load BASE system software which fits to the
newer system software. option and then load the option itself.
Stall alarm See error code 09 in Table 5-2.
Stall timer defect See error code 45 in Table 5-2.
Start mode switch - STOP position See error code 22 in Table 5-2.
Start of configuration failed Exchange the specified I/O module.
The I/O module did not respond when starting the
configuration.
System error detected Check process connections of I/O module and
The diagnosis detected a system error on I/O configuration data in DB part.
module. Read further diagnosis data with diagnosis tool.
System high load Reduce the load (see error code 42 in Table 5-2).
The load generated by the running application is
too high. Danger of overload.
System overload See error code 42 in Table 5-2.
System PROM error See error code 44 in Table 5-2.
UART defect See error code 46 in Table 5-2.
Unknown I/O module error ## Report this error to support line.
An unknown error was detected on I/O module.
User PROM error See error code 43 in Table 5-2.
V24 invalid status Check correct serial link to CPU regarding
The communication via RS232 was disturbed. influences to the cable.
Check hardware of the Advant Station 100 Series
ES.
Exchange CPU.
5-16 3BUR 000 874R0201


VFI: internal error Check AF 100 and all communication interfaces
An error occurred during communication via on AF 100 for proper operation.
AF 100. Report this error to support line.
Write module parameter failed Validate correct configuration data in DB part.
Configuration data could not be written to Check process connections to all channels of I/O
specified I/O module. module.
Load application again.
Write signal parameter failed Validate correct configuration data in DB part.
Configuration data could not be written to at least Check process connections to all channels of I/O
one channel of specified I/O module. module.
Load application again.
Write state control failed Load application again.
It was not possible to activate, passivate or to Exchange I/O module.
delete a channel of the specified I/O module.
Wrong application version See error code 5D in Table 5-2.
Zero divide Load new system software and options. Report
Division by zero - internal instruction error. this error to support line.
3BUR 000 874R0201 5-17

5.3.4 User Repair
5.3.4.1 Module Replacement
General
It is important to understand the consequences of a module exchange on-line and how it affects
the current situation. For example:
• Replacement of an I/O module affects all channels on the module. It also sometimes
indirectly affects the outputs via some application function, on another module.
• Replacement of a communication module type (PM810) affects all channels on all the
modules in the AC 70.
The system software in the Advant Controllers checks automatically that all I/O modules
function correctly. In the event of module fault, and module exchange, the module and
associated signals are marked as faulty. While the fault marking is present, the value is not
updated in the data base.
The system software checks that the module is inserted and correct. If this is the case, the fault
indicator (LED) extinguishes (after 10 seconds), the fault marking in the data base is reset and
the module resumes its normal function.
The following includes general instructions for the replacement of modules.
Practical Execution
Replace faulty or suspect modules and units in the following way:
1. Provide access to the module/unit by loosening the module locking.
2. Grip the module firmly and extract the module quickly and decisively.
3. Check that the new module can replace the old.
4. Insert the new module carefully. Push in the new module quickly and decisively.
5. Ensure that the module mates properly with the contacts in the MTU and activate the
locking mechanism in place.
6. Modules which can be replaced during operation are initialized automatically by the
system and the fault indicating LED extinguishes automatically.
5-18 3BUR 000 874R0201

Section 5.3.4 User Repair
PM810 Specific Instructions

The switches for the PM810 fieldbus address (Figure 5-5) must be set when replacing the
module.
F R
B P
T1 T2
S7 S3
S6 S2
S5 S1
S4 S0
INIT
SERVICE
STN. ADDR.
4 56
3 7 x 10
2 8
109 Station Address
5
4 6
3 7x1 Switches
PM810 2 8
109
AF 100
L+ L+ SA 1 2
L- L- SB
+ + Tx
- -
SH SH
SH SH Rx
Figure 5-5. PM810 Station Address Switches
The PM810 module can not be replaced with power applied. It also needs room to the left of an
MTU in order to be removed. In normal operation mode, before a PM810 is replaced, the supply
to the AC 70 is to be switched off. Power connections can be removed by pulling the header
terminals out of the unit. Power to external devices may need to be switched off. Fieldbus
connections can be removed by pulling the header terminals out of the unit.
I/O Specific Instructions

