CJ2 CPU Unit Hardware USER'S MANUAL - Support
Contents
1. Not lit Not lit Not lit None Suspected cause of Confirmation nehod Prevention of recur error rence terminals circuits tions tighten the terminal con e 200 VAC nections Check for disconnections Power is not being Use a tester to measure the volt Turn the power ON Investigate the reason that input age at the input terminals of the again the power was turned 4 Power Supply Unit OFF Q Connection status of e 100 VAC Reconnect and secure Periodically approxi power supply selector Use a tester check for short the terminal connec mately once a year z m O T The voltage is out of Use a tester to measure the volt Correct the power sup Same as at the left the allowable range for age at the input terminals to the ply system for the PLC the power supply Power Supply Unit 1 Power Supply Unit fail Replace the Power Supply Unit Replace the Power Depends on the type of ure and check operation Check Supply Unit error whether the POWER indicator is lit Failure at another Unit Remove in order the Units Replace the failed Unit Depends on the type of mounted in the Rack and check error the POWER indicator P I N I pe 2 Q m m O 2 1 The following table shows the allowable power supply ranges for each Power Supply Unit model Allowable power supply Model Power supply voltage voltage fluctuation CJ1W PA205R PA202_ 100 to 240 VAC 85 to2. inductive noise Prevention of recur rence During operation confirm that the connections are secure Check for vibration or shock Do not do any metal work ing in the vicinity of the control panel Close the control panel Make sure that the operat ing environment is free of dirt and dust Same as at the left CJ2 CPU Unit Hardware User s Manual 6 Troubleshooting i I O Setting Error Fatal Error An I O setting error will occur if the Units that are actually connected do not match the Unit in the regis tered I O tables mation Lit Not lit Flashing A401 10 80E0 Recovery Processing Flow I O setting error Check the location of the error Restart the PLC Use the I O table verification procedure refer to 6 1 5 I O Table Verification to check where the error occurred Turn the power OFF and back ON Is the error cleared w No y Check the Unit eS connections Replace the Unit where the error occurred Restart the PLC Restart the System Error Causes and Remedies Suspected cause of Confirmation method Prevention of recur error rence Faulty connection at Unit Check the insertion atthe Tighten the screws Same as at the left at a connector connector Restart the Unit and check whether the error is cleared Unit failure If restarting the Unit does Replace the applicable Same as at the left not clear the error check Unit w
3. CPU Unit Hardware User s Manual 6 13 o I O gr C Cc gt m oO s10113 Buljpuey 7 1 9 6 Troubleshooting 6 14 Error Causes and Remedies Suspected cause of error The I O Connecting Cable is disconnected Equipment failure e CPU Unit e I O Connecting Cable damage to bus inter face circuit A conductive object has gotten inside Faulty connector contact A foreign object has got ten inside Noise e Data corruption in bus signals e Malfunctioning in bus interface circuit Perform a visual inspec tion and pull on the Cables An I O bus error has pos sibly occurred in the fol lowing cases e f the error is not cleared when the CPU Unit is restarted e f the error occurs fre quently e f the condition improves when the Unit is replaced Check for conductive objects Check for foreign objects in the connector When the CPU Unit is restarted after the recov ery measures the error will either be cleared or will continue to occur Check whether errors become less frequent after the Unit is replaced Reconnect the cables Replace the equipment e CPU Unit e O Connecting Cable Clean the inside of the Unit with an air blower or replace the CPU Unit Replace the Unit or take off the connector and remove the foreign object Take measures against noise Investigate the path of entry e FG e Power lines e I O connecting cable
4. Prevention of recur error rence An error specific to the Refer to the manual for the Same as at the left Same as at the left Unit particular Unit Faulty connection at Unit Check the insertion at the Tighten the screws Check for vibration and at a connector connector Restart the shock Unit and check whether the error is cleared Unit failure If restarting the Unit does Replace the applicable Same as at the left not clear the error check Unit whether the error is cleared by replacing the Unit Noise Restart the CPU Unit and Take measures against Same as at the left e Data corruption in bus check whether the error noise Investigate the signals occurs again after this path of entry e FG e Power lines 6 22 CJ2 CPU Unit Hardware User s Manual 6 Troubleshooting i Special I O Unit Setting Error Non fatal Error A Special I O Unit setting error will occur if a Unit registered in the registered I O tables does not agree with the Unit actually connected in the PLC A Special I O Unit setting error will also occur if a Unit set as a Synchronous Unit in the synchronous operation parameter settings is not actually connected in the PLC or does not support synchronous unit operation mation Lit Lit Flashing A402 02 0500 to A428 to A433 055F The bit corresponding to the Unit for which the error occurred will turn ON Recovery Processing Flow error occurs Synchronous unit operation be
