AADvance The Next Step in Automation AADvance Controller Troubleshooting and Maintenance Manual ISSUE: 09 DOCUMENT: 553634 (ICSTT-RM406F_EN_P)
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Notice In no event will Rockwell Automation be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment. The examples given in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation does not assume responsibility or reliability for actual use based on the examples and diagrams.
Troubleshooting and Maintenance Manual (AADvance Controller) Issue Record Issue Date Comments 01 Dec 2008 First Issue 02 Feb2009 Update with official product titles 03 Apr 2009 Change title and add calibration procedures 04 Nov 2010 Add fuse replacement 05 Mar 2011 Release 1.2 06 Aug 2011 Update Release 1.2 version for TUV review comments 07 Apr 2012 Update Release 1.2 to add Analogue Output Module information 08 June 2012 Update for Release 1.3 & 1.3.
Standard Warnings and Cautions WARNING ELECTRICAL ARCS AND EXPLOSION RISK IN HAZARDOUS AREAS If you connect or disconnect wiring, modules or communications cabling while power is applied, an electrical arc can occur. This could cause an explosion in hazardous location installations. Do not remove wiring, fuses, modules or communications cabling while circuit is energized unless area is known to be non hazardous. Failure to follow these instructions may result in personal injury.
Troubleshooting and Maintenance Manual (AADvance Controller) Who Should Use this Manual This manual is for plant maintenance personnel who need to trace and repair a fault in an AADvance system and perform routine maintenance tasks. You should be trained and experienced in the operation and maintenance of electronic equipment and in particular with safety systems.
Troubleshooting and Maintenance Manual (AADvance Controller) Contents Chapter 1 Introduction to Maintenance Activities ................................................ 1-1 Making Repairs Promptly ................................................................................................................................. 1-1 Resolving Multiple Faults ..................................................................................................................................
Correlation of LEDs with State Variable for a Digital Output ....................................................... 3-16 Correlation of LEDs with State Variable for an Analogue Output ................................................ 3-17 View Module Firmware Versions ................................................................................................................. 3-17 Chapter 4 Troubleshooting and Rectifying Module Faults ....................................
Troubleshooting and Maintenance Manual (AADvance Controller) Chapter 7 Parts List .................................................................................................. 7-1 Chapter 8 Glossary of Terms ................................................................................... 8-1 Chapter 9 Additional Resources .............................................................................. 9-1 Regional Offices...........................................................................
Chapter 1 Introduction to Maintenance Activities Corrective maintenance activities for the AADvance controller embrace troubleshooting activities and the subsequent remedial work to rectify the problem and return the controller to normal operation. In addition, some preventive testing and maintenance should be done to make sure the system is available and healthy. In This Chapter Making Repairs Promptly ..................................................................................
Troubleshooting and Maintenance Manual (AADvance Controller) Required Tools Standard AADvance The installation and maintenance of the AADvance controller requires the following tools: Standard Tools Screwdriver, flat 0.8 x 9.0mm (1/25 c 3/8 inch), for the module clamp screws and blanking covers Screwdriver, cross head number 0, for battery cover on T9110 processor module screwdriver, flat 0.8 x 4.0mm (1/25 x 5/32 inch), for locking screws on extension cables Torque screwdriver, flat 0.6 x 3.
Return a Module If you need to return a module for any reason you should in the first instance contact your regional office (see list of regional offices at the back of this publication) to obtain an a Return Material Authorization (RMA) number. If for some reason no one is available in your regional office you may obtain an RMA number using the following procedure: 1) Create an empty email and set the title to 'RMA request' (without the quote marks). 2) Send the email to returns@icstriplex.com.
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Chapter 2 Preventive Maintenance Safety systems are designed to run continuously without manual intervention. However, some preventive maintenance should be done to make sure the system is available and healthy. This chapter describes the preventive maintenance activities for an AADvance controller. WARNING ELECTRICAL ARCS AND EXPLOSION RISK IN HAZARDOUS AREAS If you connect or disconnect wiring, modules or communications cabling while power is applied, an electrical arc can occur.
