Chapter 7 - P2 Maint and TroubleshootinR1b.indd
Contents
1. 1 1 81 Module Status Bit Port 4H MST 0 1 1 82 Module Status Bit Port 4P CE o a OA ld DI 0 1 2 1 Discrete Input F a DI 0 1 2 2 Discrete Input DI 0 1 2 3 Discrete Input DI 0 1 2 4 Discrete Input DI 0 1 2 5 Discrete Input DI 0 1 2 6 Discrete Input DI 0 1 2 7 Discrete Input DI 0 1 2 8 Discrete Input DO 0 1 3 1 Discrete Output DO 0 1 3 2 Discrete Output DO 0 1 3 3 Discrete Output E IGEEEG0 00006 IBGE S DO 0 1 3 5 71 14 l P roductivi 2000 Hardware User Manual Ist Edition Rev A Chapter 7 Maintenance and Troubleshooting i There are three columns within the Tag database that affect the forcing of all tags 1 Forceable Checking the box in this column identifies the corresponding tag as being able to be forced within the system 2 Init Forced Checking the box in this column identifies that corresponding tag as being forced as soon as the project is loaded and the processor is switched to Run mode 3 Init Force Value The state of the box in this column identifies the initial forced state of the Boolean tag e A check mark in a box equates to a logic2. fed to the Digital Output DO 0 1 3 1 c Edits written to the contact or the coil from the Data View window within the software will be written one time and will not be forced With the clock pulse driving the contact any software edits made to this contact will be allowed but will be overwritten by the logic on the very next scan Any software edits made to the output will not be allowed and will not register Edits can only change the state of the output if there are no other logistic or outside factors influencing the output In order to change the state of Logical Contactl or Digital Output DO 0 1 3 1 while the clock pulse is driving it a force must be introduced The DO 0 1 3 1 Output Edit line d represents edits sent to the digital output from the Data View window The DO 0 1 3 1 Output Force Enabled line e shows the point at which the software forces the output edit to take effect The dotted lines represent the force being enabled and then disabled by the user When the force is enabled any edits made will register at the output regardless of Logical Contactl s state When the force is disabled all output edits will be ignored Lag ical Contact D 01531 c w 1 18 i Productivity2o0 Hardware User Manual 1st Edition Rev A
3. module a power supply connection the communication ground connection or the chassis ground connection e Radiated noise is when the electrical interference is introduced into the system without a direct electrical connection much in the same manner as radio waves Reducing Electrical Noise While electrical noise cannot be eliminated completely it can be reduced to a level that will not affect system function Proper grounding of components and signal wiring along with proper isolation of voltages can minimize noise in the system 1 Grounding e Most noise problems result from improper grounding of the system A good earth ground can be the single most effective way to correct noise problems Ifa ground is not available install a ground rod as close to the system as possible e Ensure all ground wires are single point grounds and are not daisy chained from one device to another Ground metal enclosures around the system A loose wire is no more than a large antenna waiting to introduce noise into the system therefore you should tighten all connections in your system Loose ground wires are more susceptible to noise than the other wires in your system Review Chapter 5 Installation and Wiring if you have questions regarding how to ground your system 2 Isolation e Electrical noise can enter the system through the power source for the CPU and I O Installing an isolation transformer for all AC sources can correct this
4. project being transferred For more information refer to the Options topic in the help file Productivity200 Hardware User Manual 1st Edition Rev A f 1 13 Chapter 7 Maintenance and Troubleshooting B Forcing I O Points Following is a description of the actions expectations and indications of forcing a value in the Productivity2000 controller Advantages of Forces Almost all tags can be written to in the software without Forcing However if the ladder logic or an external device operator interface panel Modbus device etc is connected to your controller and writing to those tags the values you write from a Data View will be over written Conversely if you write a Forced value this will not be overwritten or reset until you manually remove the force or reset by means of a Stop to Run mode transition a Stop Mode Transfer or a controller power cycle Enabling Forces The Productivity2000 CPU is a Tag based controller where forcing a tag begins by identifying any tag you wish to be Forceable within the Tag database lt enter text gt lt enter text gt lt enter text gt lt enter text gt Type Mod Start Comment Remot MST 0 1 1 65 Module Status Bit Port 3H MST 0 1 1 66 Module Status Bit Port 3P MST 0 1 1 67 Module Status Bit Port 3P MST 0 1 1 68 Module Status Bit Port 3C MST 0
