T308-08 Hardware Troubleshooting

System 800xA training
Chapter 8 Hardware Troubleshooting
TABLE OF CONTENTS
Chapter 8 Hardware Troubleshooting ..................................................................................................................................... 1

8.1 General Information ..................................................................................................................................................... 2
8.1.1 Objectives.............................................................................................................................................................. 2
8.1.2 Legend .................................................................................................................................................................. 2
8.1.3 Reference Documentation ...................................................................................................................................... 2
8.2 Hardware Status in Control Builder............................................................................................................................... 3
8.2.1 Hardware Error Indication Icons............................................................................................................................. 3
8.2.2 Clearing Latched Alarms........................................................................................................................................ 4
8.2.3 Unit Status Tab ...................................................................................................................................................... 5
8.3 Hardware Status in Plant Explorer ................................................................................................................................ 6
8.3.1 System Status Viewer ............................................................................................................................................ 6
8.3.2 Hardware Editor Aspect ......................................................................................................................................... 7
8.3.3 Hardware Alarms................................................................................................................................................... 7
8.4 IO Module Diagnostic Flow Chart ...............................................................................................................................10
8.5 Signal Forcing.............................................................................................................................................................11
8.5.1 How to Force a Digital Output ..............................................................................................................................11
8.5.2 How to Force an Analog Output............................................................................................................................12
8.5.3 Forcing Input Signals............................................................................................................................................12
8.6 Replacing Hardware ....................................................................................................................................................13
8.6.1 How to Replace PM8xx Battery ............................................................................................................................13
8.6.2 How to Replace PM8xx (Single CPU)...................................................................................................................14
8.6.3 How to Replace PM8xx (Redundant CPU) ............................................................................................................16
8.6.4 How to Replace Modules on the CEX Bus.............................................................................................................17
8.6.5 How to Upgrade CI801 / CI830 Firmware .............................................................................................................18
8.6.6 How to Replace S800 IO Modules.........................................................................................................................21
8.6.7 How to Replace S800L IO Modules ......................................................................................................................23
8.7 Logs............................................................................................................................................................................24
8.7.1 Controller Log ......................................................................................................................................................24
8.7.2 System Log...........................................................................................................................................................25
8.8 Power Supervision.......................................................................................................................................................26
8.8.1 Power Supervision Terminals................................................................................................................................26
8.8.2 Power Supervision Alarms ....................................................................................................................................27
8.8.3 Fuses on Controller Baseplate ...............................................................................................................................27
Chapter 8 - 1
T308-08 Hardware Troubleshooting - RevC
8.1 General Information
8.1.1 Objectives
On completion of this chapter you will be able to:
• Analyze the hardware status
• Check and force I/O signals
• Exchange hardware units
• Check the power supervision
8.1.2 Legend
> Indicates when you go from one menu to a sub-menu
Italic Indicates object and file names
“ “ Indicates dialog box buttons, tabs, menus etc.
Bold Indicates important topics
Indicates start/explanation of student activity
8.1.3 Reference Documentation

3BSE036351 Industrial IT 800xA – Control and I/O
AC 800M-Controller Hardware
3BSE041880 Industrial IT 800xA – Control and I/O
Getting Started
3BSE035980 IndustrialIT 800xA - Control and I/O
Basic Control Software
Chapter 8 - 2
8.2 Hardware Status in Control Builder
8.2.1 Hardware Error Indication Icons

In Control Builder, the Project Explorer can be used to detect and investigate hardware
errors and warnings at run time. The general idea is that whenever a hardware error
occurs, it will be presented as an icon in front of the hardware unit in Project Explorer.
Error
Warning
Warnings are events that are considered to be less serious than errors. Analog input
overflow or underflow or forced IO channels are examples of hardware warnings.
Error
Warning
The errors and warnings in CBM are always transported upwards to the top hardware
container, so that they are visible even if the hardware structure is collapsed.
The strategy to examine a hardware error or warning is to expand the hardware

configuration until the specific unit where the error occurred can be seen. By double-
clicking in the unit, the hardware configuration editor is presented. Information about
the error or warning will be shown in the “Unit Status” tab.
Chapter 8 - 3
8.2.2 Clearing Latched Alarms

