Chapter 11 TROUBLESHOOTING
Contents
1. flickering during operation ERR LED goes flickering Check the error code with connected GMWIN See App 2 System Warning Flag and remove the cause of the error Is ERR Led stil flickering Write down the Troubleshooting questionnaires and contact the nearest service center REMARK Though CNF WAR appears PLC system doesn t stop but corrective action is needed promptly If not it may cause the system failure 11 0 Chapter11 Troubleshooting 11 2 3 Troubleshooting flowchart used when the RUN turns off The following flowchart explains corrective action procedure to treat the lights out of RUN LED when the power is supplied operation starts or operation is in the process RUN LED is off Tum the power unit off and on Is RUN LED off Contact the nearest service eerie Complete 1 0 Chapter11 Troubleshooting 11 2 4 Troubleshooting flowchart used when the 1 0 part doesn t operate normally The following flowchart explains corrective action procedure used when the I O module doesn t operate normally SWITCHI SWITCH2 SOLI pi C3 su When the I O module doesn t work normally Is the indicator LED of the SOL1 on Measure the voltage of power supply in SOL1 Replace the connector of the Check the status of SOLI terminal board by GMWIN it normal condition YES Correct wiring Is the terminal connector connector a2. blinking device correct the contents Complete 1 0 Chapter 11 Troubleshooting 11 3 Troubleshooting Questionnaire When problems have been met during operation of the GM7 series please write down this Questionnaires and contact the service center via telephone or facsimile e For emors relating to special or communication modules use the questionnaire included in the User s manual of the unit Telephone amp FAX No Tell FAX Using equipment model Details of using equipment CPU model OS version No Serial No GMWIN version No used to compile programs General description of the device or system used as the control object 5 The kind of the base unit Operation by the mode setting switch Operation by the GMWIN or communications Extemal memory module operation 6 Is the ERR LED of the CPU module tumed ON Yes No s 7 GMWIN eror message 8 Used initialization program initialization program 9 History of corrective actions for the error message in the article 7 10 Other tried corrective actions 11 Characteristics of the error e Repetitive Periodic Related to a particular sequence _ Related to environment e Sometimes General error interval 12 Detailed Description of enor contents 13 Configuration diagram for the applied system 1 0 Chapter 11 11 4 Troubleshooting Examples Possible troubles with various circ
3. Chapter11 Troubleshooting Chapter 11 TROUBLESHOOTING The following explains contents diagnosis and corrective actions for various errors that can occur during system operation 11 1 Basic Procedures of Troubleshooting System reliability not only depends on reliable equipment but also on short downtimes in the event of faults The Short discovery and corrective action is needed for speedy operation of system The following shows the basic i nstructions for troubleshooting 1 Visual checks Check the following points e Machine operating condition in stop and operating status Power On Off Status of 1 0 devices e Condition of wiring I O wires extension and communications cables e Display states of various indicators such as POWER LED RUN LED ERR LED and I O LED Afte r checking them connect peripheral devices and check the operation status of the PLC and the prog ram contents 2 Trouble Check Observe any change in the eror conditions during the following e Switch to the STOP position and then tum the power on and off 3 Narrow down the possible causes of the trouble where the fault lies i e e Inside or outside of the PLC e 1 0 module or another module e PLC program 11 2 Troubleshooting This section explains the procedure for determining the cause of troubles as well as the errors and corrective actions e Flowchart used when the POWER LED is tumed OFF C Flowchart used when the ERR LED is flickering D Flowc
4. Error code list Dperation ERR LED Diagnosis Restart Cause Corrective action wipes j status lickering cych time mode Contact the A S center if it reactively occurs when When power 2 OS ROM error Defect 0 4 sec the power is re applied iS applied Contact the A S center if it reactively occurs when When power 3 OS RAM error Defect 0 4 sec the power is re applied iS applied Contact the A S center if it reactively occurs when When power IC RTC error Defect 0 4 sec i the power is re applied s applied Contact the A S center if it reactively occurs when When power Fault processor Defect 0 4 sec the power is re applied is applied Contact the A S center if it reactively occurs when When power Program memory fault l Defect 0 4 sec l the power is re applied s applied Contact the A S center if it reactively occurs when When power 7 Data memory fault l Defect 0 4 sec l the power is re applied s applied Watch dog error due to RE ap 10 Re apply the power Reset During run Cold the power Replace the battery if it has error check the p rogram a3 When power rogram after cc loading it and if an error is detected STOP 0 4 sec Cold emory backup error iS applied replace the CPU module Change into Correct the memory module program and re emory module program fault STOP 0 4 sec the RUN Cold operate the system mode Change into An normal program Re load the program and start it STOP 0 4 sec the RUN Cold mo