Please refer to the S800 I/O User’s Guide for specific replacement instructions of the I/O
modules.
3BUR 000 874R0201 5-19

5-20 3BUR 000 874R0201

Section A.1 Processor Module PM810
Appendix A General Specification
A.1 Processor Module PM810
F R
B P
T1 T2
S7 S3
S6 S2
S5 S1
S4 S0
INIT
SERVICE
STN. ADDR.
4 56
3 7 x 10
2 8
109
5
4 6
3 7x1
PM810 2 8
109
AF100
L+ L+ SA 1 2
L- L- SB
+ + Tx
- -
SH SH
SH SH Rx
Figure A-1. Processor Module PM810
3BUR 000 874R0201 A-1

A.1.1 Features
• Single 24V d.c. input power supply
• Provides +24V and +5V power supply to the I/O modules on the same electrical
Modulebus
• Two AF100 twisted-pair fieldbus ports which allows configuration with
redundant/nonredundant media
• The unit can be replaced without breaking the AF100 bus
• One opto-isolated service port (RS-232) for configuration/maintenance
• Electrical and optional fiber-optical interfaces for the Modulebus
• LED indicators for R(un), F(ault), B(at ok), P(ow ok), AF100 T1 traffic, AF100 T2 traffic
and eight software controlled indicators for system status
• Init push button
• Rotary switches for setting the AF100 station address
• MC68340 Microprocessor running at 16MHz in 8-bit mode
• 512 KByte user flash memory
• 512 KByte system flash memory
• 512 KByte battery backed up RAM
• Battery backed up Real-Time-Clock (RTC)
• RAM and RTC battery back up time of at least 270 days
A.1.2 Description
PM810 has three basic parts: Module termination board (TU801-1), power supply board
(PM810-1) and the processor board (PM810-2), see the block diagram in Figure A-3.
The power supply board’s main task is to generate an isolated short circuit proof +5V supply for
the PM810 and I/O modules. It also contains opto-isolated RS232 drivers/receivers for the
service port.
The Processor board contains the MC68340 CPU, RAM, Flash PROM, Modulebus interfaces,
BAP ASIC (AF100), real time clock, LED indicators, init push-button and two screwdriver
maneuvered rotary switches for the units AF100 station address.
The termination board is a unit where most of the connections to the outside takes place. It is
grounded to the DIN-rail through a metallic spring connector. The board carries screw terminals
for power supply and redundant power supply monitoring, screw terminals for AF100 twisted-
pair, connector for the service port and the electrical Modulebus, a replaceable fuse for the
+24V supply of the I/O modules and the electrical Modulebus and a back-up battery for
memory/RTC.
A-2 3BUR 000 874R0201

Section A.1.3 Technical Data
A.1.3 Technical Data
A.1.3.1 Supply Requirements

Supply voltage (L+, L-): +24 (19.2-30) V d.c.
Table A-1. Supply Requirements with No Load of I/O Modules
Current [mA]
Voltage d.c. [V]
Typical Maximum
19.2 130 170
24 107 140
30 100 130
A 3.6V Lithium battery is used for RAM backup.
A.1.3.2 Interfaces
Service Port
Max communication speed: 20 kbit/s
Signal levels: RS-232C signal levels
Insulation test voltage: 500 V a.c. to ground
AF100 Channel 1 & 2

All data below (if not otherwise noted) fulfills IEC 1158-2 fieldbus standard.
Number of fieldbus nodes: Max 32
Cable length: Max 750 m
fieldbus cable impedance: 100 - 150 ohm
Insulation test voltage: 2 kV a.c. to ground
Transmitter data:
Output voltage level, RLOAD= 50 - 75 ohm: Min 5.5V pk-to-pk
Max 9.0V pk-to-pk
Positive and negative amplitude difference: Max +/- 0.45V
3BUR 000 874R0201 A-3