When the error or warning is gone, then you can clear the error or warning icon by
right click the object and click “clear latched unit status”:
Then the icon is cleared:
Chapter 8 - 4
8.2.3 Unit Status Tab

All hardware units have a property called Unit Status which is presented in its own
tab in the hardware configuration editor. For IO units there is also a channel with this
name that can be connected to a variable in the application.
The variable can be of the simple data type dint or of the complex data type HW
Status.
The data type HWStatus has the following components:
Component name Data type Description

HwState dint Indicates errors or warnings on HW unit.
0=OK, 1=error, 2=warning
HWStateChangeTime date_and_time Time when HWStatus changed from 0 to
1 or 2.
ErrorsAndWarnings dword Describes actual errors or warnings on
HW unit. A code (Value) as well as a text
(Description) is shown.
ExtendedStatus dword Additional information about HW unit
LatchedErrorsAndWarnings dword Latched value from the
ErrorsandWarnings. Will be reset when
the error is acknowledged.
LatchedExtendedStatus dword Latched value from the Extended Status
component. Will be reset when the error is
acknowledged.
Chapter 8 - 5
8.3 Hardware Status in Plant Explorer
8.3.1 System Status Viewer

An aspect called System Status Viewer can be used in System 800xA to diagnose
hardware errors. This aspect is typically found in the:
Control Structure > Control Network > Control Project > Controllers
Error Warning OK
Chapter 8 - 6
8.3.2 Hardware Editor Aspect

A right click of any object in the tree brings up the context menu. From the context
menu it is possible to call up the “hardware editor”.
8.3.3 Hardware Alarms

The alarm list for the controller also contains alarms from the hardware configured for
the controller. The object’s name is the last number of its position in the hardware
structure, the source name is the address of the hardware unit. For example, we
removed the DO810 hardware from the TU810, the alarm list shows that Module
missing.
Chapter 8 - 7
Alarm List shows the

hardware address and
error message
To trace a hardware error from the alarm list to CBM, just right click the alarm and
select Project Explorer:
Chapter 8 - 8
It will call up the Project Explorer in the Control Builder.
When the hardware was reinstalled, the alarm list shows you Status cleared.
Chapter 8 - 9
8.4 IO Module Diagnostic Flow Chart

Below is a flow chart illustrating a typical IO trouble shooting procedure:
How many units display error icons? A

More than one
One
Check error message

in Unit Status tab Check the Lock switch on the MTU
Wrong IO Module Unlocked Locked

IO Module
missing
Check the type and position of Lock the MTU Check the Error message in
the IO module in the CB Project the unit status tab
Explorer
Wrong IO Module
“IO Channel error” or “IO
Check the module module missing”
bus connections
Check the type and position of
the IO module compared to the
Module bus connected Module bus CB project explorer
disconnected
Replace IO Module
What IOs are not working? Connect Module bus
Analogue IOs Analogue and

digital IOs
Check the Module bus fuse Go to A
Chapter 8 - 10
8.5 Signal Forcing

Forcing IO signals is a very useful tool for diagnosing hardware problems. Using this
facility, for example, a digital output can be made to operate an item of plant that is
suspect. Similarly input signals can be forced to check that an input has the
appropriate effect on a graphic etc.
8.5.1 How to Force a Digital Output

To force a DO proceed as follows
1. Select the appropriate DO module and select Editor.
2. Select the “Status” tab.
Chapter 8 - 11
3. Left click the appropriate channel in Forced column and the Channel Value will
change color to yellow. The channel value can then be written to with either a ‘1
or 0’ to turn the Output on or off. The .IO Value and Forced components of the
variable are affected, which is reflected in the Status word.
4. To release the Force condition and return to normal operation, left click on the X
in the forced column.
8.5.2 How to Force an Analog Output

The same technique is used as for the DO except a real value is inserted into Channel
value.
8.5.3 Forcing Input Signals

