Summary of Contents for Rockwell Automation Allen-Bradley AADvance T9110
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AADvance Controller Catalog Numbers T9110, T9300, T9310, T9401/2, T9431/2, T9451, T9481/2 Original Instructions Troubleshooting and Maintenance Manual...
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If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired. In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.
This technical manual describes how to maintain, troubleshoot, and repair an AADvance® controller. 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.
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For the latest information about this product review the Product Notifications and Technical Notes issued by technical support. Product Notifications and product support are available at the Rockwell Automation Support Center at rok.auto/knowledgebase. At the Search Knowledgebase tab select the option "By Product" then scroll down and select the ICS Triplex®...
Digital Output tagname name Changed Added steps for AADvance Workbench software Examine the State Variable version 2.x and AADvance-Trusted SIS Workstation software. Added AADvance-Trusted SIS Workstation Software software AADvance license. Glossary Updated several entries. Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
ICSTT-RM406 Controller. Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1 Provides general guidelines for installing a Rockwell Automation industrial system. Product Certifications website, rok.auto/certifications. Provides declarations of conformity, certificates, and other certification details. Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
• Screwdriver, cross head number 0, for battery cover on 9110 processor module • Screwdriver, flat 0.8 mm x 4.0 mm (1/25 inch x 5/32 inch), for screws on extension cables Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
• Output range 4 mA to 20 mA with an accuracy better than 0.05 mA. 3. Bench power supply • Output range 0 V to 32 Vdc. Return a Module Before returning a module, contact your local Rockwell Automation technical support representative or send an email to returns@ra.rockwell.com to get a Return Material Authorization (RMA) number.
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Chapter 1 Introduction to Maintenance Activities Figure 1 - Flowchart Conventions Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
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Chapter 1 Introduction to Maintenance Activities Notes: Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
Measure digital output module calibration values 3 years Do a manual test Manual Test Interval NOTE All modules are returned to Rockwell Automation® for calibration. To return a module see Return a Module on page IMPORTANT Testing of the logic solver and its related field devices must be carried out according to the applicable plant or process safety analysis and the safety integrity validation.
• Module is in the shutdown state. Ready Flashing The module is being educated or synchronized. GREEN GREEN Module is educated and synchronized with partners. AMBER Module is in Recovery Mode. Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
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Quickly alternating Tx and Rx activity. No power and stays off while the module is booting up (10 to 20 seconds) Ethernet 1 and 2 GREEN Ethernet link present AMBER Tx or Rx activity on Ethernet Port Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
Module is inserted into a running system but not on-line. Push the Fault AMBER Reset button on any processor module to set the module to go on-line. Module is prepared to go on-line but no application is running. Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
Output module: output is in its energized condition. AMBER Field fault. Channel fault. Check Fuses 1. Open the fuse cover on each termination assembly and examine the fuses. 2. Look for signs of overheated, damaged, or incorrectly seated fuses. Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
3.95 mA to 4.05 mA. 4. Set the current simulation instrument to supply 12 mA, make sure that the input value is in the range 11.95 mA to 12.05 mA. Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
At the same time, make sure that each output operates as expected. Use the application software to force the outputs which do not seem to operate. • Carry out a manual examination to test each input and output. Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
Chapter Upgrading Controller Firmware Rockwell Automation issues firmware upgrades for processor modules from time to time. This chapter provides an overview of the firmware upgrade process and the instructions for using the ControlFLASH™ software. WARNING: Do not attempt to upgrade firmware on a running system.
