Chapter 8 - AutomationDirect
Contents
1. Use arrow keys to select point then use Y2 is now on ON and OFF to change the status Y 10 lt lt SHFT Ne E o From a blank display use the following lid fill indicat int i keystrokes to force Y7 ON Solid fill indicates point is on Y SHFT ie H SHFT ae BIT FORCE Y7 E From a blank display use the following No fill indicates point is off keystrokes to force Y7 OFF SHFT Yis H 2 SHFT a BIT FORCE 7 DL105 PLC User Manual 3rd Edition2. shows location in question Syntax OK display NO SYNTAX ERROR See the Error Codes Section for a complete listing of programming error codes If you get an error just press CLR and the Handheld will display the instruction where the error occurred Correct the problem and continue running the Syntax check until the NO SYNTAX ERROR message appears DL105 PLC User Manual 3rd Edition Maintenance and Troubleshooting Special There are several instructions that can be used to help you debug your program Instructions during machine startup operations e END e PAUSE e STOP END Instruction If you need a way to quickly disable part of the program just insert an END statement prior to the portion that should be disabled When the CPU encounters the END statement it assumes that is the end of the program The following diagram shows an example Normal Program New END disables X10 and Y1 XO X2 ao XO X2 YO co GZ X1 X3 X4 X1 X3 X4 1 1 1 1 X10 Y1 CD m eD ve X10 Y1 v Ca z ED e oG PAUSE Instruction This instruction provides a quick way to allow the inputs or 52 other logic to operate while disabling selected outputs The output image register is E 3 still updated but the output circuits are not For example you could make this SF conditional by adding an input contact or
3. Bad entry E502 Bad address E503 Bad command E504 Bad reference value E624 V memory only E625 Program only E627 Bad write operation E628 Memory type error should be EEPROM E640 Mis compare E506 Invalid operation E650 E520 Bad operation CPU in Run E524 Bad operation CPU in Program E505 Invalid instruction Handheld Programmer system error E651 Handheld Programmer ROM error E652 Handheld Programmer RAM error DL105 PLC User Manual 3rd Edition Maintenance and Troubleshooting Program Error The following table lists program syntax and runtime error codes Error detection Codes occurs during a Program to Run mode transition or when you use AUX 21 Check Program The CPU will also turn on SP52 and store the error code in V7755 Appendix B provides a more complete description of the error codes Error Code Description Error Code Description E4 No Program in CPU E452 X input used as output coil E401 Missing END statement E453 Missing T C E402 Missing LBL E454 Bad TMRA E406 Missing IRT E455 Bad CNT E421 Duplicate stage reference E456 Bad SR E422 Duplicate SBR LBL reference E461 Stack Overflow E431 Invalid ISG SG address E462 Stack Underflow E436 Invalid INT address E463 Logic Error E438 Invalid IRT address E464 Missing Circuit E440 Invalid Data Address E471
4. CR to control the instruction with a switch or ke a programming device Or you could just add the instruction without any conditions S so the selected outputs would be disabled at all times Normal Program PAUSE disables YO and Y1 X0 X2 YO Yo Y1 C Pause X1 X3 X4 XO X2 pe X10 Y1 s 2 X1 X3 X4 2 Ze X10 ee Eno D nd STOP Instruction Sometimes during machine startup you need a way to quickly turn off all the outputs and return to Program Mode You can use the STOP instruction When this instruction is executed the CPU automatically exits Run Mode and enters Program Mode Remember all outputs are turned off during Program Mode The following diagram shows an example of a condition that returns the CPU to Program Mode DL105 PLC User Manual 3rd Edition Maintenance and Troubleshooting 8 13 Normal Program STOP puts CPU in Program Mode XO X2 YO X10 GA Cro X1 X3 A xo x2 Yo X5 f Y1 2 x1 X3 X4 C2 1 1 gt X5 Y1 n o a GD In the example shown above you could trigger X10 which would execute the STOP instruction The CPU would enter Program Mode and all outputs would be turned off Duplicate You can also check for multiple uses of the same output coil Both programming Reference Check devices offer a way to check for this condition For example you can AUX 21 CHECK PROGRAM to check for duplicate references from a Handheld Programmer o
5. all appropriate safety precautions prior to testing any I O points o 2 oT Handheld BD Programmer Eno 33 ey stones Used Xo X2 XS X7 Y2 Insert an END statement 2 t9 Test an Output C p at the beginning of the a Point x1 x3 X4 program This disables 1 1 the remainder of the 5 program Eno From a clear display use the following keystrokes 16P STATUS STAT ENT BIT REF Use the PREV or NEXT keys to select the Y data type A Y 10 Y 0 NEXT 0 ENT Use arrow keys to select point then use ON and OFF to change the status ON lt lt SHFT NS DL105 PLC User Manual 3rd Edition Maintenance and Troubleshooting Noise Troubleshooting Electrical Noise Problems Reducing Electrical Noise o gt Z E oo OO Fofa ow 52 Faj g5 we pos Ske xo C 40 Noise is one of the most difficult problems to diagnose Electrical noise can enter a system in many different ways and they fall into one of two categories conducted or radiated It may be difficult to determine how the noise is entering the system but the corrective actions for either of the types of noise problems are similar Conducted noise is when the electrical interference is intro