This is useful for testing graphics and logic etc. This will only affect the .Value and
Forced component of the variable, as well as being reflected in the Status word.
It is carried out in exactly the same way as forcing outputs, except that in this case the
variable column will be highlighted for forcing.
Chapter 8 - 12
8.6 Replacing Hardware

Care must be taken when exchanging hardware modules and due consideration must
be given to the following points.
• Can the module be hot swapped i.e. changed without removing power?
Refer also to chapter Hardware which modules can be hot swapped.
• If the module can be hot swapped, say, for example, a digital input DI810,
because of a faulty channel, what would the affect be on the plant, caused by the
loss of signals from the other 15 channels?
• Have you the correct module (S800 modules are very similar to each other)?
• Have you upgraded the module’s firmware? As you know some modules (like
PM8xx, CI8xx) have firmware inside, and must be upgraded before replacing)
NOTE! Please refer to section 5 Maintenance in the manual AC
800M Controller - Hardware and Operation.
8.6.1 How to Replace PM8xx Battery

When a battery replacement is required the (B)attery LED will flash. This operation
can be carried out with the CPU on line.
1. Using a blade screwdriver, release the captive screw from the PM8xx and remove
the right-hand cover.
2. Identify and remove the internal battery.
3. Insert a serviceable battery and check that battery polarity and orientation are
correct, according to the marking on the housing.
4. When power is re-established, ensure that the B(attery) LED is illuminated
5. Replace the PM8xx right-hand cover and tighten the screw.
6. Dispose of the run-down Lithium battery in an approved manner.
Chapter 8 - 13
8.6.2 How to Replace PM8xx (Single CPU)

Each TP830 base plate is provided with two unique MAC addresses that provides
every CPU with a hardware identity.
This functionality takes the form of two identification addresses residing in the
nonvolatile memory of the TP830 base plate. The lowest address (a 12 character Hex
code) is located on an adhesive label attached to the TP830 base plate. The remaining
address is the lowest +1. See below for label location details.
Note it may be necessary to refer to the Release Notes to check the compatibility of
the replacement controller with regard to the revision of the base. These are identified
on the identification labels on the units.
NOTE! Without redundancy the process being controlled will

need to be stopped or operated manually.
1. Remove power from the controller, and ensure all the indicator lights are
extinguished.
2. Release the two captive screws and withdraw the unit.
Captive
Screws
3. The CPU can then be pulled from its base. Replace by carefully inserting the CPU
in the base plate and tightening the captive screws.
4. Restore power.
5. Setup the correct IP address & upgrade the firmware to ensure correct operation.
6. Download your application.
Chapter 8 - 14
Replace Processor Units complete with Base plates

1. Switch off or disconnect the power supply to the controller units.
2. Remove any detachable cables from the appropriate unit base plate.
3. Rotate the locking device to the SLIDE position (2) on the unit base plate.
4. Slide the units apart until the unit to be changed has its buses clear of the adjacent
units.
5. Turn the locking device to the OPEN position (1) and remove the base from the
DIN rail.
6. Replace the unit, turn the locking device to the SLIDE position (2) and slide all
the units back together.
7. Turn the locking device to the LOCKED position (3) and restore power.
Chapter 8 - 15
8.6.3 How to Replace PM8xx (Redundant CPU)

The RCU Link cable must NEVER be removed from the primary Processor Unit
during operation. Removal of the cable may cause the unit to stop.
The just replaced (broken) CPU might still have the IP address of the primary CPU. If,
for example, it is installed later on for testing on the same control network it might
disturb the communication to the active system running the application. Therefore,
unless sending the CPU back for repair immediately, use the IP Config tool to modify
the IP address of the just replaced CPU.
8.6.3.1 Replace without BC810

Only the PM86x can be exchanged during operation, not the associated baseplate!
1. Disconnect the Power Supply socket from the processor unit.
2. Disconnect the RCU Link cable and optical ModuleBus cable only from the
processor unit to be exchanged.
3. Using a blade screwdriver, release the two spring-loaded captive screws on the
processor unit cover.
Captive
Screws
4. Carefully remove the processor unit.