5. an completes 1 m m ra 1100
6. common temina DC input e Use only one power supply e Connect a sneak current prevention diode DC input Chapter 11 Troubleshooting e E1 gt E2 sneaked 1 0 0 Chapter 11 Troubleshooting 11 4 2 Output circuit troubles and corrective actions The following describes possible troubles with input circuits as well as their corrective actions When the output is off excessive voltage is applied to the load The load doesnt tum off When the load is C R type timer time constant fluctuates The load does not tum off Cause eLoad is halfwave rectified inside in some cases it is true of a solenoid eWhen the polarity of the power supply is as shown in C is charged When the polarity is as shown in the voltage charged in C plus the line voltage are applied across D Max voltage is approx 2V 2 If a resistor is used in this way it does not pose a problem to the output element But it may nake the performance of the diode 0 which is built in the load drop to cause problems e Leakage current by surge absorbing circuit which is connected to output element in parallel e Leakage current by surge absorbing circuit which is connected to output element in parallel e Sneak current due to the use of two different power supplies E1 lt E2 sneaks E1 is off E2 is on sneaks 1 0 0 Corrective Action e Connect registers of tens to hundreds KQ across the load in parallel e C
7. de N w Module type inconsistency error Inconsistency between the Change into Refer to the flags IO TYER IO_TYER_N specified modules by parameters i STOP 0 4 sec the RUN Cold I1O0_TYER n and correct the in corrective slot and and the loaded modules mode restart the system Module mounting dismounting error Module dismounting or additional Refer to the flags IO DEER _IO_DEER_N When scan Sis or 3 STOP 0 4 sec Cold mounting during run _IO_DEER n and correct the in corrective slot completes and restart the system Fuse disconnection error l l Refer to the flags FUSE ER FUSE_ER_N When scan Fuse disconnection during run STOP 0 4 sec Cold FUSE_ER n and correct the in corrective slot and completes restart the system When scan 1 0 module read write error completes Abnormal I D module data access Refer to the flags _SP_IFER _IP_IFER_N STOP 0 4 sec During Cold during run _IP_IFER n and restart the system execution of program 1100 w pen w Chapter11 Troubleshooting ERR LED i Operation 3 Diagnosis Restart Corrective action Flickering status l time mode cycle When power is applied Special link module interface error When scan Abnormal special link module data Refer to the flags _SP_IFER _IP_IFER_N 0 4 sec completes Cold access during run _IP_IFER n and restart the system During execution of program During run Scan
8. hartused when the RUN tumed OFF owchart used when the output load of the output module perly doesn ttum on Program cannot be writen gt lowchart used when a program can tbe written to the PLC 1 0 TI nm Chapter11 Troubleshooting 11 2 1 Troubleshooting flowchart used when the POWER LED turns OFF The following flowchart explains corrective action procedure used when the power is supplied or the power led tums off during operation Power LED is tumed OFF Is the power supply operating Supply the power No Yes No Yes Does the power led tum on No See the power supply be within AC 110 240 V Does the power led tum on Yes Replace the fuse No Is the voltage within the rated power Yes Is the fuse blown No Does the power led tum on No Connect the power cable correctly Yes Is the power supply cable connected Yes No Does the power led tum on Yes Over current protection device 1 Eliminate the excess current activated 2 Switch the input power OFF then ON Yes Write down the troubleshooting qu Does the power led tum on estionnaire and contact the near est service center Complete 11 0 Chapter11 Troubleshooting 11 2 2 Troubleshooting flowchart used when the ERR LED is flickering The following flowchart explains corrective action procedure use when the power is supplied starts or the ERR LED is