5. the CPU Unit istered I O table again A403 07 ON A checksum error has occurred in the Transfer the routing tables to the CPU Unit routing tables again A403 08 ON A checksum error has occurred in the Transfer the CPU Bus Unit setup again CPU Bus Unit setup EN Additional Information Checksums are used to detect illegal rewriting in a specific area of memory by calculating and comparing sums written to memory in advance to sums during operation When a checksum error is detected by the CJU2H CPU Unit during operation memory is automatically recovered by automatically reading data from flash memory If recovery is not possible an error occurs and operation stops Use any of the following methods to transfer the data again e Use the CX Programmer to download data e Use the automatic transfer at startup function to download data saved on a Memory Card For details refer to the CU series CU2 CPU Unit Software User s Manual Cat No W473 e Use the simple backup function to download data saved on a Memory Card For details refer to 8 3 Simple Backup The CJ2 CPU Unit has built in flash memory for backup When the CPU Unit is restarted data is transferred to memory for calculation and this sometimes enables an error to be cleared 6 16 CJ2 CPU Unit Hardware User s Manual Recovery Processing Flow Memory error Check the error status Implement the remedy Is the error cleared Yes Res
6. up a trap in the ladder Correct the ladder pro Same as at the left extremely large number program to monitor the gram was set for the number of number of repeats repeats of FOR 512 The maximum processing time for an interrupt task will not be stored in A440 if High speed interrupt function is enabled in the PLC Setup 6 12 CJ2 CPU Unit Hardware User s Manual 6 Troubleshooting i I O Bus Error Fatal Error An I O bus error will occur if there is an error in a data transfer between the CPU Unit and a Unit con nected in the Rack mation Not lit Lit A401 10 80C0 to 80C7 A4o4 1 or 80CF 1 The numbers of the slot and Rack where the I O bus error was detected are stored in word A404 POWER Lit 15 08 07 01 C The number of the slot where the error occurred in binary If it cannot be determined OF will be stored The number of the Rack where the error occurred in binary If it cannot be determined OF will be stored Recovery Processing Flow I O bus error occurs Check the error status Restart the PLC a Is the error cleared No Yes Check the error code and error information Turn the power OFF and back ON Check the I O Connecting Cable connections between all Racks Check the Unit installation Restart the PLC Is the error cleared Yes No Replace the Unit or the I O Connecting Cable Restart the PLC Restart the System CJ2
7. 264 VAC CJ1W PD025 24 VDC 19 2 to 28 8 VDC CJ2 CPU Unit Hardware User s Manual 6 7 6 Troubleshooting CPU Standby Errors When a CJ series PLC is turned ON the CPU starts cyclic servicing and enters RUN mode only after all Special I O Units and CPU Bus Units have been detected If the startup mode is RUN or MONITOR mode the CPU will remain on standby until all Units have been detected POWER Error infor mation Lit Not lit Not lit None Recovery Processing Flow CPU standby Check the location of the error Check the connection status Replace the Unit Is the error cleared Yes Restart the System Use the I O table verification procedure refer to 6 1 5 I O Table Verification to check the location where the error occurred Check the connections to the Special I O Units and CPU Bus Units Replace the Unit or remove the Unit and check whether the error is cleared to determine that the Unit that was replaced or removed just before the error was Cleared was the problem No Error Causes and Remedies Suspected cause of error Faulty connection at Unit at a connector Unit failure The remote I O power supply is OFF or there is no terminator for SYSMAC BUS 6 8 Prevention of recurrence Check the insertion at the connector Restart the Unit and check whether the error is cleared Tighten the screws Same as at the left Replace the Unit that