Output signal distortion, i.e. overvoltage,

ringing and droop: Max 10% of pk-to-pk output voltage.
Transmitted bit-rate: 1.5 Mbit/s (1)
Rise and fall time (10% - 90%): Max 130 ns
Slew-rate (at any point from 10% to 90%
of pk-to-pk signal): Max 150 V/us (2)
Transmitted bit-cell jitter (zero-crossing
point deviation): Max 15 ns
Short circuit current: Max 200 mA
Receiver data:
Input impedance, 250kHz<f<1.25 MHz: Max 8 kohm (3)
Input impedance, f=1.5 MHz: Max 6 kohm (3)
Sensitivity, i.e. pk-to-pk signal
required to be accepted: Min 700 mV
Noise rejection, i.e. pk-to-pk noise
to be rejected: Max 400 mV
Notes:
(1) IEC 1158-2 fieldbus standard specifies 1.0 Mbit/s.
(2) IEC 1158-2 fieldbus standard specified 100 V/us. TC511 are intended for
1.5 Mbit/s bit-rate (instead of 1.0 Mbit/s as specified in IEC 1158-2), and
a higher slew-rate has to be accepted.
(3) IEC 1158-2 fieldbus standard specifies the input impedance in the frequency
range 250 kHz - 1.25 MHz. TC511 are intended for 1.5 Mbit/s bit-rate, and
a specification of input impedance at 1.5MHz has been added of this reason.
A-4 3BUR 000 874R0201

Section A.1.4 Connections
Electrical Modulebus
Max 24V supply current: 1.0 A
24V supply voltage variation: same as 24V supply of PM810
Fuse for 24V supply (F1): 1.6 A Fast
Max 5V supply current: 2 A (short circuit proof)
Max 5V supply voltage variation: +/- 5%
Power Supply Monitoring Inputs

Max input voltage: 30 V
Min input voltage for high level: 15 V
Max input voltage for low level: 8V
A.1.4 Connections
A.1.4.1 Connectors for Power Supply: X1A & X1B

Table A-2. X1B Power Supply Connector
PIN Designation Description

1 L+ +24V supply
2 L+ +24V supply
3 SA Redundant power supply monitoring input
Table A-3. X1A Power Supply Connector

1 L- 0V supply
2 L- 0V supply
3 SB Redundant power supply monitoring input
3BUR 000 874R0201 A-5

A.1.4.2 Connector for AF100 channel 1: X2

Table A-4. X2B AF100 Channel 1 Twisted-pair Fieldbus Connector

1 + + signal
2 - - signal
3 SH shield
4 SH shield
A.1.4.3 Connector for AF100 channel 2: X3

Table A-5. X2A AF100 Channel 2 Twisted-pair Fieldbus Connector

1 + + signal
2 - - signal
3 SH shield
4 SH shield
A.1.4.4 Connector for Service Port: X4

Table A-6. X4 Service Port Connector

1
2 TD Transmit Data channel B
3 RD Receive Data channel B
4
5 SG Signal Ground
6
7 RDA Receive Data channel A (for debugging only)
8 TDA Transmit Data channel A (for debugging only)
9
A-6 3BUR 000 874R0201

A.1.4.5 MODBUS Connection via TC801 and TK802

The TC801 with the cable TK802 is a passive unit used for connection of two serial channels
from the SERVICE port (X4) on the PM810 to the TK802 connector (X2) on the TC801. The
MODBUS connector (X1) and the SERVICE connector (X3) are available on the TC801.
TC801 is mounted on a standard DIN rail via a mechanical latch.
D-sub 9 connector split, TC801
MODBUS connector (X1)
Power PM810 I/O I/O I/O I/O

supply
TK802V001
(100 mm)
SERVICE port (X4)
SERVICE connector (X3)
Figure A-2. MODBUS Connection to TC801 and PM810
Table A-7. X1 Connector of TC801

1
2 TD Transmit Data on MODBUS channel
3 RD Receive Data on MODBUS channel
4
5 SG Signal Ground
6
7
8
3BUR 000 874R0201 A-7