5. Fit the new processor unit and tighten the screws.
6. Check the Firmware (must be same as running CPU).
7. Reconnect the Power Supply Socket to the new processor unit.
8. Reconnect the optical ModuleBus and RCU Link cable.
9. Press the INIT push button on the replaced processor unit. Observe the startup
procedure and make sure that Dual mode is reached, that the Dual LED is lit on
both processor units.
Chapter 8 - 16
8.6.3.2 Replace with BC810

If the BC810 is powered from an external power source, the entire CPU, with base
plate can be replaced.
1. Disconnect the RCU Link cable and optical ModuleBus cable only from the
processor unit to be exchanged.
2. Disconnect the Power Supply socket from the processor unit.
3. Disconnect the Control Network cables.
4. Rotate the locking device to the SLIDE position on the unit base plate.
5. Gently ease the unit/base plate sideways in order to release the contacts of the
unit.
6. Turn the locking device anti-clockwise to the OPEN position and ease the unit
base plate outward and upward at the base. Lift the unit to remove it from the
DIN-rail.
7. Mount the new unit and fit it to BC810 CEX-Bus.
8. Reconnect the Power Supply socket to the new processor unit.
9. Reconnect the optical ModuleBus and the RCU Link cable.
10. Reconnect the Control Network cables.
11. Press the INIT push button on the replaced processor unit. Observe the startup
procedure and make sure that Dual mode is reached, that the Dual LED is lit on
both processor units.
8.6.4 How to Replace Modules on the CEX Bus

This symbol on the front of a CEX-bus module indicates that hot swapping is
supported for that unit.
In order to change the unit, unscrew the captive screw and withdraw the unit. Gently
insert the replacement module and tighten the screw.
NOTE! It is not allowed to manipulate CEX bus base plates in a
powered and running system. Before changing or
removing a base plate, all CEX modules on that segment
must be removed.
If it is required to change the base, then power must be removed. Use the technique
described earlier to replace the base.
Chapter 8 - 17
8.6.5 How to Upgrade CI801 / CI830 Firmware

CI830 / CI801 modules use a firmware which needs to be upgraded when you replace
a module.
NOTE! CI830 is going to be replaced by CI801 to support the
HART protocol.
8.6.5.1 Upgrade CI801 Firmware

A special service adapter (FS801 + cable TK802) and a connection cable TK212 are
needed to carry out the upgrade.
1. Connect your PC and the CI801, using a TK212 cable and the service adapter
(FS801+TK802) between the service port (Profibus connection) on CI801 and
COM1 or COM2 on the PC.
2. Set the station address on CI801 to 0.

3. Run the program loader32.exe and press “Next”.
4. Choose the setting “User defined: Select COM-Port and speed manually” and
press the button “Next”.
5. Select the COM-Port to be used and type in the path to the image-file.
6. Check the box “Disable optimization of speed (Fix to 9600 BD)” and uncheck the
remaining check boxes. Press the button “Download”.
7. The loading procedure takes approx. 15 minutes.
8. Set back the station address to the address used in the project.
9. Switch off and then on the power supply to the CI801 to initialize it.
Chapter 8 - 18
8.6.5.2 Upgrade CI830 Firmware

Only the connection cable TK527 is needed to carry out the upgrade. It is assumed
that the PC communication port is COM1: and the diskette drive is A.
Reset the CI830 application memory
1. Set the address switches to 99.
2. Take away the power supply for a short moment.
3. Apply power and let the FCI restart -- waiting 45 seconds.
Now the application memory is cleared.
4. Set the address switches to the desired station address.
5. Take away the power supply for a short moment.
6. Apply power and let the FCI restart -- waiting 45 seconds.
Now the FCI is cleared and ready for application programming.
Download the Firmware

Connect the PC with CI830 using a TK527 cable between the RS232 service port on
the CI830 and COM1 or COM2 on the PC.
1. Run the program loader32.exe and press “Next”.
2. Choose the setting “User defined: Select COM-Port and speed manually” and
press the button “Next”.
3. Select the COM-Port to be used and type in the path to the image-file.
Chapter 8 - 19
4. Check the box “Disable optimization of speed (Fix to 9600 BD)” and uncheck the
remaining check boxes. Press the button “Download”.
5. The loading procedure takes approx. 5 minutes.
Chapter 8 - 20
8.6.6 How to Replace S800 IO Modules

