Series Five Programmable Controller User`s Manual, GFK
Contents
1. the CPU Write down the DIP switch settings to ensure that the settings on the new CPU are the same Remove the CPU from its slot by loosening the two captive screws and pulling the module away from its backplane connectors 4 Install the new CPU module and tighten the two captive screws Ensure that the DIP switch settings are correct for your operation and verify that the CPU backup battery is properly installed 6 Reconnect any cables you may have removed to the CCM port connectors on the CPU 7 Apply power and verify system operation Replacing a Memory Cartridge 1 Place the CPU mode switch in the STOP position Turn off AC or DC power as applicable to the power supply 2 Open the top hinged door on the front of the CPU to gain access to the memory cartridge Remove the memory cartridge by grasping the top of the plastic strip at the point marked PULL then pull it towards you The cartridge will slide out of its slot CAUTION Do not remove or insert a memory cartridge with power on Handle RAM memory cartridges with care since excess charges of static electricity could damage the memory devices in the cartridge Install the new memory cartridge by orienting the cartridge so that the word PULL is towards the top of the CPU then slide the cartridge carefully into the guides in the slot until it firmly plugs into the connector at the back of the slot Tum on AC or DC power2. CPU Battery Low Replace CPU battery within one week Duplicate I O Address Error Reassign addresses and do a STORE TO CPU I O Address Range Error Correct user logic and store program again I O Bus Error Cycle from STOP to RUN or reset CPU with reset switch or Recycle power or replace base unit or device on bus Key in NEW CONFIG or OLD CONFIG command from LMS or edit I O map and do a STORE TO CPU or return to previous I O configuration See Table 5 2 in this chapter for further information With power off replace module Or edit I O map and STORE TO CPU Cycle from STOP to RUN or reset CPU with reset switch or cycle power Replace base unit or device on I O bus Replace memory cartridge battery within one week Connect or install back up battery in CPU Install battery in memory cartridge I O Config Changed I O Error I O Module Removed I O Parity Error Memory Battery low NO CPU BATTERY NO Battery in memory cartridge No Memory Cartridge Error Program Error Program Parity Error Watchdog Timer Timed Out With power off install memory cartridge Check user program correct error and store program again Store program again Cycle power Check user logic or increase Watchdog Timer preset value Table 5 2 Special Purpose Contact Bit Definition e 11 0033 Critical System Error 1 error CPU goes to
3. CPU with MC installed that contains only system parameter data Attempt to run CPU with a memory car tridge that contains register data Copy operation to CPU MC in Menu 7 failed because cartridge is write protect ed E101 NO CPU MC Insert memory cartridge into CPU E102 MC HOLDS SYS DATA Replace with a program memory car tridge E103 MC HOLDS REG DATA Replace with a program memory car tridge Reconfigure the jumper in memory car tridge to the write enable position If problem still exists replace memory cartridge Change register reference E104 WRITE FAILED E150 REG REF TOO LARGE Register reference larger than maximum register size Parity check detects error in program stored on the CPU memory cartndge Rung too complex to execute E151 BAD COMMAND Rewrite the invalid code to correct the logic Change logic to have fewer stack levels E152 PROG STACK OVERFLOW Maintenance 5 7 GFK 0122 Table 5 5 Error Code Definitions Operator Interface Unit Continued Action to Clear Errar E2XX DIAG ERROR MENU _ An I O diagnostic error has been reported Use sub menu 41 or visual inspection to 42 to the CPU determine the type of error and take cor rective action Error can be one or more of errors E201 to E262 Use sub menu 41 or visual inspection to find module location With power off tighten terminal block or install new ter