2 TD Transmit Data on SERVICE channel
3 RD Receive Data on SERVICE channel
5 SG Signal Ground
Table A-8. X3 Connector of TC801
A.1.4.6 Connector for Electrical Modulebus: X9
pin/row a b c
1 0V POWOK POS0 (0V)
2 D+ 0V POS1 (+5V)
3 D- +5V POS2 (+5V)
4 +5V POS6 (+5V) POS3 (+5V)
5 CLK+ +5V POS4 (0V)
6 CLK- 0V POS5 (+5V)
7 0V +24V 0V24
Table A-9. Electrical Modulebus Pinning (C/4 Male Angled)
A-8 3BUR 000 874R0201

Block Diagram
X3
SH2 4
3
CH2- 2
CH2+ 1
GLUE
STN.
ADDR BAP
X2
SH1 4
INIT MC68340
3
DDCC+
CH1- 2
CH1+ 1
S7-S0 FLASH
RAM +VB
Reset logic,
T1
T2 Battery
B(at) RTC RS-485

+5V +5V
P(owok) RS-485 DIN-rail
R(un) X9
F(ault)
PM810-2 0V 0V POWOK
D+,D-
CLK+,CLK-
POS(9:0)
+5V
Electrical Modulebus
+5V Connector
PM810-1 +5V +5V 0V
0V24
0V +24V
0V 0V
X4
0V
Service Port
Connector
BATOK
+5V
X1A
0V SB 3
IRQ7-N
2
L- 1
DC DC
DC DC F1
X1B
SA 3
2
L+ 1
TU801-1
Figure A-3. Processor Module PM810 Block Diagram
3BUR 000 874R0201 A-9

A-10 3BUR 000 874R0201

Index
INDEX
A DSP 3-6
ABB MasterPiece Language 1-23
Advant Station 120 ES 2-7 E
AI810 1-5 Error Codes 5-10
AI810 Analog Input Module 1-20 Error Display 5-4
AI820 1-5 Error Report 5-12
AI830 1-5 Estimate of Memory Demand 3-17
AI830 Analog Input, RTD Module 1-20 Extended MTU 1-10
AI835 1-5
AI835 Analog Input, Thermocouple/mV Module 1-21 F
AMPL 1-23 Fatal Error 4-5
AO810 1-5 FAULT 5-3
AO810 Analog Output Module 1-21 Fault Classification 5-6
AO820 1-5 Fault Detection 5-6
Auto 4-5 Fault Tracing Principles 5-6
Functional Test 2-6
B
BATTERY 5-3 G
Battery Supervision 4-4 General Specifications A-1
Block Diagram A-9
I
C I/O Modules 1-19
Cable adaptor 1-5 I/O Specific Instructions 5-19
CI810 1-5
Clear 4-5 L
Communication 3-6 LED Indicators 4-8
with local MMI 3-9 Local Operator 3-9
CPU Load
of DataSet Communication 3-24
M
of Event Detection 3-25
Memory Demand in AC 70 3-11
of Executable Units 3-18
Modbus 3-8
Total 3-27
MODBUS connection A-7
MODBUS I 3-8
D MODBUS I protocol 3-10
Data Set Peripherals 3-6 Module Termination Units 1-10
DataSet Peripheral 3-8 ModuleBus Extension 1-6
DI810 1-5 ModuleBus Optical Port 1-17
DI810 Digital Input Module 1-19 Mounting 1-15
DI820 1-5
DI820 Digital Input Module 1-19 to 1-20
O
DI821 1-5
Operator’s Interface 3-9
DO810 1-5
OPT1 1-24
DO810 Digital Output Module 1-19
OPT3 1-24 to 1-25
DO820 1-5
Optical ModuleBus Expansion 1-17
DO820 Digital Output Module 1-20
OSP 1-20
Downloading 2-8
3BUR 000 874R0201 i