Troubleshooting and Maintenance Manual (AADvance Controller) Preventive Maintenance Schedule Table 1: Recommended Schedule for Preventive Maintenance Preventive Maintenance Task Interval Review status LEDs Daily Check fuses 3 months Check wiring terminals 3 months Check seating of plug-in components 3 months Check for contamination, general condition and adequate environmental protection 3 months Check ground connection 3 months Check analogue input module calibration 2 years Check digital
1) Open the fuse cover on each termination assembly to inspect the fuses. 2) Look for signs of overheated, damaged or incorrectly seated fuses. Check Wiring Terminals To check the wiring terminals do the following: Inspect the field, power and network wiring and look for any evidence of physical stress such as chafing. Tighten terminal screws to avoid open circuits causing trips. Note: For controller power and field wiring terminals, apply a minimum tightening torque of 0.5 Nm (0.
Troubleshooting and Maintenance Manual (AADvance Controller) Check Ground Connection To check the controller ground connection, do the following: Measure the resistance of the connection to the ground stud on the 9100 processor base unit. It should be less than 0.2. Check Analogue Input Module Calibration The AADvance controller detects possible calibration drift by continually checking its measured input values. The controller uses diverse hardware to compare two measurements.
If desired, you can include this calibration check in the proof test for the loop instead. To do this, insert a calibrated current meter in series with the field device in step 2; use the field device to drive the input. Check Digital Input Module Calibration The AADvance controller detects possible calibration drift by continually checking its measured input values. The controller uses diverse hardware to compare two measurements.
Troubleshooting and Maintenance Manual (AADvance Controller) Perform the Manual Test The manual test checks for hidden failures of components which the AADvance controller alarms cannot reveal. To perform the manual test do the following: Transition each digital input to its opposite state and then back to its current state. Subject each analogue input to its full range (minimum to maximum) and check accuracy. At the same time, check each output operates as expected.
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Chapter 3 About Troubleshooting Troubleshooting covers system faults, module and channel faults, termination assemblies and field fault. The corrective troubleshooting and maintenance regime is founded on a series of automatic diagnostic systems, fault warning through module status indicators (LEDs) or reported to the application through the Workbench and a principle of repair by replacement. All modules are replaceable.
Troubleshooting and Maintenance Manual (AADvance Controller) The controller was fully operational before the fault arose. A serviceable spare module is available. There is a working network connection between the computer workstation and the AADvance controlle.r Note: You must fit the Program Enable Key (supplied with the T9100 processor base unit) in order to download application software onto the controller.
The diagnostic systems use simple LED status indications to report a problem. The LED indications identify the module and can also identify the channel where the fault has occurred. There is also a summary system healthy indication for the whole controller. The application software uses its variable structures to report a problem; these variables proved status reports and are configured using the AADvance Workbench. A Fault Reset button on each processor module serves to clear a fault indication.
Troubleshooting and Maintenance Manual (AADvance Controller) Faults occurring in the I/O subsystem are latched. In order to clear them, you must remedy the source of the fault (usually by replacing a module) and then press the Fault Reset button on the processor module. During the reset operation, the application software continues to run at its normal scan rate. There is no change in system performance and no additional vulnerability to faults.
System fault, pertaining to the AADvance system Module fault, pertaining to a particular module Channel fault, pertaining to the circuits inside an I/O module or TA serving a particular channel Field fault, pertaining to the field loop wiring outside the I/O module and TA serving a particular channel A channel fault produces a module fault and similarly a module fault produces a system fault.
Troubleshooting and Maintenance Manual (AADvance Controller) A module fault (below) A fault the controller cannot isolate it to a single module. An example would be the absence of every I/O module in a termination assembly group. The System Healthy LED on each processor module will show red. Module Fault The controller indicates a module fault when it detects a fault and can isolate it to the hardware of a particular module.
Recovery Mode Indications When the processor enters the Recovery Mode the following indications are displayed on the processor front panel when the module contains an application: Recovery Mode No Fault Present Recovery Mode Fault Present Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: 3-7
Troubleshooting and Maintenance Manual (AADvance Controller) Fault Reporting Reference Information Each module has a set of front panel status indicators.
