Rockwell-automation AADvance Controller Troubleshooting and Maintenanc Manuel d'utilisateur Page 1

AADvance The Next Step in Automation AADvance Controller Troubleshooting and Maintenance Manual ISSUE: 09 DOCUMENT: 553634 (ICSTT-RM406F_EN_P)

   x Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: Troubleshooting and Maintenance Manual (AADvance Controller) Chapter 7 Par

  Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: 1-1 Corrective maintenance activities for the AADvance controller embrace troubleshootin

   1-2 Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: Troubleshooting and Maintenance Manual (AADvance Controller) Required Tools S

  Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: 1-3 Return a Module If you need to return a module for any reason you should in the fi

   1-4 Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: Troubleshooting and Maintenance Manual (AADvance Controller) This p

  Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: 2-1 Safety systems are designed to run continuously without manual intervention. However

   2-2 Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: Troubleshooting and Maintenance Manual (AADvance Controller) Preventive Main

  Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: 2-3 1) Open the fuse cover on each termination assembly to inspect the fuses. 2) Look

   2-4 Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: Troubleshooting and Maintenance Manual (AADvance Controller) Check Ground Con

  Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: 2-5 If desired, you can include this calibration check in the proof test for the loop in

   ii Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: Troubleshooting and Maintenance Manual (AADvance Controller) This pa

   2-6 Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: Troubleshooting and Maintenance Manual (AADvance Controller) Perform the Manu

  Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: 2-7 This page intentionally left blank

  Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: 3-1 Troubleshooting covers system faults, module and channel faults, termination assembl

   3-2 Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: Troubleshooting and Maintenance Manual (AADvance Controller)  The controlle

  Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: 3-3 The diagnostic systems use simple LED status indications to report a problem. The LE

   3-4 Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: Troubleshooting and Maintenance Manual (AADvance Controller) Faults occurring

  Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: 3-5  System fault, pertaining to the AADvance system  Module fault, pertaining to a

   3-6 Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: Troubleshooting and Maintenance Manual (AADvance Controller)  A module faul

  Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: 3-7 Recovery Mode Indications When the processor enters the Recovery Mode the following

  Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: iii Notice In no event will Rockwell Automation be responsible or liable for indi

   3-8 Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: Troubleshooting and Maintenance Manual (AADvance Controller) Fault Reportin

  Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: 3-9 1. If Healthy is GREEN and all the other indicators are OFF then the module has fail

   3-10 Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: Troubleshooting and Maintenance Manual (AADvance Controller) an operating co

  Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: 3-11 Status Indicators on the T94xx Series Input and Output Module Table 3: Status In

   3-12 Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: Troubleshooting and Maintenance Manual (AADvance Controller) values), all ch

  Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: 3-13 Check: the module PST value is it set to the correct value or has it been left at

   3-14 Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: Troubleshooting and Maintenance Manual (AADvance Controller) When a fault ex

  Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: 3-15 On power up or module insertion, a module de-energizes all channels and they remain

   3-16 Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: Troubleshooting and Maintenance Manual (AADvance Controller) Correlation of

  Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: 3-17 Correlation of LEDs with State Variable for an Analogue Output View Module Firmwa

   iv Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: Troubleshooting and Maintenance Manual (AADvance Controller) Issue Record Issu

   3-18 Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: Troubleshooting and Maintenance Manual (AADvance Controller) 4) Click th

  Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: 3-19  The window now shows your controller's current firmware version information

   3-20 Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: Troubleshooting and Maintenance Manual (AADvance Controller) 3) A window op

  Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: 3-21 This page intentionally left blank

  Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: 4-1 The AADvance controller indicates a system fault through the common fault alarm for

   4-2 Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: Troubleshooting and Maintenance Manual (AADvance Controller)

  Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: 4-3 Rectify a Critical Firmware/Hardware Failure When a single critical firmware failure

   4-4 Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: Troubleshooting and Maintenance Manual (AADvance Controller) 2) Place the

  Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: 4-5 Note: The processor back up battery is supplied separately and must be installed int

  Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: v Standard Warnings and Cautions WARNING ELECTRICAL ARCS AND EXPLOSION RISK

   4-6 Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: Troubleshooting and Maintenance Manual (AADvance Controller) as this will not

  Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: 4-7 Processor Module Start Up Process Note: When inserting more than one processor mod