9. onnect C and R across the load which are of registers of tens KQ When the wiring distance from the output module to the load is long there may be a leakage current due to the line capacity e Drive the relay using a contact and drive the C R type timer using the since contact e Use other timer than the C R contact some timers have halfware rectified intemal circuits therefore be cautious 7 Timer e Use only one power supply e Connect a sneak current prevention diode If the load is the relay etc connect a counter electromotive voltage absorbing code as shown by the dot line Chapter 11 Troubleshooting Output circuit troubles and corrective actions continued The load off Over current at off state The large solenoid current Insert a small L R magnetic contact and drive the load response time fluidic load L R is large such as is directly driven with using the same contact is long the transistor output Output e The off response time can be delayed by one or more second as some loads make the current flow across the diode at the off time of the transistor output Output Surge current of the white lamp e To suppress the surge current make the dark current transistor is of 1 3 to 1 5 rated current flow destroyed Output Output a ee A surge current of 10 times or more when tumed on Sink type transistor output Source type transistor output 1 0 0 Chapter 11 Troubleshooting 11 5
10. ppropriate Is the voltage of power supply for ae applied Is the output wiring correct YES eparate the external wiring than check the condition of output module Continue YES s it normal condition Check the status of SOLI Replace the Unit 11 0 Chapter 11 Troubleshooting Are the indicator LED of the switch 1 and 2 on Check the status of the switch 1and 2 Check the status of the switch 1and 2 Is the terminal screw tighten securely Is input wiring correct Is input wiring correct s the condition of the terminal board connector appropriate YES Is input wiring correct Separate the external witch then check the status of input by fora Retighten the Replace the terminal D Correct wiring terminal screw board connector Correct the wiring Unit replacement is heck the status the needed switch 1and 2 Unit replacement is Check from the beginning needed 11 0 Chapter 11 Troubleshooting 11 2 5 Troubleshooting flowchart used when a program cannot be written to the CPU part The following flowchart shows the corrective action procedure used when a program cannot be written to the PLC module Program cannot be written to the PC CPU Switch to theremote STOP mode Is the mode setting switch set the re and execute the program write mote STOP After reading error code by using peripheral Is ERR LED
11. time over than Check the scan delay time specified by parameters During the scan delay time specified by and correct the parameters or the program and 0 4 sec execution of Cold parameters then restart the program During Unreadable instructions in the user Re load the program and restart it 0 4 sec execution of Cold program Refer to the extemal device fatal error Flag When scan External device fatal error ANNUN_ER ANC _ERR n and correct the fault 0 4 sec Cold completes devices and then restart the system l Correct the program so that the error elements that During The E_STOP function has been invoked the E STOP function can be eliminated in execution of executed the program and restart the system cold restart program If the number of computer 4 communications Communications module ae f When power Soe module is included then adjust the maximum 0 4 sec Cold configuration error ne is applied number with in 8 Special Communications module Adjust the number of high speed communications T When power Gai sec 0 initialization failure modules loaded is applied When power iS applied Data memory backup error If the batter has no error When scan completes When power If the battery has no error reset the time using the iS applied 501 RTC data error 2 sec SMWIN When scan completes When power Replace the battery which the power is being iS applied Lower battery voltage 4 sec applied When sc
12. uits and their corrective actions are explained Troubleshooting 11 4 1 Input circuit troubles and corrective actions The followings describe possible troubles with input circuits as well as corrective actions Input signal Leakage current of extemal device Such as a drive by non contact switch doesn ttum off AC input Extemal device Input signal Leakage current of extemal device doesn ttum off Drive by a limit switch with neon lamp Neon lamp AC input may be still on R Extemal device Input signal Leakage current due to line capacity of doesn ttum off wiring cable AC input Extemal device Input signal Leakage current of extemal device Drive by switch with LED indicator DC input doesn ttum off Extemal device Input signal e Sneak current due to the use of two doesn ttum off different power supplies DC input 1 0 Corrective Actions e Connect an appropriate register and capacity which will make the voltage lower across the terminals of the input module AC input e CR values are determined by the leakage current value Recommended value C 0 1 0 47 R 47 120 Q 12W Or make up another independent display circuit e Locate the power supply on the external device side as shown below AC input Extemal device e Connect an appropriate register which will make the voltage higher than the OFF voltage across the input module terminal and
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