1. If Healthy is GREEN and all the other indicators are OFF then the module has failed to boot up 2. If Healthy is GREEN and the Ready and Run are RED then the module is said to be in its shutdown state ( See topic - Module Shutdown State and Possible Causes in the Troubleshooting Manual Chap 3).
Troubleshooting and Maintenance Manual (AADvance Controller) an operating controller has at least one variable being locked/forced Aux This LED is controlled by the application.
Status Indicators on the T94xx Series Input and Output Module Table 3: Indicator Status Indicators on the 94xx Series Input and Output Module Status Healthy Description Provides an indication of the general status of the module OFF No power GREEN No module faults present RED One or more module faults are present Note. 1. The Healthy indicator may turn RED immediately upon application of power to the module, before then turning GREEN 2.
Troubleshooting and Maintenance Manual (AADvance Controller) values), all channel indicators will be off GREEN Input module: Channel input is on Output module: Output is in its energised state AMBER Field fault RED Channel fault Module Shutdown State and Possible Causes Processor Module The processor module shutdown state is the Recovery Mode. If the application was running and it has been re-booted and the Fault Reset button pressed the module enters the Recovery Mode.
Check: the module PST value is it set to the correct value or has it been left at zero.
Troubleshooting and Maintenance Manual (AADvance Controller) When a fault exists on a channel, the module will report safe values for that channel and the Discrepancy status variable reports TRUE.
On power up or module insertion, a module de-energizes all channels and they remain de-energized until command states are received from a running application. Group Output Module Shutdown As long as one module in a group continues to receive updated command state values from a running application within the PST, each channel is driven according to its commanded state.
Troubleshooting and Maintenance Manual (AADvance Controller) Correlation of LEDs with State Variable for an Analogue Input Correlation of LEDs with State Variable for a Digital Output 3-16 Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089:
Correlation of LEDs with State Variable for an Analogue Output View Module Firmware Versions Using the AADvance Workbench you can view the module firmware information on screen and save this information with your project. Using an update function view the latest information and save it as an external text file. To do this proceed as follows: Note: To view the firmware version numbers of the modules you must be connected using Debug to a running controller. 1) Select the Equipment View tab.
Troubleshooting and Maintenance Manual (AADvance Controller) 4) Click the Update button.
The window now shows your controller's current firmware version information. The information displayed is as follows: MAC Addresses - MAC addresses for the controllers. There are two addresses per controller set by the BUSP chip inserted into the processor base unit; However, 6 MAC addresses are displayed regardless if the system is a Single, Dual or Triple processor system.
Troubleshooting and Maintenance Manual (AADvance Controller) 3) A window opens with a default text file name Version_Report.txt; Enter your own file name and click Save. The saved text file can be viewed in Notepad.
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Chapter 4 Troubleshooting and Rectifying Module Faults The AADvance controller indicates a system fault through the common fault alarm for the system. This chapter explains how to troubleshoot and rectify a system and module fault. WARNING ELECTRICAL ARCS AND EXPLOSION RISK IN HAZARDOUS AREAS If you connect or disconnect wiring, modules or communications cabling while power is applied, an electrical arc can occur. This could cause an explosion in hazardous location installations.
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Rectify a Critical Firmware/Hardware Failure When a single critical firmware failure occurs, such as a software watchdog failure, or self-test detects a hardware failure, the processor module will automatically reboot into the Recovery Mode.
Troubleshooting and Maintenance Manual (AADvance Controller) 2) Place the processor module on to the dowel pins on the processor base unit. Make sure the slot on the head of the module clamp screw is vertical and then push the module home until the connectors are fully mated. 3) The module locking screw requires a quarter turn clockwise to lock. Use a broad (9mm) flat blade screwdriver to lock the locking screw. Note: The locking screw acts as a power interlock device.
Note: The processor back up battery is supplied separately and must be installed into each new processor. To install a new battery, do the following: (Part No: T9905 Poly-carbonmonofluride Lithium Coin Battery, BR2032 (recommended type) , 20mm dia; Nominal voltage 3V; Nominal capacity (mAh) 190; Continuous standard load (mA) 0.03; Operating temperature -30°C to 80°C, supplied by Panasonic.