5. the base connector as follows 1 Turn off power to the base 2 Remove a module from the base 3 Reapply power to the base 4 Check for power supply normal operation 5 Repeat procedure until defective module is found and replaced Device A 5V charge may be originating from the base or CPU communications port Test as follows 1 Turn off power to the CPU 2 Disconnect all external devices i e communication cables from the CPU 3 Reapply power 4 If power supply operates normally then check for a shorted device or shorted cable 7 6 Productivity2ov Hardware User Manual 1st Edition Rev A Chapter 7 Maintenance and Troubleshooting n IG Run Indicator If the CPU will not enter the Run mode the RUN indicator is off the problem is usually in the application program unless the CPU has a critical error If a critical error has occurred the CPU LED should be on You can use a programming device to determine the cause of the error A complete list of error codes can be found in Appendix B CPU Indicator If the CPU indicator is on a critical error has occurred in the CPU Generally this is not a programming problem but an actual hardware error The CPU indicator should blink briefly and then do an automatic reboot If the error clears you should monitor the system and determine what caused the problem You will find this problem is sometimes caused by high frequency electrical noise intro
6. A WARNING To minimize the risk of electrical shock always disconnect the system power before inspecting the physical wiring 2 If you are using a separate termination panel check those connections to make sure the wiring is connected to the proper location 1 First disconnect the system power and check all incoming wiring for loose connections EA 3 If the connections are acceptable reconnect the system power and measure the voltage at the base terminal strip to ensure it is within specification If the voltage is not correct shut down the system and correct the problem 4 If all wiring is connected correctly and the incoming power is within the specifications required the base power supply should be returned for repair Faulty CPU There is no simple test for a faulty CPU other than substituting a known good one to see if this corrects the problem If you have experienced major power surges it is possible the CPU and power supply have been damaged If you suspect this is the cause a line conditioner should be installed on the incoming line This will keep damaging voltage spikes from reaching the CPU Productivity2000 Hardware User Manual 1st Edition Rev A f 17 5 Chapter 7 Maintenance and Troubleshooting B PWR Indicator cont d Device or Module Causes the Power Supply to Shutdown Module If the PWR LED is operating normally but the power supply shuts down check each module for a possible bent pin on
7. Forceable tab of the Data View window as shown in the previous view 2 You will also see CPU Data Forced in Red in the lower right of the Status bar of your software interface MATH N Generator Result 40532 0 1 5 1 GEN Ramp Genera 0 se Scale Linear Formula oa SCL Scale Non Linear UM Selected Summation SW Switch STA Array Statistics SIMPLE COUNTER CPA Copy Array Current Value A0532 0 1 5 1 0 FLA Fill Array Done A0532 0 1 5 2 1 Sha Shift Rotate Array PEELS 7 CNT Counter SCNT Simple Counter STME Simple Timer ME Timer mW gt CPU USB 2 0 P2 550 Project File Status NotSaved CPUProject Status UptoDate Run Time Transfer Available EN NOTE Only Forced tags with an initial force value specified in the Tag database will be retained after a Stop to Run transition Stop Mode transfer or a power cycle All forced values are retained during a Run Time transfer Productivity2000 Hardware User Manual 1st Edition Rev A f 7 17 Chapter 7 Maintenance and Troubleshooting sss ee Force Value Timing Chart The chart below shows how the states of a Digital Output are varied when forces and edits are applied The ladder rung at the top of the chart a shows the logical arrangement of Logical Contactl and Digital Output DO 0 1 3 1 Under normal operation Logical Contact b is driven by a clock pulse This clock pulse is then