6. maa TANN Bit Forcing with Direct Access you need the capability to force an I O point to be either on or off Before you use a programming device to force any data type it is important you understand how the DL105 CPUs process the forcing requests WARNING Only authorized personnel fully familiar with the application should make program changes Do thoroughly consider the impact of any changes to minimize the risk of personal injury or damage to equipment Bit Forcing Bit forcing temporarily changes the status of a discrete bit For example you may want to force an input on even though the program has turned it off This allows you to change the point status stored in the image register The forced value will be valid until the CPU writes to the image register location during the next scan This is useful you just need to force a bit on to trigger another event The following diagrams show a brief example of how you could use the i our D2 HPP Handheld Programmer to force an I O point The example assumes you co have already placed the CPU into Run Mode From a clear display use the following keystrokes 16P STATUS STAT ENT BIT REF X Use the PREV or NEXT keys to select the Y data type Once the Y appears press 0 to start at YO A an Y 10 Y 0 NEXT 0
7. Duplicate coil reference E441 ACON NCON E472 Duplicate TMR reference E451 Bad MLS MLR E473 Duplicate CNT reference SsoUeUAIUle D 5 a 4 fe E e D n gt fe fe 5 amp DL105 PLC User Manual 3rd Edition 8 6 Maintenance and Troubleshooting CPU Indicators o gt ome OO kofa OO ae To es oo SF ko c os PWR Indicator The DL105 Micro PLCs have indicators on the front to help you diagnose problems with the Fal system In normal runtime operation only the RUN and PWR indicators are on The table below is a OM V7 quick reference to potential problems Indicator Status Potential Problems ii PWR LED off 1 System voltage incorrect I ig P GPU 2 PLC power supply faulty NCICALOIS RUN LED off 1 CPU programming error x a a 2 CPU in program mode El or CPU LED on 1 Electrical noise interference Bi 2 Internal CPU defective sels 5 In general there are three reasons for the CPU power status LED PWR to be OFF 1 Power to the unit is incorrect or is not applied 2 PLC power supply is faulty 3 Other component s have the power supply shut down If the voltage to the power supply is not correct the PLC may not operate properly or may not operate at all Use
8. Maintenance and Troubleshooting In This Chapter Hardware System Maintenance Diagnostics CPU Indicators Communications Problems O Point Troubleshooting Noise Troubleshooting Machine Startup and Program Troubleshooting Maintenance and Troubleshooting Hardware System Maintenance Standard No regular or preventative maintenance is required for this product there are no Maintenance internal batteries however a routine maintenance check about every one or two months of your PLC and control system is good practice and should include the following items e Air Temperature Check the air temperature in the control cabinet so the operating temperature range of any component is not exceeded e Air Filter If the control cabinet has an air filter clean or replace it periodically as required e Fuses or breakers verify that all fuses and breakers are intact e DL105 Air Vents check that all air vents are clear If the exterior case needs cleaning disconnect the input power and carefully wipe the case using a damp cloth Do not let water enter the case through the air vents and do not use strong detergents because this may discolor the case Diagnostics Diagnostics Your DL105 Micro PLC performs many pre defined diagnostic routines with every CPU scan The diagnostics can detect various errors or failures in the PLC The two primary error classes are fatal and non fatal Fatal Errors Fat
9. Or not equal STR STRN Store greater than or equal Store less than AND ANDN And greater than or equal And less than DL105 PLC User Manual 3rd Edition Maintenance and Troubleshooting 8 15 We ll use the program logic shown to de scribe how this process works In the ex xo x1 Yo ample we ll change XO to C10 Note the example assumes you have already placed the CPU in Run Mode CO Use the MODE key to select Run Time Edits MODE CHANGE MODE NEXT NEXT ENT RUN TIME EDIT Press ENT to confirm the Run Time Edits Note the RUN LED on the D2 HPP MODE CHANGE Handheld starts flashing to indicate RUNTIME EDITS Run Time Edits are enabled Find the instruction you want to change X0 je SHFT A SHFT FD REF a En e 00000 STR X0 cz o 2 c3 So Press the arrow key to move to the X Then enter the new contact C10 22 gt gt suet C B A RE RUNTIME EDIT 2 co STR C10 Press ENT to confirm the change ent Note once you press ENT the next address is displayed OR CO DL105 PLC User Manual 3rd Edition 8 16 Maintenance and Troubleshooting Forcing I O Points There are many times especially during machine startup and troubleshooting that D Z oo exe ac ow 52 Fa esa we pa Sk ke 40 wee
