To estimate overall controller power dissipation it is necessary to include the field power component dissipated within the controller. Referto the table “Field Loop Power Heat Dissipation”. The field power requirements should be calculated separately and is dependent on the number and type of field elements. Refer to the specifications for the Digital and Analogue output modules for details of the channel output electrical specifications.

System Design Considerations for Heat Dissipation and Cooling

The controlleris designed to operate in its specified environment without forced air cooling. However, forced air cooling may be needed in individual circumstances when the controller shares its enclosure with other heat producing equipment and the internal temperature could exceed the recommended operating temperature range.

Module Orientation

Rockwell only recommend that modules are oriented vertically, if modules are mounted in any other orientation, then specific temperature tests must be done to achieve reliable and predictable operation.

Maximum Air Temperature

The maximum air temperature rating in an enclosure where AADvance modules are installed to support predictable operation is 70 °C (158 ° F).

Estimate Heat Dissipation

The heat in the enclosure is generated from several sources such as the power supplies, the AADvance modules and some of the field loop power. Use the following calculation and the data given in the tables to estimate the overall heat dissipation:

• Power supply consumption (Watts x (100-efficiency) (%) + the sum of the system power consumed by the modules + part of the field power that is in the enclosure.

The following module power dissipation values are worst case values over the range of operating voltages and currents.

Estimating Center of Gravity Information

If it is necessary to calculate the location of the center of gravity of an AADvance controller destined for a maritime or other shock-mounted application, it is reasonable to assume the center of gravity of each assembly of modules and their base unit is at the geometric center of the assembly

Design Considerations for Electrical Grounding

All applications of the controller will require at least two separate ground (earth) systems:

• An AC safety ground (sometimes called the ‘dirty ground’) to protect people in the event of a fault. The ground stud on the T9100 processor base unit, and all exposed metalwork such as DIN rails, will be bonded to the AC safety ground.

• An instrument ground (sometimes called the ‘clean ground’ or the ‘0 Vdc ground’) to provide a good stable 0 V reference for the system. Every signal return will be referenced to the instrument ground. The instrument ground will be isolated from the AC safety ground.

The AC safety ground and the instrument ground will usually be made available through bus-bars. Bus-bars must be of copper; they may be nickel plated. For a small application, you may use ground studs instead of bus-bars.

Some field wiring, such as communications cables, will need shielded (screened) cable. There may be a shield ground, in addition to the AC safety and instrument grounds, to provide a common point to terminate shields of such cables. The shield ground will usually be connected to the AC safety ground; or, more rarely, to the instrument ground. In practice, the continuity of the shield connections will be more important than the goodness of the ground connection provided.

The controller input and output modules incorporate galvanic isolation. Nevertheless, it is possible that a particular application will require the provision of barrier strips with galvanic isolation, for example to provide consistency with an existing installation. In these cases, there may be a separate intrinsic safety ground as well.

Specify software requirements

For information about supported operating systems and other software product version support, refer to product release notes from the Product Compatibility and Download Center (PCDC): rok.auto/pcdc.

Design Considerations for Maintenance Activities

Maintenance Activities

The design of the installation must allow preventive and corrective maintenance activities to take place. Corrective maintenance tasks will embrace the identification and renewal of defective modules and other assemblies and, when exhausted, renewal of the back-up battery within the T9110 processor module.

Fuses on the termination assemblies can be replaced so access to the fuses is required. There are no user-serviceable parts inside modules therefore repair is by replacement; defective modules should be returned to Rockwell Automation forinvestigation and repair.

Design Provisions

The design of the controller installation should make the following provisions:

• Clear access to remove and install modules, termination assemblies, base units and security dongle (Program Enable key). Repair of controller modules will be by module replacement.

In addition, it may be appropriate to make the following provisions:

• A lock on the door of the enclosure, to deter unauthorized access and possible unofficial modifications.

• Lighting.

• Utility sockets.

Connecting the AADvance Controller to the Network

The T9100 processor base unit has six auto-sensing 10/100BASE-TX Ethernet ports which allow it to connect to a local area network through standard Rj45 Ethernet cable. These are two ports for each processor module.

If a direct connection is required from the controller to the computer (for example, during setting up) use a crossover cable. This will depend on the characteristics of the network interface in the PC.

The fixed connectors on the controller are RJ45 sockets. Use Cat5e (enhanced) cables with RJ45 modular plugs forthe network cabling.

Connect the network cables to the sockets on the T9100 processor base unit.

• For each network connection, insert the RJ45 modular plug on the cable into the appropriate socket.

• Make sure the length of the cable does not exceed 100m (328 ft).

Referto the illustration for an example.

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