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• Slot - the slot the module has been allocated • Module - the module identity • Serial - the module hardware serial number • Versions - The firmware versions in the module 5. Click Apply Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
5. Perform the step that corresponds to the selected driver type: • Ethernet devices Select OK, then for each device, enter the IP address (or Host Name if DNS is supported) under Host Name. Select Add New as necessary. Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
7. Close the RSLinx Classic Lite software. Use ControlFLASH to upgrade firmware Use ControlFLASH to simultaneously upgrade the firmware of up to three processor modules that are installed in the same processor base unit. Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
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Aux status indicator becomes amber. The Aux status indicator becomes amber to indicate that the module is loading Recovery Mode. When the module is ready, the Ready, Run, Force, and Aux status indicators become amber. Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
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Status dialog box prompts that the update is completed. The processor module operational firmware is updated. 11. View the module firmware version to verify that the upgrade is successful. For more information, see View Module Firmware Versions on page Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
There is also a summary system healthy indication for all of the controller. The application uses its variable structures to report a fault problem; these variables give status reports and are configured using the Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
As an example, a non-critical item might be monitored every three hours and reported after 24 hours like this. Figure 2 - Diagnostic Threshold Pushing the Fault Reset button resets every counter which has reached the fault threshold. Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
• Extract diagnostic data. (a) For AADvance Workbench software version 1.x. (b) For AADvance Workbench software version 2.1 and AADvance-Trusted SIS Workstation software. AADvance Workbench software version 2.0 does not support this feature. Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
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Reset button pushed the module enters Recovery Mode. Recovery Mode with Fault Present After a critical application failure the Healthy and System Healthy status indicators stay Green for a number of seconds then go Red. Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
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• Check: the application program to see if the I/O module is installed in the equipment and if so if it is installed into the correct I/O Bus and Slot. Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
A channel fault produces a module fault indication and a system fault indication, similarly a module fault will also produce a system fault. The relationships between the classes of faults and the status indicators are shown in the illustration. Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
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Channel Fault The controller indicates a channel fault when it detects a fault and can isolate it to a fault on a channel of an I/O module. The controller always reports a Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
Discrepancy as TRUE and the module reports 'safe' values back to the application for the faulty channel. Degraded Channel Reporting Values When a fault exists on a channel, the module will report safe values for that channel and the Discrepancy status variable reports TRUE. Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
As long as one module in a group continues to receive updated command state values from a running application in the PST, each channel is driven according to its commanded state. This covers the situation when only one module out of Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
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This makes sure that these channels do not get stuck energized, and that the remaining module can energize or de-energize these channels according to the commanded state received from a running application. Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
Failure to follow these instructions can cause injury. Troubleshooting Module Use this flow chart to start a new fault investigation. Faults Figure 4 - Fault Finding Process - System Level Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
If you are installing more than one processor module make sure they all have the same firmware build. Installation 1. Examine the coding pegs on the 9100 processor base unit and make sure they fit the sockets on the rear of the processor module: Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
With the power switched on place the processor module into slot A on the Base Unit connectors and push the module home until the connectors are fully mated. Turn the locking screw and lock the module in position. Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
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If the firmware revision is different upgrade the firmware using the ControlFLASH™. IMPORTANT When inserting a second and third processor module they MUST be inserted one at a time and allowed to educate before inserting the next one. Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
The battery condition is monitored by the module diagnostics every 24 hours. If the battery voltage is low or the battery is missing, a variable and the Battery processor module Healthy status indicator goes red indicating a faulty battery, which needs replacing. Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
NOTE For a new processor the backup battery is supplied separately and must be installed into each new processor module. Replace a Faulty Processor Back-up Battery Use the following official Rockwell Automation battery or one of an equivalent specification. Part No and Description T9905: Polycarbon monofluoride Lithium Coin Battery, BR2032 (recommended type), 20 mm dia;...