Troubleshooting and Maintenance Manual (AADvance Controller) as this will not only reset the processor clock but will also keep the time accurately during normal operation. Refer to the AADvance Configuration Guide, Chapter 4 for the SNTP set up instructions. Alternatively use the following procedures to set the processor clock using the Processor Variables.
Processor Module Start Up Process Note: When inserting more than one processor module they MUST be inserted one at a time and the module be allowed to educate (in the case of a 2nd and 3rd processor). Table 4: Single Processor Module Installation Procedure (New Processor Module) Step Task 1. Install the processor into a processor base unit slot. 2.
Troubleshooting and Maintenance Manual (AADvance Controller) Step Task Ready GREEN Run RED to GREEN (Flashes GREEN as the module educates) System Healthy GREEN Force GREEN Aux Off (Application Dependent) Serial 1 Dependent on data connection Serial 2 Dependent on data connection Ethernet 1 Dependent on data connection Ethernet 2 Dependent on data connection Table 5: Procedure for Installation of a 2nd and 3rd Processor Note: The second and third processor modules must be programmed wit
Step Task GREEN Force Will remain OFF as the Module boots up (10 to 20 seconds) then stays OFF until the module has educated and the application is running Aux Will remain OFF as the Module boots up (10 to 20 seconds) then is dependent upon data connection Serial 1 Will remain OFF as the Module boots up (10 to 20 seconds) then is dependent upon data connection Serial 2 Will remain OFF as the Module boots up (10 to 20 seconds) then is dependent upon data connection Ethernet 1 Will remain OFF as the
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You can do the following with an on-line update: Change application variables or the program. Add new I/O base units, termination assemblies and extra I/O modules. Delete modules from the system. Change the size of a termination assembly to change the size of the I/O module configuration. Move a module to a different slot.
Troubleshooting and Maintenance Manual (AADvance Controller) Important Note: Adding modules by an on-line update will increase the application cycle time by the amount of time required by the additonal modules and conversly deleting modules will reduce the application cycle time. Install I/O Modules Inspect the module: Before inserting a new I/O module, inspect it for damage. The identification labels on the sides of the I/O module will be hidden once the module is installed.
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Chapter 5 Troubleshooting and Rectifying Channel/Field Faults The AADvance controller indicates a channel fault that could be a faulty termination assembly or field fault by a Channel LED on an I/O module showing amber instead of the usual green. This chapter provides recommended approaches to troubleshoot and remedy channel/field faults. It should be read in conjunction with the operation and maintenance manual or equivalent documentation for the system.
Troubleshooting and Maintenance Manual (AADvance Controller) 1) Select the Equipment tab to use the Project Tree View to locate the channel you wish to investigate. 2) Identify the reference for the State variable. This will be of one of two forms: %IBnnn.0.7 for an input module %QBnnn.0.7 for an output module (illustrated) Note: From Release 1.2, live data is available in the view shown above. For earlier releases, use the Spy List as described below.
4) Double-click on the Name field. 5) Select the tagname for the state variable from the drop down list. The State variable is added to the Spy list. The value of the State variable ('2' in this example) will update in real time to reflect the state of the I/O channel. Note: If the Spy List is empty, double-click on the ellipsis (...) to create the entry.
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Diagnose an Analogue Input Channel Use this circuit diagram in conjunction with chart 'B'.
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Troubleshooting and Maintenance Manual (AADvance Controller) Diagnose a Digital Output Channel Use this circuit diagram in conjunction with chart 'C'.
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Troubleshooting and Maintenance Manual (AADvance Controller) Diagnose an Analogue Output Channel Use this circuit diagram in conjunction with chart 'D'.
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Troubleshooting and Maintenance Manual (AADvance Controller) Replacing Fuses The digital/analogue Input Termination Assemblies and digital output termination assemblies have fuses that can be easily accessed and replaced without removing the module or the termination assembly. Use the following procedures to replace the fuses. Digital Input Fuses T9901: No 396/TE5 50mA time lag fuse; UL 248-14, 125 V,T Leadfree; manufactured by Littlefuse.
3) Insert new fuse using long nosed pliers. 4) Close the fuse cover. Replacing Digital Output Fuses To replace a Digital Output Termination Assembly fuse follow this procedure: 1) Use a small screwdriver to open the fuse cover.
