Rockwell Automation Allen-Bradley AADvance T9110 User manual

AADvance Controller
Catalog Numbers T9110, T9300, T9310, T9401/2, T9431/2,
T9451, T9481/2
Troubleshooting and Maintenance Manual Original Instructions

2Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021
AADvance Controller Troubleshooting and Maintenance Manual
Important User Information
Read this document and the documents listed in the additional resources section about installation, configuration, and
operation of this equipment before you install, configure, operate, or maintain this product. Users are required to familiarize
themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws, and standards.
Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required to
be carried out by suitably trained personnel in accordance with applicable code of practice.
If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be
impaired.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use
or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for
actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software
described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is
prohibited.
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
Labels may also be on or inside the equipment to provide specific precautions.
WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment,
which may lead to personal injury or death, property damage, or economic loss.
ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property
damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.
IMPORTANT Identifies information that is critical for successful application and understanding of the product.
SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous
voltage may be present.
BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may
reach dangerous temperatures.
ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to
potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL
Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).

Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021 3
Preface
About This Publication 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. Because of the many variables and requirements related
to any particular installation, Rockwell Automation does not assume
responsibility or reliability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, with respect to use of
information, circuits, equipment, or software described in this manual.
All trademarks are acknowledged.
Disclaimer
It is not intended that the information in this publication covers every possible
detail about the construction, operation, or maintenance of a control system
installation. You should also refer to your own local (or supplied) system safety
manual, installation and operator/maintenance manuals.
Revision and Updating Policy
This document is based on information available at the time of its publication.
The document contents are subject to change from time to time. The latest
versions of the manuals are available at the Rockwell Automation Literature
Library under "Product Information" information "Critical Process Control &
Safety Systems".
Rockwell Automation Support
Any required support can be accessed through the Rockwell Automation
Support Website at rok.auto/support.
Registration for Automatic Product Safety Advisories and Product Notices
from Rockwell Automation, which are available by email, is obtained by using
the Technical Support Center link (available on the above web-page) and
signing in with either a TechConnectSM Account or free Rockwell Automation
Member Account. Account holders can subscribe to important product
updates, including Product Safety Advisories and Product Notices.
All repair actions for AADvance products are tracked against a SAP ticket
number and customers can request a Root Cause Fault Analysis (RCFA) report.
Downloads
The product compatibility and download center is rok.auto/pcdc.

4Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021
Select the Find Downloads option under Download
In the Product Search field enter "AADvance" and the AADvance option is
displayed.
Double click on the AADvance option and the latest version is shown.
Select the latest version and download the latest version.
AAdvance Release
This technical manual applies to AADvance system release 1.40.
Latest Product Information
For the latest information about this product review the Product Notifications
and Technical Notes issued by technical support. Product Notifications and
product support are available at the Rockwell Automation Support Center at
rok.auto/knowledgebase.
At the Search Knowledgebase tab select the option "By Product" then scroll
down and select the ICS Triplex® product AADvance.
Some of the Answer ID’s in the Knowledge Base require a TechConnect
Support Contract. For more information about TechConnect Support Contract
Access Level and Features, click this link: Knowledgebase Document ID: IP622
- TechConnect Support Contract - Access Level & Features.
This will get you to the login page where you must enter your login details.
Purpose Of This Manual
This manual specifies the maintenance requirements and describes the
procedures to assist troubleshooting and maintenance of an AADvance
system.
Who Should Use Manual
This manual is for plant maintenance personnel who are experienced in the
operation and maintenance of electronic equipment and are trained to work
with safety systems.
Environmental Compliance
Rockwell Automation maintains current product environmental information
on its website at rok.auto/pec.
IMPORTANT A login is required to access the link. If you do not have an
account then you can create one using the "Sign Up" link at the
top right of the web page.

Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021 5
Download Firmware, AOP,
EDS, and Other Files
Download firmware, associated files (such as AOP, EDS, and DTM), and access
product release notes from the Product Compatibility and Download Center at
rok.auto/pcdc.
Summary of Changes This publication contains the following new or updated information. This list
includes substantive updates only and is not intended to reflect all changes.
Global changes
This table identifies changes that apply to all information about a subject in the
manual and the reason for the change. For example, the addition of new
supported hardware, a software design change, or additional reference
material would result in changes to all of the topics that deal with that subject.
New or enhanced features
This table contains a list of topics changed in this version, the reason for the
change, and a link to the topic that contains the changed information.
Subject Reason
Changed
workstation to computer Technical improvement
Changed
LED to status indicator Technical improvement
Added AADvance®-Trusted® SIS Workstation
software information where applicable Enhancement
Changed
Workbench to software where applicable Technical improvement
Applied latest publication template Marketing product change
Topic Page Reason
Rockwell Automation Support 3Added section.
AAdvance Release 4Updated AADvance system release information.
Return a Module 12 Updated procedure.
View Module Firmware Versions 23 Added steps for AADvance Workbench software
version 2.x and AADvance-Trusted SIS
Workstation software.
Upgrade the processor module firmware 25 Updated procedures.
Latching and Non-Latching Faults 33
Added information for AADvance Workbench
software version 2.x and AADvance-Trusted SIS
Workstation software.
I/O Module Channel Degradation and
Shutdown 38 Updated information.
Fault Finding Process - System Level 41 Changed
Workbench variable to status variable .
Rectify a Critical Processor Firmware/Hardware
Failure 42 Updated information.
Troubleshooting Remote Fault Reset/Join 49 Updated information.
Set the Real Time Clock Manually 49 Removed Rack from list headings.
Understanding the State Variable
(<variablename>.STA) 51 Changed
<tagname>.STA to
<variablename>.STA .
Correlation of Status Indicators with State Variable
for a Digital Output 54 Updated Knowledgebase Document ID.
Examine the State Variable 63
Changed tagname to name .
Added steps for AADvance Workbench software
version 2.x and AADvance-Trusted SIS
Workstation software.
Software 78 Added AADvance-Trusted SIS Workstation
software AADvance license.
Glossary 83 Updated several entries.

6Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021
Additional Resources These documents contain additional information concerning related products
from Rockwell Automation.
Resource Description
AADvance Controller Safety Manual, ICSTT-RM446
This technical manual defines how to safely apply AADvance controllers for a Safety
Instrumented Function. It sets out standards (which are mandatory) and makes
recommendations to make sure that installations satisfy and maintain their required safety
integrity level.
AADvance Controller System Build Manual, ICSTT-RM448 This technical manual describes how to assemble a system, switch on and validate the
operation of your system.
AADvance Controller Configuration Guide Workbench 1.x, ICSTT-RM405 This software technical manual defines how to configure an AADvance controller
using the AADvance Workbench software version 1.x to satisfy your system operation and
application requirements.
AADvance Controller Configuration Guide Workbench 2.x, ICSTT-RM458 This software technical manual defines how to configure an AADvance controller
using the AADvance Workbench software version 2.x to satisfy your system operation and
application requirements.
AADvance-Trusted SIS Workstation Software User Guide, ICSTT-UM002 This publication provides how-to instructions for AADvance-Trusted SIS Workstation
software configuration and use.
AADvance Controller OPC Portal Server User Manual, ICSTT-RM407 This manual describes how to install, configure and use the OPC Server for an AADvance
Controller.
AADvance Controller PFH and PFDavg Data, ICSTT-RM449 This document contains the PFH and PFDavg Data for the AADvance Controller. It includes
examples on how to calculate the final figures for different controller configurations.
AADvance Controller Solutions Handbook, ICSTT-RM447 This technical manual describes the features, performance and functionality of the
AADvance controller and systems. It gives guidance on how to design a system to satisfy
your application requirements.
AADvance Controller Troubleshooting and Maintenance Manual, ICSTT-RM406 This technical manual describes how to maintain, troubleshoot and repair an AADvance
Controller.
Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1 Provides general guidelines for installing a Rockwell Automation industrial system.
Product Certifications website, rok.auto/certifications. Provides declarations of conformity, certificates, and other certification details.

Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021 7
Table of Contents
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
About This Publication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Download Firmware, AOP, EDS, and Other Files . . . . . . . . . . . . . . . . . . . . 5
Summary of Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Chapter 1
Introduction to Maintenance
Activities
Making Repairs Promptly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Resolving Multiple Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Required Test Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Return a Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Conventions Used in Flow Charts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Chapter 2
Preventive Maintenance Preventive Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Status Indicators on the 9110 Processor Module . . . . . . . . . . . . . . . . 16
Status Indicators on the 94xx Series Input and Output Module. . . 18
Check Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Check Wiring Terminals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Check Seating of Plug-in Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Check Physical Condition and Environmental Conditions . . . . . . . . . . 20
Check Ground Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Check Analogue Input Module Calibration Values. . . . . . . . . . . . . . . . . . 20
Check Digital Input Module Calibration Values . . . . . . . . . . . . . . . . . . . . 21
Perform the Manual Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Chapter 3
Upgrading Controller Firmware View Module Firmware Versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Upgrade the processor module firmware . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Download software and firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Install software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Configure RSLinx Classic software . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Use ControlFLASH to upgrade firmware . . . . . . . . . . . . . . . . . . . . . . . 27
Chapter 4
About Troubleshooting Prerequisites for Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Internal Diagnostics and Fault Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Actions of the Diagnostic Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Latching and Non-Latching Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Module Shutdown State and Possible Causes . . . . . . . . . . . . . . . . . . . . . . 33
Fault Indications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
I/O Module Channel Degradation and Shutdown . . . . . . . . . . . . . . . . . . 38

8Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021
Degraded Channel Reporting Values . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Output Channel Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Chapter 5
Troubleshooting and Rectifying
Module Faults
Troubleshooting Module Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Rectify a Critical Processor Firmware/Hardware Failure . . . . . . . . . . . . 42
Install a 9110 Processor Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Processor Module Start Up Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Faulty Processor Back-up Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Replace a Faulty Processor Back-up Battery . . . . . . . . . . . . . . . . . . . . 46
Remote fault reset/Join . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Troubleshooting Remote Fault Reset/Join . . . . . . . . . . . . . . . . . . . . . . 49
Set the Real Time Clock Manually. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Chapter 6
Troubleshooting and Rectifying
Channel/Field Faults
Understanding the State Variable (<variablename>.STA) . . . . . . . . . . . 51
Correlation of Status Indicators with State Variable for a Digital
Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Correlation of Status Indicators with State Variable for an Analogue
Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Correlation of Status Indicators with State Variable for a Digital
Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Correlation of Status Indicators with State Variable for an Analogue
Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Start Troubleshooting Channel/Field Faults . . . . . . . . . . . . . . . . . . . . . . . 55
Examine the State Variable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Replacing Channel Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Replace an Input Channel Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Replacing Digital Output Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Install I/O Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
I/O Module Start-up Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Install a New Termination Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Operation and Maintenance Plan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Input Module Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Planned Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Field Device Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Handling Module Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Keeping Maintenance Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Preserving Functional Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Product Level Module and Firmware Updates . . . . . . . . . . . . . . . . . . 74
Modification Records and Change Management. . . . . . . . . . . . . . . . 74
Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Chapter 7
Parts List Base Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Special Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Termination Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021 9
Expansion Cable Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Blanking Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Spares and Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Demonstration Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Miscellaneous Items. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Appendix A
History of Changes Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83

10 Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021