S800 modules can be hot swapped and the following procedure should be adopted.
1. Using a suitably long screwdriver with an adequate size blade, rotate the plastic
switch on the right side of the module through 900 counterclockwise when the slot
in the plastic switch will be horizontal.
Rotate plastic
switch
2. The green run light will be extinguished and the red fault light will be lit,
indicating that the module is disabled. The module can then be lifted vertically
from the base.
3. On the base there are 2 six position rotary keys marked A - F. Check that the new
module corresponds to the settings of the base. (You may have the wrong
module). The diagram below shows the position of the keys in the compact and
standard TUs.
Keys
4. Carefully push the replacement module into the base. When it is seated the red
fault light should be on.
5. Rotate the rotary switch clockwise through 900 at which point the Red Fault LED
should extinguish and the green (R)un LED light.
Chapter 8 - 21
8.6.6.1 How to Replace S800 Terminating Units

If the TU is part of the base cluster then power must be removed from the CPU. If the
TU to be changed is part of a remote cluster, then power only needs to be removed
from that cluster and the remainder of the IO can continue to operate.
NOTE! The terminating units cannot be changed without first
removing the power.
1. Carry out steps 1 and 2 of the previous section.

2. It will now be necessary to create a space in order to remove the base. Depending
upon the position of the TU to be changed, will depend whether units are to be
eased to the right or to the left in order to create the necessary space.
Locking
tabs
DIN Rail
Release Tabs
3. Locate the locking tab just below the module bus connection and using a thin
screwdriver, gently push down to release the tab and ease the units apart. When
the faulty TU has been mechanically isolated on both sides, using a screwdriver,
pull down on the DIN rail tab to release the TU.
4. Insert the replacement TU by first hooking on the top of the DIN rail, then pulling
down the release tab ease the TU onto the bottom of the DIN rail.
5. Slide the TUs together to reconnect the module bus. Insert the module into the TU
and reapply power. Rotate the rotary switch clockwise through 900 at which point
the Red Fault LED should extinguish and the green (R)un LED light.
Chapter 8 - 22
8.6.7 How to Replace S800L IO Modules

As the base is an integral part of the module, these units cannot be hot swapped as
the module bus has to be broken. To change the units proceed as follows.
1. Remove the power from the units.
2. Disconnect the terminal blocks from the module, leaving the field wiring
connected to the terminal block
3. Turn the locking devices of the adjacent units to slide.
4. Ease the modules apart until the module bus connection is clear.
5. Turn the locking device of the unit to be removed to open, and remove the module
from the DIN rail.
6. Replace the module, slide the units back together and turn all locking devices to
the locked position.
7. Replace the field wiring terminal blocks.
8. Reapply power.
Chapter 8 - 23
8.7 Logs
8.7.1 Controller Log

If there are unusual problems with a controller, the controller log can be a very
important information resource. This log can be copied and removed from a system
for analysis off site.
Select Controller > Remote System > Show Controller Log to read the controller
log from the controller.
All crash dumps saved in the controller log are translated. You can read all other
information, such as warning printouts, module type, firmware version, etc.
All I/O units are written to the controller log when a hardware configuration is
downloaded. When an I/O module is removed and replaced on line, the event(s) are
written to the controller log. Time stamp, hardware position, I/O unit type and Product
Revision are written to the controller log file as well.
The file is also located on the hard drive in the Control Builder Log Files folder. The
Controller log is fetched from the controller ONLY when asked via the Remote
System tool.
Chapter 8 - 24
When the controller log is displayed to the user, it is shown in a text editor, such as
Notepad.
NOTE! If you have to report a problem to ABB SupportLine,

then it's always good to attach a copy from the controller
log to speed up the case handling.
8.7.2 System Log