4. Install a RAM or EEPROM cartridge in the CPU or insert the EPROM memory cartridge in the OIU to copy data E627 BAD WRITE Reconfigure the memory cartridge jumper to the write enable position E640 MISCOMPARE Data mismatch detected while performing Clear the OIU or CPU memory cartridge a verification in sub menu 73 or 79 as applicable and retry the copy opera tion 5 10 Maintenance GFK 0122 Table 5 5 Error Code Definitions Operator Interface Unit Continued Action to Clear Error F641 VOLUME LEVEL Cassette recorder volume level set too Readjust volume level and repeat opera high or too low when in sub menu 77 tion 78 or 79 Checksum error when copying between cassette tape and OIU or external com puter and OIU CPU detected an unknown op code value during execution of a program instruc tion E642 CHKSUM ERROR Repeat operation after clearing the OIU memory cartridge or other medium where appropriate E650 MACHINE CODE Press CLR key If problem persists reload program or provide more protec tion from electrical noise or other inter ference for CPU Press CLR key and repeat operation If problem persists replace the OIU E651 SYSTEM ROM Checksum error exists in OIU ROM E652 SYSTEM RAM Checksum error exists in OIU RAM Press CLR key and repeat operation If problem persists replace the O
5. Use correct syntax parameters Check target source and all interconnects Verify target information Check and reload program Error Code Current I O configuration is different than the one stored in the memory cartridge I O address duplicated when assigned manually I O address in user logic exceeds valid address range Specified target address is not an intelligent module Invalid ID specified for intelligent module target Syntax error present in command parameters Timeout when communicating with target No information obtained from target device Translated program error Table 5 5 Error Code Definitions Operator Interface Unit Action to Clear Error E003 S W TIMEOUT CPU scan time was greater than software Set longer software watchdog sub menu watchdog timer 54 or change ladder logic Low voltage on CPU back up battery Replace CPU battery Cat No IC655ACCS550 Install or reconnect CPU battery Copy program to another memory car tridge and replace battery IC655ACC549 Install battery in memory cartridge E041 CPU BATTERY LOW E042 NO CPU BATTERY E043 CPU MC BATTERY LOW Missing or disconnected CPU battery Low voltage on CMOS RAM memory cartridge battery E044 NO MC BATT Missing CMOS RAM memory cartridge battery Attempt to access CPU MC when it is not installed Attempt to run
6. at a n S gt oo 4 0 Jd ae a E 4 as E en 2 O 4 Oo Q E a y ul v T am 5 EI 5 g OE a a 2 3 3 23 8 4 z B By g da E 4 pug b3 23 S O 3 ear 2 1 py Gu O 2 q e s 28 ig ap sE Fa pa a 2 2858 8 8 38 s 28 58 dl o y gel FE e g z amp y 22 SP E E 325 gg g E y 0 cl T s i Bo 33 26 y Sie Ep pE 3 T RE Ge 8B Sag p g ES EE 58 2835 TA Bu 482828 2ps FE E t G mm E a 0 ERa HE f 3 0 D o e Q Q El 50d pp fp PBS FEZ Az Go SE we 2 a 0 r 532 BB 26h BRS 288 lt 2 22 48 t t I 1 a 0 i 8 1 0 t A e Ef E sk z Ez E zE ze ze i 3 0 600 6 6 O 060 00 00 Es A pe av 5 213 fr T m El S iy 5 c g 8 C1 O ez Pe 4 4 tem fond U a E E o lt E j O O pal gt p A pond A K e Au 4 Q A A m O PIE oe a For detailed error de re Maintenance 5 GFK 0122 Error Definition and Action Required The LEDs on the CPU are a good troubleshooting aid When combined with the capabilities of the programmer with Logicmaster 5 or when using the Series Five Operator Interface Unit you can quickly troubleshoot the majority of system errors that may occur The following table lists the errors that may be detected by the CPU Two tables are found in this section the first lists the error codes definitions and corrective actions when using Logicmaster 5 software and the second table lists error codes and messages cause of error and corrective actions when using the O
7. minal block on module Use sub menu 41 or visual inspection to determine module type and location of missing module With power off in stall module and secure to base unit Use sub menu 41 or visually find module type and location With power off re place fuse or module Adjust voltage correct fault or replace supply n a E201 MISSING TERM BLOCK Loose or missing terminal block on I O module E202 MISSING I O MODULE I O module loose or missing since last power cycle E203 I O MDL FUSE BLOWN Fuse blown on an output module E204 LOW VOLTAGE EXT PS External 24 Vdc power supply is too low or has failed n a E208 ILLEGAL MODULE CODE E221 NO SERIES 3 I O PS Power supply failed or power off on Se ries Three I O base unit Series Three 1 0 module or modules func tioning abnormally CPU has detected that I O loading in a base unit exceeds the power supply ca pacity Faulty link in the 1 O chain Turn on power repair or replace power supply in Series Three base unit Determine which module is defective and replace Use high capacity power supply or adjust I O module arrangement E222 S3 I O ABNORMAL OP E226 PS OVERLOAD E250 YO CHAIN Check I O expander cables Local 1 0 In terface module Cycle power if CPU won t enter RUN mode replace base unit or device on bus Us