8. 6 Troubleshooting 6 1 6 Types of Errors The type of error that has occurred can be identified by checking the indicators on the front of the CPU Unit and the Power Supply Unit or by using the CX Programmer to check the error status The errors detected by the CPU Unit are listed in the following table For details on errors that are not detected by the CPU Unit refer to 6 3 Non CPU Unit Errors and Rem edies Error name ON OFF a Power supply error CPU Standby CPU reset ore CPU error WDT error USB port communications error RS 232C port communications error Error code stored in es Operation status Operation stops Operation stops e Operation stops n stops Operation continues C Operation continues Cycle time exceeded error time Cycle time exceeded error error mai 0x809F 0x809F Operation stops I O bus error 0x80C0 to Ox80C7 Ox80CE Ox80CF VO setting error VO setting error error Ox80E0 Too many Too many I O points error Too many I O points error error Ox80E1 Unit number ee Ox80E9 9V ee o Rack number C Ox80EA oe See error Ox80F0 Memory error error Ox80F 1 Version error Version error 0x80F2 E Card Transfer Ox80F4 E FALS D error 0xC101 to OxC2FF eae Duplicated refreshing error error Duplicated refreshing error ON Flashing 0x008B Operation continues Basic Basic VO error Basic I O error 0x009A PLC Setup erro
9. corruption SRAM is used for the CPU Unit user memory SRAM is affected by cosmic rays neutrons and naturally occurring radiation so data can become corrupted 6 17 o I O gr C Cc gt m oO s10113 Buljpuey 7 1 9 6 Troubleshooting i Basic I O Error Non fatal Error A basic I O error occurs when there is an error at a Basic I O Unit mation Lit Flashing A402 12 009A A408 1 Error Information 15 08 07 01 L gt Number of slot where the Unit with the error is mounted in binary Number of Rack where the Unit with the error is mounted in binary Recovery Processing Flow Basic I O error occurs Check the location of the error Check the error information A408 Replace the Unit Check the cause of the error and take measures to prevent it from occurring again Restart the System Error Causes and Remedies Suspected cause of Conima on Method Prevention of recur error rence A fuse is burned out Measure the voltage atthe Replace the fuse Check the maximum power supply terminals switching current Check whether 24 V is being supplied Check whether the problem is solved by replacing the fuse The external power supply Measure the voltage atthe Turn ON the power supply Investigate the reason that is OFF disconnected power supply terminals the power was turned Check whether 24 V is OFF being supplied Other errors specific t
10. d Prevention of recur error rence The model of a CPU Bus Check the Units in the Correct the I O table set Same as at the left Unit in the registered I O PLC tings tables is different from the model the Unit actually mounted in the PLC 6 24 CJ2 CPU Unit Hardware User s Manual
11. ence A connector is discon Check the connection at Reconnect the connector Check for vibration and nected the connector shock Battery voltage is low Check whether the erroris Replace the battery Periodically replace the cleared by replacing the For details refer to 7 2 battery Replacing the Battery battery 6 20 CJ2 CPU Unit Hardware User s Manual 6 Troubleshooting i CPU Bus Unit Error Non fatal Error A CPU Bus Unit error occurs when there is an error in the data conversion between the CPU Unit and a CPU Bus Unit mation Flashing A402 07 0200 to O20F A417 The bit corresponding to the unit number where the error occurred turns ON Bits 00 to 15 correspond to unit numbers 0 to F POWER Lit Recovery Processing Flow CPU Bus Unit error Occurs Check the location where the error occurred Restart the PLC Is the error cleared Yes Use the I O table verification procedure refer to 6 1 5 I O Table Verification to check where the error occurred Turn the power OFF and back ON Check the Unit connections o I O gr C Cc gt m oO Replace the Unit where the error occurred Restart the PLC Restart the System s10113 Buljpuey 7 1 9 Error Causes and Remedies Suspected cause of Confirmationtmethod Remedy Prevention of recur error rence An error specific to the Refer to the manual for the Same as at t