8. MAINTENANCE AND TROUBLESHOOTING In This Chapter Hardware Maintenance sseeseesesessesssossossesesossesecsscssecsecsecoseesecessossosecoseoseeseceseesee 7 2 Diano ES gases enesuten E E EE A cance case eyeresnuenese 7 3 CPU INOLA OIS age crc cs cop E E EE 7 4 PR IOCAN aE EE EEE A EEE EEE EE E 7 5 ROR IOIO sarn E A E E E OOOO 7 7 CPU MCC AOU perior r E ENEA EO EE EEEE EEEE 7 7 Communications Problems ssssscesssssesrsirasirisiririsisicndsis sta idi sisene osts r srir NENESE EPONE r Enni 7 7 I O Module Troubleshooting ccssesisersvesencccsancesasaveonsdcostsaebabsos ace eaasaesepanamesenaseenwaxennasaess 7 8 Noise TEOUDICSHOOUING sissien ESNE AERE a 7 10 Run Time vs Stop Mode Transfer INstruction ccescecessceeesceeessceeesceeesseeees 7 11 POR CUI TO POMS oerien e E 7 14 Chapter 7 Maintenance and Troubleshooting B Hardware Maintenance Standard Maintenance The Productivity2000 is a low maintenance system requiring only a few periodic checks to help reduce the risks of problems Routine maintenance checks should be made regarding two key items e Air quality cabinet temperature airflow etc e CPU battery Air Quality Maintenance The quality of the air your system is exposed to can affect system performance If you have placed your system in an enclosure check to see that the ambient temperature is not exceeding the operating specifications If there are filters in the enclosure clean or replac
9. al 1 or ON and e An unchecked box equates to a logical 0 or OFF The value placed in this field for Integer or Floating point tags will be written into the tag Forcing Tags in Your System All forcing of tags can be accomplished through the Data View window or directly in the sA Faffa E E a NEEN Data View 1 Tagname Modbus 7 Value Edit Force Tag Data Type View As Comment i a E S DO 0 L 3 2 Discrete Output DO 0 1 3 3 Discrete Output CPU in Run Boolean System Re On during Run Conveyor Run Boolean Reset Boolean poson oooga program interface while in Monitor mode as long as the Forceable box has been checked in Tag Database I O may also be directly forced in I O View by clicking on individual I O points Productivity2000 Hardware User Manual 1st Edition Rev A f 7 1 5 Chapter 7 Maintenance and Troubleshooting E From the DataView Window enter the tags you wish to force or you can view all forceable tags from the Forceable Tags tab automatically created for you when you enable tags as forceable in the tag database Tag Data Type Module Status Bit Module Status Bit Module Status Bit Discrete Input Discrete Input Discrete Input Discrete Input Discrete Output Discrete Output Discrete Output Discrete Output Analog Output Inte Analog Output Inte Analog Output Inte Analog Output Inte Modu
10. duced into the CPU from an outside source Check your system grounding and install electrical noise filters if the grounding is suspected If power cycling the system does not reset the 7 error or if the problem returns you should replace the CPU Communications Problems If a communication error occurs the indicator will come on and stay on until a successful communication has been completed If you cannot establish communications with the CPU check these items e The cable is disconnected e The cable has a broken wire or has been wired incorrectly e The cable is improperly terminated or grounded e The device connected is not operating at the correct baud rate e The device connected to the port is sending data incorrectly e A grounding difference exists between the two devices e Electrical noise is causing intermittent errors e The CPU has a bad communication port the CPU should be replaced Productivity2000 Hardware User Manual 1st Edition Rev A f 7 7 Chapter 7 Maintenance and Troubleshooting eee sss I O Module Troubleshooting Things to Check If you suspect an I O error there are several things that could be causing the problem e A blown fuse e A loose terminal block e The 24 VDC supply has failed e The module has failed e The I O configuration check detects a change in the I O configuration Error Codes See Appendix B for Productivity2000 error code information Also in the Productivity Suit
11. e them as necessary to ensure adequate airflow A good rule of thumb is to check your system environment every one to two months Make sure the Productivity2000 is operating within the system operating specifications CPU Battery Replacement A battery is included with the CPU but is not installed The battery can be installed to retain the Time and Date along with any Tagname values that are set up as retentive The battery is not needed for program backup Step One i Step Two Press spring lock Insert battery and and swing battery ra close compartment compartment away from CPU Battery Optional Coin type 3 0V Lithium D2 BAT 1 battery 560mA battery number CR2354 Take care to insert battery behind metal tab 7 2 Productivi 2000 Hardware User Manual Ist Edition Rev A Chapter 7 Maintenance and Troubleshooting n I Diagnostics Diagnostics Your Productivity2000 system performs many pre defined diagnostic routines with every CPU scan The diagnostics have been designed to detect various types of failures for the CPU and I O modules There are two primary error classes critical and non critical Critical Errors Critical errors are errors the CPU has detected that offer a risk of the system not functioning safely or properly If the CPU is in Run Mode when the critical error occurs the CPU will switch to Stop Mode Remember in Stop Mode all outputs are turned off If the critical err