10. al errors are errors which may cause the system to function improperly perhaps introducing a safety problem The CPU will automatically switch to Program Mode if itis in Run Mode Remember in Program Mode all outputs are turned off If the fatal error is detected while the CPU is in Program Mode the CPU will not allow you to transition to Run Mode until the error has been corrected Some examples of fatal errors are e Power supply failure e Parity error or CPU malfunction e Particular programming errors o gt Z E oo OO Fofa ow 52 Faj es we pos s ke C 40 Non fatal Errors Non fatal errors are errors that need your attention but should not cause improper operation They do not cause or prevent any mode transitions of the CPU The application program can use special relay contacts to detect non fatal errors and even take the system to an orderly shutdown or switch the CPU to Program Mode if desired An example of a non fatal error is e Particular programming errors Finding Diagnostic The programming devices will notify you of an error if one occurs while online Information e DirectSOFT provides the error number and an error message e The handheld programmer displays error numbers and short descriptions of the error Appendix B has a complete list of error messages in order by error number Many error messages point to supplemental V memory locations which contain related information Special relays SP conta
11. cts also provide error indications DL105 PLC User Manual 3rd Edition Maintenance and Troubleshooting V memory Error The following table names the specific memory locations that correspond to certain Code Locations types of error messages Error Class Error Category Diagnostic V memory User Defined Error code used with FAULT instruc V7751 tion System Error Fatal Error code V7755 Major Error code V7756 Grammatical Address where syntax error occurs V7763 Error Code found Error Code found during syntax check syntax check v7764 o CPU Scan ee of scans since last Program a to Run Mode transition Current scan time ms scan time ms V7775 o Maximum scan time i V7777 Special Relays SP The special relay table also includes status indicators which can indicate errors For 5 Corresponding to a more detailed description of each of these special relays refer to Appendix D a Error Codes E ca So BD CPU Status Relays Accumulator Status Relays a3 SP12 Terminal Run mode SP60 Acc is less than value a SP16 Terminal Program mode SP61 Acc is equal to value SP20 STOP instruction was executed SP62 Acc is greater than value SP22 Interrupt enabled SP63 Acc result is zero System Monitoring Relays SP64 Half borrow occurred SP40 Critical error SP65 Borrow occurred SP41 Non critical error SP66 Half carry occurred SP44 Program memory error SP67 Carry oc
12. curred SP50 Fault instruction was executed SP70 Result is negative sign SP51 Watchdog timeout SP71 Pointer reference error SP52 Syntax error SP73 Overflow SP53 Cannot solve the logic SP75 Data is not in BCD SP76 Load zero DL105 PLC User Manual 3rd Edition o gt c T oo OO Fofa ow a Faj es we pos s Oo a 40 Maintenance and Troubleshooting DL105 Micro PLC These errors can be generated by the CPU or by the Handheld Programmer Error Codes depending on the actual error Appendix B provides a more complete description of the error codes The errors can be detected at various times However most of them are detected at power up on entry to Run Mode or when a Handheld Programmer key sequence results in an error or an illegal request Error Description Error Description Code Code E003 Software time out E526 Unit is offline E004 Invalid instruction E527 Unit is online RAM parity error in the CPU E528 CPU mode E099 Program memory exceeded E540 CPU locked E151 Invalid command E541 Wrong password E155 RAM failure E210 Power fault E542 Password reset E601 Memory full E312 Communications error 2 E602 Instruction missing E313 Communications error 3 E604 Reference missing E316 Communications error 6 E620 Out of memory a nine eu E621 EEPROM Memory not blank Egel Communicauons errar E622 No Handheld Programmer EEPROM E501
13. duced into the system by way of a attached wire panel connection etc It may enter through an I O circuit a power supply connection the communication ground connection or the chassis ground connection 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 While electrical noise cannot be eliminated it can be reduced to a level that will not affect the system 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 If a ground is not available install a ground rod as close to the system as possible 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 can act as a large antenna introducing noise into the system Therefore tighten all connections in your system Loose ground wires are more susceptible to noise than the other wires in your system Review Chapter 2 Installation Wiring and Specifications if you have questions regarding how to ground your system Electrical noise can enter the system through the power source for the PLC and O circuits Installing an isolation transformer for all AC sources can correct this problem DC sources should be well grounded good quality supplies Separate input wiring from output wiring Never