   4-8 Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: Troubleshooting and Maintenance Manual (AADvance Controller) Step Task Ready

  Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: 4-9 Step Task GREEN Force Will remain OFF as the Module boots up (10 to 20 seconds) the

   4-10 Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: Troubleshooting and Maintenance Manual (AADvance Controller)

  Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: 4-11 You can do the following with an on-line update:  Change application variables

   4-12 Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: Troubleshooting and Maintenance Manual (AADvance Controller) Important Note:

  Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: 4-13

   4-14 Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: Troubleshooting and Maintenance Manual (AADvance Controller)

  Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: 4-15

   vi Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: Troubleshooting and Maintenance Manual (AADvance Controller) Who Should Use th

  Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: 5-1 The AADvance controller indicates a channel fault that could be a faulty termination

   5-2 Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: Troubleshooting and Maintenance Manual (AADvance Controller) 1) Select the

  Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: 5-3 4) Double-click on the Name field. 5) Select the tagname for the state variable fr

   5-4 Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: Troubleshooting and Maintenance Manual (AADvance Controller)

  Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: 5-5 Diagnose an Analogue Input Channel Use this circuit diagram in conjunction with cha

   5-6 Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: Troubleshooting and Maintenance Manual (AADvance Controller)

  Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: 5-7

   5-8 Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: Troubleshooting and Maintenance Manual (AADvance Controller) Diagnose a Digit

  Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: 5-9

   5-10 Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: Troubleshooting and Maintenance Manual (AADvance Controller) Diagnose an Ana

  Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: 5-11 Tracing a Channel/Field Fault on an Analogue Output

   5-12 Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: Troubleshooting and Maintenance Manual (AADvance Controller) Replacing Fuses

  Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: 5-13 3) Insert new fuse using long nosed pliers. 4) Close the fuse cover. Repla

   5-14 Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: Troubleshooting and Maintenance Manual (AADvance Controller) 2) Remove the

  Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: 5-15 2) The module is aligned onto the controller by two steel dowel pins and is now re

   6-16 Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: Troubleshooting and Maintenance Manual (AADvance Controller) The provision

  Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: 6-17 maximum interval between these tests shall be defined before installation. It is hi

   6-18 Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: Troubleshooting and Maintenance Manual (AADvance Controller)  Method of de

  Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: 6-19  Scope definition  Hazard and risk analysis  System Functional and Safety Req

   viii Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: Troubleshooting and Maintenance Manual (AADvance Controller) Contents Chap

   6-20 Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: Troubleshooting and Maintenance Manual (AADvance Controller)  The sequence

  Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: 7-1 Bases Part No. Part Description T9100 Processor base unit T9300 I/O base unit (3 way

   7-2 Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: Troubleshooting and Maintenance Manual (AADvance Controller) T9831 Analogue i

  Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: 7-3 Spares & Tools Part No. Part Description T9901 Replacement input fuse 50mA (pack

   7-4 Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: Troubleshooting and Maintenance Manual (AADvance Controller) Micellaneous Ite

  Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: 8-1 Glossary of Terms A accuracy The degree of conformity of a measure to a standar

   8-2 Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: Troubleshooting and Maintenance Manual (AADvance Controller) black channel A

  Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: 8-3 Chapter 7 Glossary of Terms Compiler Verification Tool (CVT) The Compiler Verifi

   8-4 Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: Troubleshooting and Maintenance Manual (AADvance Controller) EUC Equipment Un

  Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: 8-5 Chapter 7 Glossary of Terms G group A collection of two or three input modules (

  Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: ix Correlation of LEDs with State Variable for a Digital Output ...

   8-6 Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: Troubleshooting and Maintenance Manual (AADvance Controller) integer A variab

  Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: 8-7 Chapter 7 Glossary of Terms O on-line The state of a controller that is executin

   8-8 Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: Troubleshooting and Maintenance Manual (AADvance Controller) redundancy The u

  Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: 8-9 Chapter 7 Glossary of Terms SNCP SNCP (Safety Network Control Protocol) is the S

   8-10 Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: Troubleshooting and Maintenance Manual (AADvance Controller) voting system A

  Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: 9-1 For more information about the AADvance system refer to the associated Rockwell Auto

   9-2 Document: 553634 (ICSTT-RM406F_EN_P) Issue: 089: Troubleshooting and Maintenance Manual (AADvance Controller) PFH avg and PFDa