12. e programming software you can go to Tools gt CPU Error History and Tools gt CPU Event History Next click on CPU Error or Event History tab to get an updated list of critical errors non critical errors and event history that should indicate problems or changes to the I O This list will give the GBS group base slot numbers Some Quick Steps When troubleshooting the Productivity2000 I O modules there are a few facts you should be aware of which may assist you in quickly correcting an I O problem e The output modules cannot detect shorted or open output points If you suspect one or more points on a output module to be faulty you should measure the voltage drop from the common to the suspect point Remember when using a Digital Volt Meter leakage current from an output device such as a triac or a transistor must be considered A point which is off may appear to be ON if no load is connected to the point The I O point status indicators on the modules are logic side indicators This means the LED which indicates the ON or OFF status reflects the status of the point in respect to the CPU For an output module the status indicators could be operating normally while the actual output device transistor triac etc could be damaged With an input module if the indicator LED is ON the input circuitry should be operating properly To verify proper functionality check to see that the LED goes off when the input s
13. er 7 Maintenance and Troubleshooting oS CPU Indicators The Productivity2000 CPU has indicators on the faceplate to help diagnose problems with the system The table below gives a quick reference of potential problems associated with each status indicator The pages following the table contain a detailed analysis of each of these indicator problems Indicator Status Potential Problems 1 System voltage is incorrect 2 Power supply CPU is faulty 3 Other components such as an 1 0 module has power supply shorted 1 CPU programming error 2 switch in STOP position CPU blink CPU internal error PWR off RUN will not come on CPU Status Indicators Green LED is illuminated when power is on Green LED is illuminated when CPU is in RUN mode Red LED is illuminated during power on reset power down or watch dog time out 7 4 l Productivity2ov Hardware User Manual 1st Edition Rev A Chapter 7 Maintenance and Troubleshooting n I PWR Indicator There are three general reasons for the CPU power status LED PWR to be OFF 1 Power to the base is incorrect or is not applied 2 Base power supply is faulty 3 Other component s have the power supply shut down Incorrect Base Power If the voltage to the power supply is not correct the CPU and or base may not operate properly or may not operate at all Use the following guidelines to correct the problem
14. hdittrich Documents P3 New Test adpro oi Exit Productivity2000 Hardware User Manual 1st Edition Rev A f 71 l1 Chapter 7 Maintenance and Troubleshooting eee ee sss Run Time Transfers Run Time Transfer allows the user to transfer edits to a project in the CPU without stopping the CPU scan therefore not stopping the process Be aware that a Run Time Transfer will affect the length of your scan time which should be considered if your process is susceptible to varying or lengthy scan times The download time is longer compared to a Stop Mode transfer During a Run Time transfer the current project file continues running until the entire project file is transferred to the CPU Once downloaded the ladder logic files swap and begin executing the new file The Tag Database is shared between the two project files during a Run Time transfer therefore current operating values will not be effected Because the Tag database is shared any edits to the Tag database will force a Stop Mode transfer Stop Mode Transfers Run time transfer is not available Do you want to perform stop mode transfer Note that stop mode transfer will put CPU in stop mode before transfer and back to run mode after transfer Cancel Stop Mode Transfers allows the user to transfer any and all ladder Tag Database and configuration changes to the CPU Because the CPU is in stop mode the project transfer is much faster than a Run T