8. they are different measure the voltage at the input module terminals Refer to the Series Five Programmable Controller I O Specifications Manual GFK 0123 for specific module information If the measured voltage indicates a faulty I O device replace it or the field wiring or its power source If this does not solve the problem replace the input module Maintenance 5 11 SE GFK 0122 4 If the signal is a coil wired to a field device compare its status to the LED on the applicable output module If they are different check the power source to ensure that an excitation voltage is available If field power to the device is not present check the power source and its wiring If the correct field power source is available but the status is wrong at the output module replace the output module 5 If the signal is a coil and either there is no output module or the output is the same as the coil state examine the logic driving the output using the programming device and a hard copy of your program Working from right towards left locate the first contact that is not passing power available to it from the conditional logic at its immediate left Troubleshoot that signal using the procedures in steps 2 and 3 if the signal is an input or steps and 5 if the signal is a coil 6 If the signal is a timer that has stopped at a non zero value below its preset value replace the CPU module 7 If the signal is the control over a cou
9. 5 9 GFK 0122 Table 5 5 Error Code Definitions Operator Interface Unit Continued E601 MEMORY FULL Attempt to program instruction too large Copy program onto a larger memory car for available memory tridge and continue entering program While searching for data in registers Press CLR and respecify data value or sub menu 33 no data that was speci register range fied was found in the specified register range Attempt made to read write an intelligent I O module through sub menu 47 how ever location specified was for a con ventional I O module Attempt made to communicate with a CCM station ID that does not exist Copying operation incomplete because of insufficient memory remaining on mem ory cartridge 1 Blank check with sub menu 74 has detected data on the OIU memory car tridge 2 Attempt to copy to or erase a write protected RAM or EEPROM cartridge 3 Attempt to copy to UVEPROM car tridge that already contains data E603 DATA MISSING E610 BAD I O TYPE Retry operation specify correct base unit slot for the intelligent module E611 BAD COMMS ID Set correct CCM ID E620 OUT OF MEM Change to larger memory cartridge or restructure program E621 MC NOT BLANK Clear the memory cartridge using sub menu 73 or use another memory car tridge Change jumper in memory cartridge to unprotected positio
10. 9 inch Rack Mounting Bracket IC655ACC554 OIU Mounting Bracket CPU Batteries Memory Cartridges Interface and Special Modules IC655CPU500 CPU module IC655ACC549 Battery memory cartridge IC655ACC550 Battery CPU IC655MEM501 4K 24K RAM memory with battery back up IC655MEMS503 16K RAM memory with battery back up IC655MEMS5 12 8K 24K EPROM memory UV erasable IC655MEMS13 16K EPROM memory UV erasable IC655MEMS521 4K EEPROM memory electrically erasable 1C655APUSOO ASCHU BASIC Module 1C65SAPUS10 High Speed Counter IC655APU521 Axis Positioning Module IC655BEMS00 Local I O Interface module IC655BEMS10 Genius Bus Controller module IC655BEM530 Series Three I O Interface module 1C655CBL330 Series Five to Series Three Cable 3 feet 1m 1C655CCM500 CCM Communications Module Input Modules IC655ALG516 Analog Input 1 to 5V 0 to 10V 10 to 10V 4 to 20 mA 8 Channels IC655MDL501 12 24 V de Input Negative Logic 16 Circuits IC655MDL502 12 24 V dc Input Negative Logic 32 Circuits IC655MDL503 24 V dc Input Positive Negative Logic 64 Circuits IC65SMDL511 24 48 V ac dc Isolated Input Positive Logic 16 Circuits IC655MDL512 12 24 V ac dc Input Positive Logic 32 Circuits IC6SSMDL524 Input Simulator 16 or 32 Circuits switchable IC655MDL525 115 230 V ac Input 16 Circuits 1C655MDL526 115 V ac Input 32 Circuits IC655MDL527 115 230 V ac Isolated Input 16 Circuits IC655MDL533 5 12 V de TTL Input Positive Negative ogic 64