The System log file is created the first time Control Builder M is started (or if there is
no log file) and is used to store general information. Examples of information logged
are starting and stopping of Control Builder M, users logging in and out, changes in
system privileges and changes in the setup made in the Tools menu.
The System log accessed by Selecting Tools > Maintenance > Analysis > System
Log.
Chapter 8 - 25
8.8 Power Supervision
8.8.1 Power Supervision Terminals

The AC800M controllers and the FCI modules have same power supervision terminals
named SA and SB as shown in the following drawings.
AC 800M Controllers
Fieldbus Communication Interfaces (FCI modules)
For detailed information about power supervision wiring please refer to chapter
AC800M Hardware. If redundant 24V power supplies are used, then one power supply
should be connected to SA, the other to SB.
Chapter 8 - 26
8.8.2 Power Supervision Alarms

The SA & SB terminals act like two digital inputs and to monitor this signal, the
hardware status word must be checked like for other hardware states.
There is also a Function Block PowerFailureInfos available in the Basic Library,
which provides information on power failure status, such as number and duration. In
addition, the total number of power failures since the last reset and the duration of
these can also be presented.
NOTE! The internal battery must be installed to see the Power

Failure Information.
8.8.3 Fuses on Controller Baseplate

There are two fuses on the AC800M controller’s base plate:
Fuses for
Modulebus and
CEX-bus
CPU Baseplate
Modulebus fuse
When the modulebus fuse is broken, only the Analog Output modules lose power,
while the AI, DI, DO modules are still working.
Chapter 8 - 27
CEX-bus fuse
When the CEX-bus fuse is broken, all Communication Interface modules on the CEX-
bus lose power. There is no communication between CPU and any CI module, while
the IO modules on the Modulebus are still working.
Chapter 8 - 28

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System 800xA training

Chapter 8 Hardware Troubleshooting

Chapter 8 Hardware Troubleshooting ..................................................................................................................................... 1

8.1 General Information

8.1.3 Reference Documentation

8.2 Hardware Status in Control Builder

8.2.1 Hardware Error Indication Icons

The strategy to examine a hardware error or warning is to expand the hardware

8.2.2 Clearing Latched Alarms

Then the icon is cleared:

8.2.3 Unit Status Tab

The data type HWStatus has the following components:

Component name Data type Description

8.3 Hardware Status in Plant Explorer

8.3.1 System Status Viewer

8.3.2 Hardware Editor Aspect

8.3.3 Hardware Alarms

Alarm List shows the

It will call up the Project Explorer in the Control Builder.

8.4 IO Module Diagnostic Flow Chart

How many units display error icons? A

Check error message

Wrong IO Module Unlocked Locked

Analogue IOs Analogue and

Check the Module bus fuse Go to A

8.5 Signal Forcing

8.5.1 How to Force a Digital Output

2. Select the “Status” tab.

8.5.2 How to Force an Analog Output

8.5.3 Forcing Input Signals

8.6 Replacing Hardware

8.6.1 How to Replace PM8xx Battery

8.6.2 How to Replace PM8xx (Single CPU)

NOTE! Without redundancy the process being controlled will

Replace Processor Units complete with Base plates

8.6.3 How to Replace PM8xx (Redundant CPU)

8.6.3.1 Replace without BC810

4. Carefully remove the processor unit.

8.6.3.2 Replace with BC810

8.6.4 How to Replace Modules on the CEX Bus

8.6.5 How to Upgrade CI801 / CI830 Firmware

8.6.5.1 Upgrade CI801 Firmware

2. Set the station address on CI801 to 0.

8.6.5.2 Upgrade CI830 Firmware

Download the Firmware

5. The loading procedure takes approx. 5 minutes.

8.6.6 How to Replace S800 IO Modules

8.6.6.1 How to Replace S800 Terminating Units

1. Carry out steps 1 and 2 of the previous section.

8.6.7 How to Replace S800L IO Modules

8.7.1 Controller Log

NOTE! If you have to report a problem to ABB SupportLine,

8.7.2 System Log

8.8 Power Supervision

8.8.1 Power Supervision Terminals

Fieldbus Communication Interfaces (FCI modules)

8.8.2 Power Supervision Alarms

NOTE! The internal battery must be installed to see the Power

8.8.3 Fuses on Controller Baseplate

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