15. ignal is removed Leakage current can be a problem when connecting field devices to I O modules False input signals can be generated when the leakage current of an output device is great enough to turn on the connected input device To correct this install a resistor in parallel with the input or output of the circuit The value of this resistor will depend on the amount of leakage current and the voltage applied but usually a 10K to 20K resistor will work Ensure the wattage rating of the resistor is correct for your application The easiest method to determine if a module has failed is to replace it if you have a spare However if you suspect another device to have caused the failure in the module that device may cause the same failure in the replacement module as well As a point of caution you may want to check devices or power supplies connected to the failed module before replacing it with a spare module 7 8 Productivity2o0 Hardware User Manual 1st Edition Rev A Chapter 7 Maintenance and Troubleshooting n IE Testing Output Points Output points can be set ON or OFF using the force function to override a point even while the program is running However this is not a recommended method to test the output points If you want to do an I O check independent of the application program follow the procedure in the table below Action Use Productivity Suite programming software to communicate online to the CPU Change
16. ime Transfer and also loads all initial values to the tags once the project is switched from Stop to Run Following are conditions that will force the user to perform a Stop Mode Transfer 1 Any changes to the hardware configuration such as A Adding or removing hardware B Changing the configuration of a piece of hardware e Ethernet or serial port configuration e Hot swap enable or disable on any module or base C Adding an EhterNet IP device and any configured changes 2 Adding gt 5000 tags of any type Excluding Strings and Structures NOTE This limit is accumulated between each stop mode transfer 3 Adding gt 50 000 characters or changing the length of a String data type Tag NOTE This limit is accumulated between each stop mode transfer 1 1 2 i Productivity2o0 Hardware User Manual 1st Edition Rev A 4 Changes to Data Logger Chapter 7 Maintenance and Troubleshooting 5 Changes to Modbus Server settings under Project Properties 6 Changes to the buffer size for a FILI instruction 7 Adding gt 5 000 elements of a Structures data type to Tag Database NOTE This limit is accumulated between each stop mode transfer 8 Enabling Bit of Word under Project Properties 9 Enabling Structures in Project Properties 10 Enable and Disable of EhterNet IP Adapter As the CPU goes from Stop to Run after a Stop Mode Transfer tags are initialized as if the project is being executed for the fi
17. le Status Bit Module Status Bit Discrete Output Discrete Output Discrete Output Discrete Output Discrete Output Discrete Output Discrete Output Discrete Output Discrete Output MST 0 1 1 81 MST 0 1 1 82 MST 0 1 1 83 DI 0 1 2 1 DI 0 1 2 2 DI 0 1 2 3 DI 0 1 2 4 Was_DO 0 1 3 1 Was_DO 0 1 3 2 Was_DO 0 1 3 3 Was_DO 0 1 3 4 AOQS32 0 1 5 2 AOQS32 0 1 5 3 AOQS32 0 1 5 4 AOQS32 0 1 5 6 MST 0 1 5 26 MST 0 1 5 25 ES DO 0 1 3 15 DO 0 1 3 14 DO 0 1 3 13 DO 0 1 3 12 DO 0 1 3 11 DO 0 1 3 10 DO 0 1 3 9 DO 0 1 3 8 pooooogooooogpogogo0na sonoonnofas poooooooasaon HEBER E pooooooasgsooa OER From either of these windows you have the option to select the check box in the Force column When this box is checked and the row is selected selected rows show high lighted blue and you select the Send Edit s button the current row s will be forced NOTE You can select multiple rows by clicking and holding down the left mouse button and dragging up or down This selects consecutive rows If you wish to select various rows simple hold the Ctrl control key on your keyboard while left mouse clicking the rows 1 16 i P roductivity200 Hardware User Manual 1st Edition Rev A Chapter 7 Maintenance and Troubleshooting Identifying Forced Values There are two indications that forces are active on your controller 1 All active forces will be shown in the
18. or is detected while the CPU is in Stop Mode the CPU will not enter Run Mode until the error has been corrected Here are some examples of critical errors e Base power supply failure e Parity error or CPU malfunction e I O configuration errors e Certain programming errors Non Critical Errors Non critical errors are flagged by the CPU as requiring attention They can neither cause the CPU to change from Run Mode to Stop Mode nor do they prevent the CPU from entering Run Mode There are system tags the application program can use to detect if a non critical error has occurred The application program can be used to take the system to an orderly shutdown or to switch the CPU to Stop Mode if necessary Some examples of non fatal errors are e Backup battery voltage low e All I O module errors e Certain programming errors Finding Diagnostic Information The CPU automatically logs critical and non critical error codes Logged errors can be found in the following places marked with a time and date stamp e Displayed on OLED of the CPU module by scrolling through the menu e Under the Monitor Debug tool of ProductivitySuite in the CPU Error History window the 20 most recent critical and non critical errors are listed Error Codes See Appendix B Productivity2000 Error Codes for a complete list of error messages sorted by error types Productivity2000 Hardware User Manual 1st Edition Rev A f 7 3 Chapt