11. Chapter 5 5 1 Maintenance GFK 0122 Introduction This chapter presents a basic guide to troubleshooting procedures for the Series Five Programmable Logic Controller The Series Five PLC is designed to provide many years of trouble free operation If a failure should occur it can usually be quickly isolated and the defective assembly replaced with minimum downtime It is important to quickly identify the source of the problem and whether it is hardware or software related The maintenance concept for the Series Five PLC is to replace failed assemblies modules rather than individual components Troubleshooting Aids The CPU has many internal bits and diagnostic registers which can be used in the user program or external CCM compatible computer to implement a custom diagnostic package Many of these internal bits and registers are used by Logicmaster 5 to report errors Most typical problems are isolated through interpretation of the LEDs on individual modules or through error codes or messages on the program ming device s screen These troubleshooting aids help diagnose not only the Series Five PLC but also the total control system The main diagnostic tool is the programming device which can be a Workmaster II portable computer a Workmaster or Cimstar I industrial computer or an IBM PC XT AT PS 2 or compatible personal computer with Logicmaster 5 software Many hardware related faults can be attributed to incorrect switch settings
12. Circuits Maintenance 5 17 GFK 0122 Table 5 6 Series Five PLC Parts List Continued Catalog Number Description of Item Output Modules IC655ALG566 Analog Output 0 to 10V 4 to 20 mA 2 Channels IC655ALG567 Analog Output 10 to 10V 2 Channels 1IC6S5MDL551 12 24 V de Output Negative Logic 16 Circuits IC655MDL552 12 24 V de Output Negative Logic 32 Circuits IC6SSMDLS555 12 24 V de Output Positive Logic 16 Circuits IC65S5MDL556 12 24 V de Output Positive Logic 32 Circuits IC655MDL575 115 230 V ac Output 16 Circuits IC65SMDL576 115 230 V ac Isolated Output 16 Circuits IC655MDL577 115 230 V ac Output 32 Circuits IC655MDL580 Relay Output 16 Circuits IC655MDL581 Relay Output 32 Circuits IC6SSMDL586 Isolated Relay Output 16 Circuits IC655MDL593 5 12 V dc TTL Output Positive Logic 64 Circuits List of Fuses The following table contains a list of fuses that are used in Series Five Output modules Table 5 7 Fuses Used in Output Modules Catalog Current Slow Fast Qty On User Module Name Number a i Rating Blow Module 24 V de Out Neg Logic IC655MDL551 MFS1SH8 24 V de Out Neg Logic IC6553MDL552 MFS1SH3 24 V de Out Pos Logic IC65SMDL555 MF51SH8 24 V dc Out Pos Logic IC655MDL556 MF51SH3 115 230 V ac Out IC655MDL575 MF51SH8 115 230 V ac Isol Out 1IC655MDL576 MC3 115 230 v ac Out 1C655MDL577 MC5 Relay Out IC655MDL580 MFS1SH8 MF515H3 MF51SH8 20 mm x 5 2 mm cartridge type MC3
13. IU E653 MC BATT LOW Battery voltage in OIU memory cartridge low Replace battery in memory cartridge or use another memory cartridge General I O Troubleshooting Procedures I O troubleshooting procedures depend upon knowledge of the logic program installed for your applica tion The following procedures are general in nature and should be adjusted to fit your specific application The following steps assume that the CPU is in the RUN mode operating with outputs enabled 1 If the Series Five PLC has stopped with some of the outputs energized locate the signal timer coil input etc that should cause the next operation to happen The state of that signal can be monitored by Logicmaster 5 2 If the signal is an input compare the state of the input monitored with the programmer with the state of the LED for that input on the input module If they are different replace the module Do not install or remove any I O module when power is applied to the base unit Failure to adhere to this warning could cause a module to be damaged Voltages from user devices may be present on a module s screw terminals though power to a base unit is turned off Care must be taken any time that you are handling the module s terminal board or any wires connected to it 3 If an input state and the applicable LED on the input module agree compare the LED status with the actual input device limit switch pushbutton etc If