12. he left Same as at the left Unit particular Unit Faulty connection at Unit Check the insertion at the Tighten the screws Check for vibration and at a connector connector Restart the shock Unit and check whether the error is cleared Unit failure If restarting the Unit does Replace the applicable Same as at the left not clear the error check Unit whether the error is cleared by replacing the Unit Noise Restart the CPU Unit and Take measures against Same as at the left check whether the error noise Investigate the occurs again path of entry e FG e Power lines e Data corruption in bus signals CJ2 CPU Unit Hardware User s Manual 6 21 6 Troubleshooting i Special I O Unit Error Non fatal Error A Special I O Unit error occurs when there is an error in the data conversion between the CPU Unit and a Special I O Unit ERR ALM Error flag Errorcode Error information POWER RUN Lit Flashing A402 06 0300 to 035F A418 to A423 or OSFF Lit The bit corresponding to the unit number where the error occurred turns ON Recovery Processing Flow Special I O Unit error occurs Restart the Special I O Unit Is the error cleared No Yes Check the Unit connections Replace the Special I O Unit Restart the Special I O Unit Reset or turn the power OFF and back ON Restart the System Error Causes and Remedies Suspected cause of Confirmation method Remedy
13. hether the error is o I O gr C Cc gt m oO s10113 Buljpuey 7 1 9 cleared by replacing the Unit Noise Restart the CPU Unit and Take measures against Same as at the left check whether the error noise Investigate the continues to occur path of entry e FG e Power lines e Data corruption in bus signals CJ2 CPU Unit Hardware User s Manual 6 15 6 Troubleshooting i Memory Error Fatal Error A memory error will occur if there is a memory error in the CPU Unit or if a checksum error is detected checksum checked by the PLC with each cycle The details of the cause of the error will be stored in the error information in the Auxiliary Area mation Lit Not lit A401 15 80F1 A403 1 1 Individual bits in A403 indicate where the memory error occurred Recovery Measures Check the detailed error contents in the error information in the Auxiliary Area and then implement the following recovery measures If these measures cannot solve the problem there is a strong probability that the Unit has failed so replace the Unit Error information Error contents Recovery measures A403 00 ON A checksum error has occurred in the user Transfer the user program to the CPU Unit program memory again A403 04 ON A checksum error has occurred in the PLC Transfer the PLC Setup to the CPU Unit Setup again A403 05 ON A checksum error has occurred in the reg Transfer the I O tables to
14. ing used No o I O gr C Cc gt m oO Yes Check if error is caused by synchronous unit operation settings A428 to A433 will tell you which Unit caused the error Perform the recovery procedure Operation recovered s10113 Buljpuey 7 1 9 Check if error is caused by registered I O settings A428 to A433 will tell you which Unit caused the error Perform the recovery procedure Restart the system CJ2 CPU Unit Hardware User s Manual 6 23 6 Troubleshooting Error Causes and Remedies for Synchronous Unit Operation Settings Suspected cause of Confirmation method Prevention of recur error rence A Unit set in the synchro Check the operation man Transfer the settings Same as at the left nous unit operation set ual for the Unit again tings does not support synchronous unit opera tion A Unit set in the synchro Check the Units in the Transfer the settings Same as at the left nous unit operation set PLC again tings does not exist in the PLC A Unit set in the synchro Check the Units in the Move the Synchronous Same as at the left nous unit operation set PLC Unit to the CPU Rack tings does not exist on the If O tables have been CPU Rack i e it is on an registered change the Expansion Rack registered I O tables Error Causes and Remedies for Registered I O Table Settings Suspected cause of Gonnrmationnieihe
15. ing Cable is incorrectly installed Check the connections Reconnect If the Cable is dis e The IN OUT connectors are reversed the cable connected check e The cable does not have good contact at the for vibration and shock connectors e Two or more I O Control Units are mounted on the CPU Rack or an I O Control Unit is mounted to an Expansion Rack 1 The following table shows the allowable power supply ranges for each Power Supply Unit Allowable power supply Model Power supply voltage voltage fluctuation CJ1W PA205R PA202_ 100 to 240 VAC 85 to 264 VAC CJ1W PD025 24 VDC 19 2 to 28 8 VDC l Precautions for Correct Use Observe the following points when using Expansion Racks e Always confirm the safety of any related equipment before turning the power supply ON or OFF e When the power supply is interrupted to an Expansion Rack the CPU Unit will stop program execution and the same operations as are performed when the power supply to the CPU Unit is interrupted will be performed For example if the power OFF interrupt task is enabled it will be executed If power is then restored to the Expansion Rack the CPU Unit will perform star tup processing The same operational status as existed before the power interrupt will not nec essarily be continued CJ2 CPU Unit Hardware User s Manual 6 9 o I O gr C Cc gt m oO s10113 Buljpuey 1 9 6 Troubleshooting i CPU Errors CPU er