Troubleshooting and Maintenance Manual (AADvance Controller) 2) Remove the blown fuse with a pair of long nosed pliers. 3) Insert a new fuse using the same long nosed pliers. 4) Close the fuse cover. Install a New Termination Assembly To install a new termination assembly, do the following. Remove the I/O Module(s) Remove each I/O module that uses the termination assembly: 1) Locate the head of the clamp screw on the front of the module.
2) The module is aligned onto the controller by two steel dowel pins and is now retained by the friction of its backplane connectors. Grasp the module at the top and bottom and pull it away from the controller. Disconnect and Remove the Existing Termination Assembly 1) Record the identity and location of each wire at the terminal block. Then disconnect each wire.
Troubleshooting and Maintenance Manual (AADvance Controller) Chapter 6 Operation and Maintenance Plan The provision of an Operation and Maintenance Plan ensures that functional safety can be maintained beyond the commissioning of the system.
maximum interval between these tests shall be defined before installation. It is highly recommended the test interval be less than the Proof Test Interval used to calculate the PFD values. Field Device Maintenance The Operation and Maintenance Plan shall include field maintenance activities, such as re-calibration, testing and replacement of devices, which were specified by the system design requirements. In general, adequate provision for these measures will be defined by the client.
Troubleshooting and Maintenance Manual (AADvance Controller) Method of detecting product related defects and the reporting of these to the original designers Methods for detecting systematic failure that may affect other elements of the system or other systems, and links to the satisfactory resolution of the issues Procedures for tracking all reported anomalies, their work around and resultant corrective action where applicable Maintaining Functional Safety Design changes will inevitably occur dur
Scope definition Hazard and risk analysis System Functional and Safety Requirements System engineering Application programming System production System integration Installation and commissioning The definition of these procedures shall include the review and authorization process to be adopted for system changes. Baselines Baselines shall be declared, beyond which any change shall follow the formal change management procedure.
Troubleshooting and Maintenance Manual (AADvance Controller) The sequence in which the hazards are to be removed. Methods which permit the removal of interactions between safety functions whilst maintaining functional safety for the remaining potential hazards and without initiating safety responses. This shall include the interaction between systems. A definition of the modules and materials which are to be returned to Rockwell Automation for safe disposal following decommissioning.
Chapter 7 Parts List Bases Part No. Part Description T9100 Processor base unit T9300 I/O base unit (3 way) Modules Part No.
Troubleshooting and Maintenance Manual (AADvance Controller) T9831 Analogue input TA, 16 channel, simplex, commoned T9832 Analogue input TA, 16 channel, dual T9833 Analogue input TA, 16 channel, TMR T9851 Digital output TA, 24Vdc, 8 channel, simplex, commoned T9852 Digital output TA, 24Vdc, 8 channel, dual T9881 Analogue output TA, 8 channel, simplex commoned T9882 Analogue output TA, 8 channel, dual T9844 Frequency Input Module TA, Simplex, Active (not yet released) T9845 Frequency Input
Spares & Tools Part No. Part Description T9901 Replacement input fuse 50mA (pack of 20)* see notes (for T9801/2/3 and T9831/2/3) T9902 Replacement output fuse 10A (pack of 20) * see notes (for T9851/2) T9903 Replacement coding pegs (pack of 20) T9904 Replacement backplane clips (pack of 20) T9905 Replacement processor 3V lithium cell (pack of 20) *see notes T9906 Replacement program enable key T9907 Installation tool kit T9908 Fuse Extractor Tool Software Part No.
Troubleshooting and Maintenance Manual (AADvance Controller) Micellaneous Items Part No. Part Description T9020 Euro BUSP Kit Notes: T9901: No 396/TE5 50mA time lag fuse; UL 248-14, 125 V,T Leadfree; manufactured by Littlefuse. T9902: SMF Omni-Block, Surface Mount Fuse Block 154 010, with a 10A, 125V Fast Acting Fuse, Littlefuse. T9905: Poly-carbonmonofluride Lithium Coin Battery, BR3032, 20mm dia; Nominal voltage 3V; Nominal capacity (mAh) 190; Continuous standard load (mA) 0.