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Procedure To replace a faulty battery, do the following: 1. Use a small cross head screwdriver to release and remove the battery cover. 2. Remove the battery by pulling on the blue ribbon. Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
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Processor diagnostic log entries. The specific functions that the battery maintains on complete loss of power are the following: • Real Time Clock – The battery provides power to the RTC chip itself. Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
The following procedure assists in setting the clock: Set up the following variables in the Dictionary RTC Control Variables (all BOOLEAN Outputs) • RTC Control: RTC_Read • RTC Control: RTC_Write • RTC Control: Year Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
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4. Lock and force the RTC Read variable to TRUE. 5. The RTC Status now displays the new date and time of the processor. 6. Unlock all the RTC Control variables. Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
A digital input channel without line monitoring can find and report states 2, 3, 4, 6 and 7, but cannot find an open circuit or short circuit. A line monitored input can find and report every state, including an open circuit or short circuit. Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
Troubleshooting and Rectifying Channel/Field Faults Correlation of Status Indicators with State Variable for an Analogue Input Analogue input channels are always line monitored. An analogue input channel can detect and report every state from 1 to 7. Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
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Chapter 6 Troubleshooting and Rectifying Channel/Field Faults Analogue Inputs Digital Input Healthy Channel State Condition .STA Faulted Channel fault Over voltage Amber Short circuit Energised Green Field fault Green Indeterminate De-energised Amber Open circuit Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
For details on how the AADvance digital output module detects field faults, see Knowledgebase Document ID: QA23147 AADvance/bulletin 1715: Digital output channel diagnostic test. Sign in to your Rockwell Automation account to view Knowledgebase articles. Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
• For analogue input modules use chart 'B'. • For digital output modules use chart 'C'. • For analogue output modules use chart 'D'. Use this circuit diagram in conjunction with chart 'A'. Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
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Chapter 6 Troubleshooting and Rectifying Channel/Field Faults Figure 5 - Digital Input Circuit Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
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Chapter 6 Troubleshooting and Rectifying Channel/Field Faults Figure 6 - Chart A: Fault finding Process Digital Input Use this circuit diagram in conjunction with chart 'B'. Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
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Chapter 6 Troubleshooting and Rectifying Channel/Field Faults Figure 8 - Chart B: Fault Finding Process Analogue Input Use this circuit diagram in conjunction with chart 'C' Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
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Chapter 6 Troubleshooting and Rectifying Channel/Field Faults Figure 9 - Digital Output Circuit Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
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Chapter 6 Troubleshooting and Rectifying Channel/Field Faults Figure 10 - Chart C: Fault finding Process Digital Output Use this circuit diagram in conjunction with chart 'D'. Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
Examine the State Variable Use the State variable (<variablename>.STA) to find field faults. To do this, you have to identify the Name of the variable, and then add the variable to the Spy List: Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
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3. Select Debug Target and then open the Spy List. 4. Double-click on the Name field. 5. Select the Name for the state variable from the drop down list. • The State variable is added to the Spy list. Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
If the circuit is energized it is possible to make an electrical arc and cause an explosion. Failure to follow these instructions can cause injury to persons. Replace an Input Channel Fuse 1. Open the fuse cover. Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
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Chapter 6 Troubleshooting and Rectifying Channel/Field Faults 2. Find the blown fuse and remove it. 3. Insert the new fuse. Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
Replacing Digital Output Fuses To replace a fuse in a Digital Output Termination Assembly do the following: 1. Use a small screwdriver to open the fuse cover. 2. Remove the blown fuse with long nosed pliers. Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
The identification labels on the sides of the I/O module will be hidden when the module is installed. Therefore before installation write down the location of the module and the details shown on the label. Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
Install the Input/Output Module and turn the locking screw to the lock position. The module will provide the following status indications: Healthy GREEN Ready Channel 1 – 8 The input module will follow its start-up sequence and the module will educate. Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
2. Depress the retaining tab below the termination assembly (multiple tabs for dual and triple modular redundant versions) and then pull the termination assembly downwards. 3. Lift out the termination assembly. Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
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1. Insert the retaining clip on the back of the termination assembly into the slot on the I/O base unit. • Press the termination assembly onto the base unit and then slide the assembly up as far as it will go. Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
Proof Test Interval used to calculate the PFD values. Field Device Maintenance The Operation and Maintenance Plan must include field maintenance activities, such as re-calibration, testing and replacement of field devices. Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