19. problem e DC power sources should be well grounded good quality power supplies Switching DC power supplies commonly generate more noise than linear supplies e Separate input wiring from output wiring Never run I O wiring close to high voltage wiring 7 10 l Productivi 2000 Hardware User Manual Ist Edition Rev A Chapter 7 Maintenance and Troubleshooting ees Run Time vs Stop Mode Transfer Instruction Here we describe the actions and differences between Run Time amp Stop Mode transfers as shown in this dialog box Select Transfer Type Which type of transfer do you want to perform Note that stop mode transfer will put CPU in stop mode before transfer and back te run mode after transfer The above dialog is accessed two ways only when CPU is online AND in run mode Perform either of the following to transfer project to the CPU 1 Click on the To CPU icon on the Tool Bar or gj Compile Project HB To CPU 2 Click through from the File menu gt Transfer Project gt To CPU New Project E Open Project Close Project H Save Project Ctrl S Save Project As Import i Export To Compile Project age Setup From CPU tri Page Setup From CPU Ctrl F9 Transfer Project to CPU Print Ctrl P hi To Removable Media Project Properties Pd From Removable Media C Users hdittrich Documents P 2 New Test adpro C Users
20. rst time This includes Retentive Tags If it s desirable that the values of Retentive Tags be retained through a Stop Mode Transfer there are two methods available Both options may be enabled and they can be found under Tools gt Options gt Project Transfer 1 Upload current retentive values and copy to initial values This option works during program upload When selected place the CPU in Stop Mode so Retentive Tag values are stable then upload the project Productivity Suite will copy the current value of all Retentive Tags to their Initial Values in the Tag Database of the project Perform your edits and transfer the project back to the CPU When the CPU goes back to run your Retentive Tags will be initialized with their old values This is a simple process and is convenient for quick edits to the program but the CPU must remain in Stop Mode while the project is edited to ensure that no retentive values have changed during editing Transfer Project from CPU Options Upload current retentive values and copy to initial values Transfer Project to CPU Options Transfer documentation instruction and ladder rung comments Transfer GS drive configuration Copy current retentive tag values to initial values 2 Copy current retentive tag values to initial values This option works during program download This process is more involved but the CPU will use the values from the project currently running as the initial values of the
21. to Program Mode Go to the first rung of the ladder Insert a rung with an END statement This will cause program execution to occur only at address 0 and prevent the application program from turning the 1 0 points on or off Change to Run Mode Use the programming device to set turn on or off the points you wish to test When you finish testing 1 0 points delete the END statement at the first rung operation that can result in a risk of personal injury or equipment damage Make sure you have taken all appropriate safety precautions prior to testing any 1 0 points WARNING Depending on your application forcing 1 0 points may cause unpredictable machine 7 NOTE The LED on Analog I O modules displays actual voltage current and digital values without connecting a meter Productivity2000 Hardware User Manual 1st Edition Rev A f 7 9 Chapter 7 Maintenance and Troubleshooting pc Ml Noise Troubleshooting Electrical Noise Problems Noise is one of the most difficult problems to diagnose Electrical noise whether conducted or radiated can enter a system in many different ways It may be difficult to determine how the noise is entering the system but the corrective actions for either type of noise problem are similar e Conducted noise is when the electrical interference is introduced into the system by way of an attached wire panel connection etc It may enter through an I O
Download Pdf Manuals
Related Search