16. is causing the standby the undetected Unit If the error is not cleared remove the Units in order until the status returns to normal e Replace the Special I O Unit or Interrupt Unit for which is displayed when the I O tables are read e Replace the failed Unit Determined by the cause of the failure Check whether the power is turned ON Check the termi nator settings Turn ON the power or set the terminators If the error is not cleared replace the Unit CJ2 CPU Unit Hardware User s Manual 6 Troubleshooting EN Additional Information The CJ2 CPU Units support the following function e Startup Condition Setting After the power supply is turned ON it is possible to start operation of the CPU Unit in RUN mode or MONITOR mode even if there is one or more Units that has not completed startup Select the Start running program when initializing Unit Inner board recognition Check Box in the PLC Setup For details refer to the CU series CJ2 CPU Unit Software User s Manual Cat No W473 p CPU Reset The CPU Unit is being reset and Programming Devices cannot be connected mation Lit Not lit Not lit None Error Causes and Remedies Suspected cause of error Confirmation method ai Power to an Expansion Rack is OFF Use a tester to measure Turn ON the Investigate the the voltage at the input reason that the terminals of the Power power was OFF Supply Unit 1 The I O Connect
17. o Refer to the manual for the Same as at the left Same as at the left Units particular Unit 6 18 CJ2 CPU Unit Hardware User s Manual 6 Troubleshooting i Option Board Errors An Option Board error will occur if the Option Board is removed while the power is being supplied mation Lit Lit Flashing A315 13 00D1 A402 00 Recovery Processing Flow Restart the PLC No Yes Check the Unit connections o I O gr C Cc gt m oO Replace the Option Board Restart the PLC Restart the System Error Causes and Remedies Suspected cause of Confirmation method Prevention of recur error rence s10113 Buljpuey Z 9 The Option Board was Check the mating of the Reconnect Check for vibration and removed while the system Option Board connector shock was operating Option Board failure If restarting does not clear Replace the Option Board Same as at the left the error check whether the error is cleared by replacing the Option Board CJ2 CPU Unit Hardware User s Manual 6 19 6 Troubleshooting i Battery Error Non fatal Error A battery error occurs when the battery voltage drops mation Lit Flashing A402 04 00F7 7 Recovery Processing Flow Battery error occurs Check the battery connections No Restart the System Error Causes and Remedies Suspected cause of Confiimation method Prevention of recur error r
18. r PLC Setup error error 0x009B ee a Option Board error error 0x00D1 Backup memory error memory error OxOOF 1 Tag memory error 3 memory error Tag memory error 3 Ox00F2 N ee System work errors errors Ox00F3 wn O Battery error error 0x00F7 CPU Bus Unit error 0x0200 to g 0x020F Cc S Special I O Unit error 0x0300 to Ox035F Ox03FF CPU Bus Unit ceil error 0x0400 to Ox040F FAL a error 0x4101 to Ox42FF a I O Unit setting 0x0500 to ee Ox055F 1 The indicator status is the same for CPU errors and fatal errors but they can be distinguished because a Programming Device can be connected when a fatal error occurs but not when a CPU error occurs 2 For details on fatal errors and non fatal errors refer to A 3 Fatal and Non fatal Error Details 8 CJ2H CPU6L1 EIP only Note The indicator status shows the status of the errors that have occurred in RUN or MONITOR mode 6 6 CJ2 CPU Unit Hardware User s Manual 6 Troubleshooting 6 1 7 Handling Errors This section describes the measures to take for the errors that most commonly occur First check the error status Then make a preliminary determination of the cause of the error confirm the cause cor rect the error and take measures to ensure that it will not occur again For all other errors refer to A 3 Fatal and Non fatal Error Details i Power Supply Errors A power supply error occurs when a voltage of 5 V is not output from the Power Supply Unit mation
19. r supply to the CPU Unit is interrupted will be performed For example if the power OFF interrupt task is enabled it will be executed If power is then restored to the Expansion Rack the CPU Unit will perform startup processing The same operational status as existed before the power interrupt will not neces sarily be continued 6 10 CJ2 CPU Unit Hardware User s Manual 6 Troubleshooting i Communications Error Peripheral USB Port A communications error will occur if there is an error in communications between the peripheral USB Port and a connected device POWER RUN ERR ALM PRPHL COMM Error flag Error code Error information Lit Lit Not lit Not lit Not lit None Error Causes and Remedies Suspected cause of ConA on method Prevention of recur error rence The communications Perform a visual inspec Reconnect the cables During operation confirm cable is disconnected tion and pull on the cables that the connections are secure Check for vibration or shock i Communications Error Serial Port RS 232C A communications error will occur if there is an error in communications between the serial RS 232C port and a connected device POWER RUN ERR ALM PRPHL COMM Error flag Error code Error information Lit Lit Not lit Not lit Not lit None Error Causes and Remedies Suspected cause of Gennmatonmethoe Prevention of recur error rence Communications set Check whe