14. lace the unit if you have a spare However if you suspect a field device is defective that device may cause the same failure in the replacement PLC as well As a point of caution you may want to check devices or power supplies connected to the failed I O circuit before replacing the unit with a spare o gt Z E oo OO Fofa ow 52 Faj g5 we pos s ke C 40 DL105 PLC User Manual 3rd Edition Maintenance and Troubleshooting Ea Testing Output Output points can be set on or off in the DL105 series CPUs If you want to do an I O Points check out independent of the application program follow the procedure below Step Action 1 Use a handheld programmer or DirectSOFT32 to communicate online to the PLC 2 Change to Program Mode 3 Goto address 0 Insert an END statement at address 0 This will cause program 4 execution to occur only at address 0 and prevent the application pro gram from turning the I O points on or off 5 Change to Run Mode 6 Use the programming device to set turn on or off the points you wish to test When you finish testing I O points delete the END statement at address 0 WARNING Depending on your application forcing I O points may cause ped J 2 unpredictable machine operation that can result in a risk of personal injury or 2 kon equipment damage Make sure you have taken
15. r you can use the PLC Diagnostics menu option within DirectSOFT The following example shows how to perform the duplicate reference check with a Handheld Programmer sed os Use AUX 21 to perform syntax check Jg Oe c3 cir S P Aux ent AUX 21 CHECK PRO 0 1 SYN 2 DUP REF gs OQ Oo Select duplicate reference check a 5 enr You may not get the busy BUSY display if the program is not very long One of two displays will appear 00024 E471 Error Display example ae DUP COIL REF shows location in question NO DUP REFS Syntax OK display If you get an error just press CLR and the Handheld will display the instruction where the error occurred Correct the problem and continue running the Duplicate Reference check until no duplicate references are found pataa NOTE You can use the same coil in more than one location especially in programs containing Stage instructions and or OROUT instructions The Duplicate Reference check will find occurrences even though they are acceptable DL105 PLC User Manual 3rd Edition fe c o oO OO kofa va es To esa oo SF D Z S Maintenance and Troubleshooting Run Time Edits The DL105 Micro PLC allows you to make changes to the application program during Run Mode These edits are not bumpless Instead CPU scan is momentarily interrupted and the ou
16. run low voltage I O wiring close to high voltage wiring DL105 PLC User Manual 3rd Edition Maintenance and Troubleshooting 8 11 Machine Startup and Program Troubleshooting The DL105 Micro PLCs provide several features that can help you debug your program before and during machine startup This section discusses the following topics which can be very helpful e Program Syntax Check e Duplicate Reference Check e Special Instructions e Run Time Edits e Forcing I O Points Syntax Check Even though the Handheld Programmer and DirectSOFT provide error checking during program entry you may want to check a program that has been modified Both programming devices offer a way to check the program syntax For example you can use AUX 21 CHECK PROGRAM to check the program syntax from a Handheld Programmer or you can use the PLC Diagnostics menu option within DirectSOFT This check will find a wide variety of programming errors The following example shows how to use the syntax check with a Handheld Programmer Use AUX 21 to perform syntax check c B AUX 21 CHECK PRO CLR 2 1 AUX ENT 1 SYN 2 DUP REF SaoueUdIUle Select syntax check default selection o 2a 4 fe Cc a fo o gt fe fe a 5 Co You may not get the busy display BUSY if the program is not very long One of two displays will appear Error Display example 00050 E401 MISSING END
17. s a fatal error If a fatal error has occurred the CPU LED should be on You can use a programming device to determine the cause of the error Both of the programming devices Handheld Programmer and DirectSOFT will return an error message describing the problem Depending on the error there may also be an AUX function you can use to help diagnose the problem The most common programming error is Missing END Statement All application programs require an END statement for proper termination A complete list of error codes can be found in Appendix B If the CPU indicator is on a fatal error has occurred in the CPU Generally this is not a programming problem but an actual hardware failure You can power cycle the system to clear the error 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 introduced 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 error or if the problem returns you should replace the CPU Communications Problems 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