Index
P Testing Output Signals 2-4

PC Elements 1-23 Time Synchronization 4-4
Performance Time Synchronization Slave 4-6
of AC 70 3-18 Time Tagged Events 4-2
PM810 Specific Instructions 5-19 TK801V003 1-6
POWER 5-3 TK801V006 1-6
Power and Cooling 3-29 TK801V012 1-6
Power Supply 1-22 TK811V015 1-6
Load Calculation 3-5 TK811V050 1-6
Procedure TK811V150 1-6
Power Up 2-7 TU810 1-6
TU810 Compact MTU 1-10 to 1-11
R TU811 1-6
RE810 1-6 TU811 Compact MTU 1-10, 1-12
Redundant AF 100 Line Supervision 4-4 TU830 1-6
Redundant Power Supply Supervision 4-4 TU830 Extended MTU 1-10, 1-12
Reset Button 4-8 TU831 1-6
RS232 Port 4-8 TU831 Extended MTU 1-10, 1-13
RUN 5-3 TU835 1-6, 1-10
TU835 Extended MTU 1-14
TU836 1-6, 1-10
S
TU836 Extended MTU 1-14
SD811 1-6
SD811 Power Supply 1-22
SD812 1-6
SD812 Power Supply 1-22
serial interface 3-8
Specifications A-1
Start Mode 4-4
Station Address Switches 4-8
Status Display 5-3
Stop 4-5
System Software 1-23
T
T1 5-3
T2 5-3
TB805 1-5
TB806 1-5
TB807 1-5
TB810 1-5, 1-17
TB811 1-5
TB820 1-5
TC501V150 1-5
TC505 1-5
TC513 1-5
TC514 1-6
TC515 1-6
Terminator 1-5
Testing Input Signals 2-3
ii 3BUR 000 874R0201

3BUR 000 874R0201
September 1997

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Advant® OCS Advant Controller 70

with Master software

Copyright © 1997 Industrial Systems AB. All rights reserved.

3BUR 000 874R0201

3BUR 000 874R0201 i

Chapter 3 - Configuration/Application Building

ii 3BUR 000 874R0201

Chapter 4 - Runtime Operation

3BUR 000 874R0201 iii

Appendix A - General Specification

iv 3BUR 000 874R0201

3BUR 000 874R0201 v

vi 3BUR 000 874R0201

1.1 General Information

1.2 Equipment Requirements

3BUR 000 874R0201 1-1

1.3 Manual Organization

General Site Planning Design Product Preventive Appendix A

1-2 3BUR 000 874R0201

Configuration Application Building

1.4 Related Documentation

Table 1-1. AC 70 Related Documentation

3BUR 000 874R0201 1-3

Table 1-1. AC 70 Related Documentation (Continued)

1.5 Release History

1-4 3BUR 000 874R0201

1.6 AC 70 Station Product Overview

Table 1-2. I/O Station with S800 I/O Components

3BUR 000 874R0201 1-5

Table 1-2. I/O Station with S800 I/O Components (Continued)

1-6 3BUR 000 874R0201

Advant Controller 400

Figure 1-1. AC 70 Overview

Figure 1-2. AC 70 Stations Connected Via the Fieldbus Network

3BUR 000 874R0201 1-7

1-8 3BUR 000 874R0201

1.6.1 Processor Module 810

Figure 1-3. PM810 Front Panel

3BUR 000 874R0201 1-9

1.6.1.1 Electromagnetic Compatibility and CE-marking

1.6.2 Module Termination Units

1-10 3BUR 000 874R0201

1.6.2.1 TU810 Compact MTU for 50 Volt Applications

3BUR 000 874R0201 1-11

Figure 1-4. Compact MTU with I/O Module, Dimensions in mm(in.)

1.6.2.2 TU811 Compact MTU for 250 Volt Applications

1.6.2.3 TU830 Extended MTU for 50 Volt Applications

1-12 3BUR 000 874R0201

The TU830 is used with the following S800 I/O modules:

Figure 1-5. Extended MTU with I/O Module, Dimensions in mm(in.)

1.6.2.4 TU831 Extended MTU for 250 Volt Applications

3BUR 000 874R0201 1-13

1-14 3BUR 000 874R0201

3BUR 000 874R0201 1-15

1-16 3BUR 000 874R0201

Optical ModuleBus Expansion

Figure 1-9. Location of TB810 ModuleBus Optical Port in PM810

3BUR 000 874R0201 1-17

ModuleBus Optical Port TB810