Procedures for tracking all reported anomalies, their temporary solutions and resultant corrective action where applicable • The information requirements placed on the end users by this procedure must be clearly documented and given to the end user Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
Decommissioning The procedure for decommissioning the system must be specified. This procedure must include the requirements for the safe decommissioning of the system and, where applicable, the safe removal or return of materials. Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
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This must include the interaction between systems. • A definition of the modules and materials which are to be returned to Rockwell Automation for ethical disposal following decommissioning. Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
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Chapter 6 Troubleshooting and Rectifying Channel/Field Faults Notes: Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
IEC 61131 Workbench, USB key, single user, single controller T9082D IEC 61131 Workbench, hard disk key, single user, single controller T9083U IEC 61131 Workbench, USB key, multiple controllers T9083D IEC 61131 Workbench, hard disk key, multiple controllers Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
Software: Added AADvance-Trusted SIS Workstation software AADvance® license. Glossary: Updated several entries. ICSTT-RM406I-EN-P, July 2019 Change Updated for Release 1.34 IEC 61508 Edition 2.0 certification Updated Preface release number to 1.34 Legal requirements Updated trademarks Removed print location Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
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Issue 04, November 2010 Change Add fuse replacement Issue 03, April 2009 Change Change title and add calibration procedures Issue 02, February 2009 Change Update with official product titles Issue 01, December 2008 Change First issue Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
An example is ASCII over RS-232-C. See also 'RS-232-C, RS- 422, RS-485'. The probability that a system will be able to carry out its designated function availability when required for use — normally expressed as a percentage. Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
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A group of conductors which carry related data. Typically allocated to address, data and control functions in a microprocessor-based system. A mechanism for deciding which device has control of a bus. bus arbitration Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
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Common Industrial Protocol. A communications protocol, formally known as 'CIP over Ethernet/IP', created by Rockwell Automation for the Logix controller family, and which is also supported by the AADvance controller. AADvance controllers use the protocol to exchange data with Logix controllers.
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Item of equipment connected to the field side of the I/O terminals. Such field device equipment includes field wiring, sensors, final control elements and those operator interface devices hard-wired to I/O terminals. Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
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A backplane assembly which holds up to three I/O modules and their I/O base unit associated termination assembly or assemblies in an AADvance controller. Part number 9300. See 'I/O module' and 'termination assembly'. Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
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The removal and then reinsertion of an electronic module into a system while live insertion the system remains powered. The assumption is that removal of the module and reinsertion will cause no electrical harm to the system. Also referred to as 'hot swap'. Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
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The state of a controller that is executing the application. on-line A series of standards specifications which support open connectivity in industrial automation. A value passed from the processor module to an I/O module. output (variable) Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
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A set of rules that is used by devices (such as AADvance controllers, serial protocol devices and engineering computers) to communicate with each other. The rules encompass electrical parameters, data representation, signalling, authentication, and error detection. Examples include MODBUS, TCP and IP. Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
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Safety Instrumented Function. A form of process control that performs specified functions to achieve or maintain a safe state of a process when unacceptable or dangerous process conditions are detected. Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
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Independent third party certification against a defined range of international TÜV certification standards including IEC 61508. Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
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A redundant system (m out of n) which requires at least m of the n channels to voting system be in agreement before the system can take action. The maximum voltage level that can be applied between circuits or withstand voltage components without causing a breakdown. Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
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Notes: Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
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AADvance Controller Troubleshooting and Maintenance Manual Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021...
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At the end of life, this equipment should be collected separately from any unsorted municipal waste. Rockwell Automation maintains current product environmental information on its website at rok.auto/pec. AADvance, Allen-Bradley, ControlFLASH, expanding human possibility, ICS Triplex, Rockwell Automation, Rockwell Software, TechConnect, and Trusted are trademarks of Rockwell Automation, Inc.
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