20. rors are error that occur in the CPU Unit itself A CPU error occurs when the WDT watchdog timer times out Programming Devices cannot be connected when a CPU error occurs Error Causes and Remedies EER ake zi Confirmation method Unit failure A CPU error has possibly occurred Replace the CPU Unit in the following cases If the error is not cleared when the CPU Unit is restarted after the recovery measures If the error occurs frequently If the condition improves when the Unit is replaced A conductive object Check for conductive objects Clean the inside of the has gotten inside Unit with an air blower or replace the CPU Unit Noise When the CPU Unit is restarted Take measures against e The microcomputer after the recovery measures the noise Investigate the inside the CPU Unit error will either be cleared or will path of entry is malfunctioning continue to occur Check whether FG errors become less frequent after He e Power lines the Unit is replaced 4 Precautions for Correct Use Prevention of recur rence Same as at the left Do not do any metal working in the vicinity of the control panel Close the control panel Same as at the left e Always confirm the safety of any related equipment before turning the power supply ON or OFF e When power supply is interrupted to an Expansion Rack the CPU Unit will stop program exe cution and the same operations as are performed when the powe
21. tart the System Error Causes and Remedies If the measures described above do not clear the error take the measures shown in the following table Suspected cause of error Unit failure e Memory element failure e Memory peripheral cir cuit failure A conductive object has gotten inside Noise e Data corruption in mem ory e Microcomputer malfunc tioning e Memory write circuit malfunctioning Software error CJ2 CPU Unit Hardware User s Manual Replace the CPU Unit A memory error has prob ably occurred in the follow ing cases e f the error is not cleared when the CPU Unit is restarted after the recovery measures If the error occurs fre quently If the condition improves when the Unit is replaced Check for conductive objects When the CPU Unit is restarted after the recov ery measures the error will either be cleared or will continue to occur Check whether errors become less frequent after the Unit is replaced Replace the Unit Clean the inside of the Unit with an air blower or replace the CPU Unit Take measures against noise Investigate the path of entry e FG e Power lines 6 Troubleshooting Prevention of recur rence Determined by the cause of the failure Do not do any metal work ing in the vicinity of the control panel Close the control panel Same as at the left None None None 1 This refers to errors caused by data
22. ther the DIP e Correctly set DIP switch Same as at the left tings are incorrect switch pin 5 setting and pin 5 and the serial port and the serial port settings settings in the PLC Setup in the PLC Setup are cor e Correct the host computer rect serial port settings and the If a host computer is con program nected check the host computer serial port set o I h O y C Cc gt m Oo s10113 Buljpuey 9 tings and the program A communications Check the cable connec Correct the cable connec Same as at the left cable is incorrectly tions tions connected A communications Perform a visual inspection Reconnect the cables During operation confirm cable is disconnected and pull on the cables that the connections are secure Check for effects of vibration or shock CJ2 CPU Unit Hardware User s Manual 6 11 6 Troubleshooting i Cycle Time Exceeded Error Fatal Error Cycle Time Exceeded Error A cycle time exceeded error will occur if the PLC cycle time exceeds the setting for Watch Cycle Time in the PLC Setup mation Lit Not lit A401 08 809F None Error Causes and Remedies Suspected cause of Contirmaton method Prevention of recur error rence An interrupt task with a Check the Max Interrupt Divide the interrupt task Same as at the left long processing time was Task Processing Time into sections executed A440 An incorrect value an Set
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