18. t shorted or open output points If you suspect one or more faulty points 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 ora transistor must be considered A point which is off may appear to be on if no load is connected the point e The I O point status indicators are logic side indicators This means the LED which indicates the on or off status reflects the status of the point with respect to the CPU On an output point the status indicators could be operating normally while the actual output device transistor triac etc could be damaged With an input point if the indicator LED is on the input circuitry is probably operating properly Verify the LED goes off when the input signal is removed e Leakage current can be a problem when connecting field devices to an I O point 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 20KQ resistor will work Verify the wattage rating of the resistor is correct for your application e Because of the removable terminal blocks on the DL105 the easiest method to determine if an I O circuit has failed is to rep
19. the correct baud rate 9600 baud 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 PLC has a bad communication port and should be replaced For problems in communicating with DirectSOFT on a personal computer refer to the DirectSOFT manual It includes a troubleshooting section that can help you diagnose PC problems in communications port setup address or interrupt conflicts etc DL105 PLC User Manual 3rd Edition Bunooussjqnoiy pue SOUBUSIUIe 8 8 Maintenance and Troubleshooting I O Point Troubleshooting Possible Causes If you suspect an I O error there are several things that could be causing the problem e High Speed I O configuration error e A blown fuse in your machine or panel the DL105 does not have internal I O fuses e A loose terminal block e The auxiliary 24 VDC supply has failed e The Input or Output Circuit has failed Some Quick Steps When troubleshooting the DL105 Micro PLCs there are a few facts you should be aware of These facts may assist you in quickly correcting an I O problem e HSIO configuration errors are commonly mistaken for I O point failure during program development If the I O point in question is in XO X3 or YO Y2 check all parameter locations listed in Chapter 3 that apply to the HSIO mode you have selected e The output circuits cannot detec
20. the following guidelines to correct the problem WARNING To minimize the risk of electrical shock always disconnect the system power before inspecting the physical wiring 1 First disconnect the external power 2 Verify that all external circuit breakers or fuses are still intact 3 Check all incoming wiring for loose connections If you re using a separate termination block check those connections for accuracy and integrity 4 lf the connections are acceptable reconnect the system power and verify the voltage at the DL105 power input is within specification If the voltage is not correct shut down the system and correct the problem 5 If all wiring is connected correctly and the incoming power is within the specifications the PLC internal supply may be faulty The best way to check for a faulty PLC is to substitute a known good one to see if this corrects the problem The removable connectors on the DL105 make this relatively easy If there has been a major power surge it is possible the PLC internal power supply has been damaged If you suspect this is the cause of the power supply damage consider installing an AC line conditioner to attenuate damaging voltage spikes in the future DL105 PLC User Manual 3rd Edition RUN Indicator CPU Indicator 8 7 Maintenance and Troubleshooting 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 ha
21. tputs are maintained in their current state until the program change is complete This means if the output is off it will remain off until the program change is complete If the output is on it will remain on WARNING Only authorized personnel fully familiar with all aspects of the application should make changes to the program Changes during Run Mode become effective immediately Make sure you thoroughly consider the impact of any changes to minimize the risk of personal injury or damage to equipment There are some important operational changes during Run Time Edits 1 If there is a syntax error in the new instruction the CPU will not enter the Run Mode 2 Ifyou delete an output coil reference and the output was on at the time the output will remain on until it is forced off with a programming device 3 Input point changes are not acknowledged during Run Time Edits So if you re using a high speed operation and a critical input comes on the CPU may not see the change VA OZD TNR Not all instructions can be edited during a Run Time Edit session The following list shows the instructions that can be edited Mnemonic Description Memorie Description SG STR STAN AND ANDN And And not ORO Oracoes _ Output accumulator to discrete points CMPD Compare accumulator constant STRE STRNE Store equal Store not equal ANDE ANDNE And equal And not equal ORE ORNE Or equal
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