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

Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021 11
Chapter 1
Introduction to Maintenance Activities
Corrective and preventative maintenance activities for the AADvance®
controller include troubleshooting activities and repair procedures to correct
the problem and return the controller back to full operation. Preventative
maintenance and testing procedures are needed to keep the system available
and healthy.
Making Repairs Promptly A fault indication does not necessarily mean an important part of the
controller is not operational. Some faults have no immediate effect — for
example, a fault in one of the diagnostic systems. Nevertheless, the problem
must be rectified in a timely manner.
System repair must be done promptly, to make sure that faults do not build up.
This principle applies as much to a redundant arrangement, which needs to
make sure that fault-tolerant operation continues, as it does to a simplex
controller. Multiple failures can cause a plant shutdown.
Resolving Multiple Faults The fault diagnosis procedures in this manual will find a solution for a single
fault. If you follow one of the processes to its conclusion but if a fault
indication persists, then other faults are present. Quarantine faulty
components you have removed during your first investigation, then repeat the
fault finding procedure.
Required Tools Standard AADvance
The installation and maintenance of the AADvance controller requires the
following tools and test equipment:
Standard Tools
• Screwdriver, flat 0.8.mm x 9.0 mm (1/25 inch x 3/8 inch), for the module
clamp screws and blanking covers
• Screwdriver, flat 0.6 mm x 3.0 mm (1/40 inch x 1/8 inch), or a similar that
will open fuse covers on termination assemblies.
• 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
WARNING: Never permit an AADvance controller used for a safety-critical
function to operate for an extended time with a failed module. Replace the
module in less than the MTTR assumed for PFD calculations to preserve the
SIL level for the system.

12 Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021
Chapter 1 Introduction to Maintenance Activities
• Torque screwdriver, flat 0.6 mm x 3.0 mm (1/40 inch x 1/8 inch), for dc
power wiring terminals
• Torque screwdriver, flat 0.4 mm x 2.0 mm (1/64 inch x 5/64 inch), for field
wiring terminals
• 2 x wrench, open end, 10 mm, for ground stud nuts
• Allen key (hex wrench), 2.5 mm, for plug and sockets assemblies used
with extension cables
Special Tools
• Long nosed pliers to remove the fuses on termination assemblies.
• Digital voltmeter, for troubleshooting activities
• Resistor 1k8, for troubleshooting analogue input modules
• Resistor 1k 1W, for troubleshooting digital output modules
• Resistor 250R 1W, for troubleshooting analogue output modules
Required Test Equipment The maintenance of the AADvance controller requires the following test
equipment.
1. Digital voltmeter
• DC voltage range 0 V to 32 Vdc or better.
• Resistance resolution 0.01 W or better.
2. Current simulation instrument
• Output range 4 mA to 20 mA with an accuracy better than 0.05 mA.
3. Bench power supply
•Outputrange0Vto32Vdc.
Return a Module Before returning a module, contact your local Rockwell Automation technical
support representative or send an email to [email protected] to get a
Return Material Authorization (RMA) number.
For more information, see rok.auto/support.
To get an RMA number by using email
1. Send an email to [email protected] with the subject RMA request.
Leave the message empty.
An email message with instructions returns.
2. Follow the instructions in the email message.
Conventions Used in Flow
Charts
This technical manual includes flow charts. The charts use solid and broken
lines to show different kinds of activities.
IMPORTANT All test equipment must be calibrated and regularly tested for
accuracy

Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021 13
Chapter 1 Introduction to Maintenance Activities
Figure 1 - Flowchart Conventions

14 Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021
Chapter 1 Introduction to Maintenance Activities
Notes:

Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021 15
Chapter 2
Preventive Maintenance
Safety systems are designed to run continuously without manual intervention.
However, some manual preventive maintenance must be done to make sure
the system stays available and healthy.
This chapter describes the preventive maintenance activities for an
AADvance® controller.
Preventive Maintenance
Schedule
The preventative maintenance tasks must be done at the following intervals:
ARC FLASH HAZARD: 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 cause personal injury.
Table 1 - Recommended Schedule for Preventive Maintenance
Preventive Maintenance Task Interval
Review status indicators Daily
Examine fuses 3 months
Examine wiring terminals 3 months
Examine seating of plug-in components 3 months
Look for contamination, examine general condition and make sure
there is sufficient environmental protection 3 months
Measure resistance of the ground connection 3 months
Measure analogue input module calibration values 2 years
Measure analogue output module calibration values 2 years
Measure digital input module calibration values 3 years
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 12.
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. The manual test
interval is used by the Probability of Failure on Demand (PFD)
data analysis as part of the certification process.

16 Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021
Chapter 2 Preventive Maintenance
Status Indicators on the 9110 Processor Module
Table 2 - Status Indicators on the T9110 Processor Module
Indicator Status Description
Healthy
OFF No power.
RED • Flashes RED briefly after being installed as the module is booting up
• Continuous RED means a Module has a fault.
GREEN
As the module boots up it goes GREEN, this lasts for 10 to 20 seconds.
When the module is operational the status indicator stays GREEN.
When in the recovery mode and no faults are present the status indicator is
GREEN.
Fault Indications:
• If Healthy is GREEN and all the other indicators on the module are OFF
then the module has failed to boot up.
• If Healthy is GREEN and Ready and Run are RED then the module is in its
shutdown state.
Ready
OFF No power.
RED • Module is booting up (10 to 20 seconds) or not educated or synchronized
with partners.
• Module is in the shutdown state.
Flashing
GREEN The module is being educated or synchronized.
GREEN Module is educated and synchronized with partners.
AMBER Module is in Recovery Mode.

Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021 17
Chapter 2 Preventive Maintenance
Run
OFF No power and stays off while the module is booting up (10 to 20 seconds)
RED
• Module is not educated/synchronized; No application loaded; the
processor module is in the Recovery Mode and the base level firmware is
running.
• Module is in the shutdown state.
GREEN The module contains an application and it is running.
AMBER
Module is in Recovery Mode.
or
The module contains the application but the application has stopped. Press
Fault Reset to start the application.
System Healthy
OFF No power and stays off while the module is booting up (10 to 20 seconds).
RED
There is a fault on one or more modules.
or
The application has stopped because the module has entered Recovery
Mode.
GREEN No system or module faults present or
The system is in Recovery Mode.
Force
OFF No power and stays off while the module is booting up (10 to 20 seconds)
GREEN No variables are being locked/forced
AMBER Module is in the Recovery Mode. or
An operating controller has at least one variable being locked/forced.
Aux
OFF No power and stays off while the module is booting up (10 to 20 seconds),
or under application control.
GREEN The module is under application control.
AMBER Module is under application control. or
The module is in the Recovery Mode.
Serial 1 and 2
OFF No power and stays off while the module is booting up (10 to 20 seconds).
RED Serial port pulse stretched Tx.
GREEN Serial port pulse stretched Rx.
AMBER Quickly alternating Tx and Rx activity.
Ethernet 1 and 2
OFF No power and stays off while the module is booting up (10 to 20 seconds)
GREEN Ethernet link present
AMBER Tx or Rx activity on Ethernet Port
Table 2 - Status Indicators on the T9110 Processor Module
Indicator Status Description

18 Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021
Chapter 2 Preventive Maintenance
Status Indicators on the 94xx Series Input and Output Module
Table 3 - Status Indicators on the 94xx Series Input and Output Module
Indicator Status Description
Healthy
OFF No power.
GREEN No module faults present.
RED
The module has one or more faults.
• The Healthy indicator can turn RED immediately after power is applied to
the module, before then turning GREEN
• If Healthy is GREEN and the Ready and Run are RED then the module is
said to be in its "shutdown state" refer to the Troubleshooting Manual -
Chapter 3 for more information on the shutdown state.
Ready
OFF No power or module is unlocked.
GREEN Locked and prepared to report channel values.
RED Locked but not prepared to report channel values.
Run
OFF No power or module is unlocked.
GREEN Module is on-line and supplying data to/receiving data from application
AMBER Module is inserted into a running system but not on-line. Push the Fault
Reset button on any processor module to set the module to go on-line.
RED Module is prepared to go on-line but no application is running.

Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021 19
Chapter 2 Preventive Maintenance
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.
Channel 1 - 8
OFF
Input module: field switch is open.
Output module: output is in its de-energized condition.
Note: If the run indicator is not green (the module is not reporting channel
values), all channel indicators will be off.
GREEN Input module: input is on.
Output module: output is in its energized condition.
AMBER Field fault.
RED Channel fault.
Table 3 - Status Indicators on the 94xx Series Input and Output Module
Indicator Status Description

20 Rockwell Automation Publication ICSTT-RM406J-EN-P - February 2021
Chapter 2 Preventive Maintenance
Check Wiring Terminals
To examine the wiring terminals do the following:
•Examinethefield, power and network wiring and look for any signs of
physical stress such as chafing.
•Tightenanyloose terminal screws to help prevent open circuits causing
trips, see torque values in note above.
Check Seating of Plug-in
Components
To examine the seating of plug-in components, do the following:
•ExaminetheAADvance controller and make sure all plug-in items cable
assemblies and base unit bus connectors, are correctly seated.
Check Physical Condition
and Environmental
Conditions
To examine the physical condition of the controller and the environmental
conditions, do the following:
•ExaminetheAADvance controller assemblies for contamination,
corrosion, dampness and dust.
• Look for unauthorized modifications.
• Look for exposed parts (where covers are missing), bare wires and
damaged insulation.
•Makesurethatlocal ventilation and air conditioning systems are
operating correctly.
Check Ground Connection To measure the controller ground connection, do the following:
• Measure the resistance of the connection to the ground stud on the 9100
processor base unit, it must be less than 0.2 ?. If it is above this figure
then check the ground stud connection.
Check Analogue Input
Module Calibration Values
The AADvance controller detects possible calibration drift by continually
checking its measured input values. The controller uses diverse hardware to
compare two measurements. It is recommended that you do this calibration
drift check every two years. You can make sure that an analogue input is
within the stated accuracy (±0.05mA) without taking a module out of service
using the following procedure:
1. Use the AADvance®Workbench software or AADvance®-Trusted®SIS
Workstation software to lock the input channel.
• The input value freezes, allowing the procedure to continue operating.
2. Disconnect the field device at the termination assembly and connect a
calibrated current simulation instrument in its place.
3. Set the current simulation instrument to supply 4 mA, make sure that
the input value is in the range 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.
IMPORTANT For controller power and field wiring terminals. When installed a
minimum tightening torque of 0.5 Nm (0.37 ft. lb.) has to be used.
For serial connections a minimum tightening torque of 0.22 Nm
(0.16 ft. lb.) has to be used.