Glossary of Terms Glossary of Terms A asynchronous accuracy A data communications term describing a serial transmission protocol. A start signal is sent before each byte or character and a stop signal is sent after each byte or character. An example is ASCII over RS232-C. See also 'RS-232-C, RS-422, RS-485'. The degree of conformity of a measure to a standard or a true value. See also 'resolution'. achievable safe state A safe state that is achievable. Note: Sometimes, a safe state cannot be achieved.
Troubleshooting and Maintenance Manual (AADvance Controller) black channel BS EN 60204 A communication path whose layer (i.e. cabling, connections, media converters, routers/switches and associated firmware/software, etc.) has no requirement to maintain the integrity of safety critical data transferred over it.
Chapter 7 Glossary of Terms Compiler Verification Tool (CVT) creepage distance The Compiler Verification Tool (CVT) is an automatic software utility that validates the output of the application compilation process. This process, in conjunction with the validated execution code produced by the AADvance Workbench, ensures a high degree of confidence that there are no errors introduced by the Workbench or the compiler during the compilation of the application.
Troubleshooting and Maintenance Manual (AADvance Controller) EUC fault warning routing equipment Equipment Under Control. The machinery, apparatus or plant used for manufacturing, process, transportation, medical or other activities. Intermediate equipment which routes a fault warning signal from the control and indicating equipment to a fault warning receiving station.
Chapter 7 Glossary of Terms G I/O module group A collation of interfaces for field sensors (inputs) or final elements (outputs), arranged in a self-contained and standardized physical form factor. A collection of two or three input modules (or two output modules), arranged together to provide enhanced availability for their respective input or output channels. H hand-held equipment Equipment which is intended to be held in one hand while being operated with the other hand.
Troubleshooting and Maintenance Manual (AADvance Controller) integer M A variable type defined by the IEC 61131 standard. manual call point IXL IXL stands for ISaGRAF eXchange Layer.This is the communication protocol between ISaGRAF based components. K key connector The receptacle on the AADvance controller for the program enable key. A 9-way 'D' type socket, located on the 9100 processor base unit.
Chapter 7 Glossary of Terms O processor base unit on-line A backplane assembly which holds all of the processor modules in an AADvance controller. Part number 9100. See also 'processor module'. The state of a controller that is executing the application software. OPC A series of standards specifications which support open connectivity in industrial automation.
Troubleshooting and Maintenance Manual (AADvance Controller) redundancy safety-critical state The use of two or more devices, each carrying out the same function, to improve reliability or availability. A faulted state which prevents the execution of a process demand. resolution The smallest interval measurable by an instrument; the level of detail which may be represented. For example, 12 bits can distinguish between 4096 values.
Chapter 7 Glossary of Terms SNCP TCP SNCP (Safety Network Control Protocol) is the Safety Protocol that allows elements of an AADvance System to exchange data. SNCP is a SIL 3 certified protocol which provides a safety layer for the Ethernet network making it a "Black Channel". Transmission control protocol. One of the core protocols of the Internet Protocol suite. It provides reliable, ordered delivery of a stream of bytes from a program on one computer to another program on another computer.
Troubleshooting and Maintenance Manual (AADvance Controller) voting system A redundant system (m out of n) which requires at least m of the n channels to be in agreement before the system can take action. W withstand voltage The maximum voltage level that can be applied between circuits or components without causing a breakdown.
Chapter 9 Additional Resources For more information about the AADvance system refer to the associated Rockwell Automation technical manuals shown in this document map. Publication Purpose and Scope Safety Manual This technical manual defines how to safely apply AADvance controllers for a Safety Instrumented Function. It sets out standards (which are mandatory) and makes recommendations to ensure that installations meet their required safety integrity level.
Troubleshooting and Maintenance Manual (AADvance Controller) PFH avg and PFDavg Data This document contains the PFHavg and PFDavg Data for the AADvance Controller. It includes examples on how to calculate the final figures for different controller configurations. The data supports the recommendations in the AADvance Safety Manual Doc No: 553630. Regional Offices Rockwell Automation Oil and Gas Resources are available in Regional Offices worldwide.