14. MCS 9 mm x 2 7 mm pigtail type soldered in place 5 18 Maintenance GFK 0122 Accessory Kit for the Series Five PLC An accessory kit IC655ACC520 is available to support the Series Five PLC This kit contains many of the most commonly used components that may get damaged or lost during normal operation such as fuses screws terminal covets etc Rather than attempting to order all of these parts separately this kit provides a convenient means of ordering and storing these parts Each kit should be sufficient to support several PLCs depending on their I O count Items included in the kit are listed below Table 5 8 Accessory Kit Quantity in Kit 2 sets 2 keys per set 1 CPU keys CPU door with CCM hinged door and OIU port cover I O wiring labels for inside faceplate 16 32 pt 50 of each type Plastic bead chain I O faceplate to module 20 Screws washers all sizes 10 of each Dust covers for I O bus port connector 4 Dust covers for I O expansion port connector 2 Fuses fast blow 2A 3A 3 15A 5A 8A 5 of each Faceplate for I O module Faceplate for power supply Module access side cover Jumper bar for power supply Jumper for register size configuration Keying inserts for terminal block 16 and 32 point Memory cartridge labels CMOS RAM EPROM EEPROM 10 of ach 36 labels each type Maintenance 5 19 GFK 0122 Figure 5 6 is an illustration of the acce
15. STOP mode 11 0034 Non Cnitical System Error 1 error CPU remains in RUN mode 11 0035 Diagnostic Error 1 error detected 11 0036 Battery Not Normal 1 CPU or memory cartridge battery voltage low 11 0037 Memory Error 1 latches if a memory cartridge error occurs 11 0038 I O Error 1 latches if I O bus error is detected 11 0039 Communications Error 1 Turned ON by a CPU CCM error Next successful communications will tum it off 1 error detected I O configuration has changed since last 11 0040 I O Configuration Error power up 11 0042 Watchdog Timeout 1 Watchdog timer has timed out 11 0043 Internal Program Error 1 Error 11 0044 Internal Math Error 1 Error 11 0045 Smart Module Comm Error 1 Error 11 0065 I O Retry Parity Status 1 Parity error after specified number of retries 0 OK no parity error detected 1 Non critical rack 0 Critical rack that reported parity error setting 11 0065 11 0066 Non Cnitical Rack 1 1 1 1 w chart for basic troubleshooting ag status indicators rocedure u O 3 D E pan A O o O E gt 2 bo E A amp s 3 5 5 r i B gt os A 2 ES 33 f z go BE 3 2 S Je v gt sg O a 8 Qu Y AS Q 3 O pl E gt E ha J E Y vo Y vo a z amp 33 Slo 2 Bio g i 2 a Q a 5 J gt 5 B E 2 b ME oD v 3 z B v 56 fr g Hs 3 2 E ala 3 os Ey a f ly GE
16. an operation which is illegal when the CPU is in the STOP mode CPU mode keyswitch not in the OIU posi tion E351 MODULE ID Reassign the correct intelligent module ID in user logic program E352 BGND SETTING Key in CLR and retry communications E353 BGND TOUT Key in CLR and retry communications E360 TIME OUT Press the CLR key and retry communica tons E361 COMM ERROR Retry communications check cable con nections check OIU mounting to CPU Download program from computer to CPU or insert memory with program Rekey correct sequence of keys E4XX NO PROGRAM E501 BAD ENTRY E504 BAD REF VAL Re enter correct value E520 BAD OP RUN Change CPU mode to allow the operation E521 BAD OP RDIS Change CPU mode to allow the operation E524 BAD OP STOP Change CPU mode to allow the operation E525 KEYSWITCH Tum key to OIU position E526 OIU OFFLINE Attempt to perform an operation while OTU is off line Attempt to perform a password protected operation without logging on to the locked CPU Wrong password entered for the memory cartridge in the OIU Use sub menu 64 to put OIU on line E540 CPU LOCKED Logon to the locked CPU with sub menu 81 and repeat operation E541 WRONG PWORD Re enter correct password for the memory cartridge in the OIU Maintenance
17. block over the edge connector on the circuit board and firmly push down Tighten the two screws on the terminal block then replace the plastic faceplate cover 6 Reapply power to the base unit and to the field devices and verify that the system is operating properly 5 16 Maintenance GFK 0122 A list of parts for the Series Five PLC is provided in table 5 6 It is recommended that a spare parts kit be available so that your Series Five PLC system can be returned to service with a minimum amount of downtime if a problem does occur Table 5 6 Series Five PLC Parts List Catalog Number Description of Item Base Units Power Supplies Cables Miscellaneous 1C655CHS506 Base Unit with 6 I O slots 1C655CHS508 Base Unit with 8 YO slots IC655CBL500 YO Expander Cable 1 feet 5 m IC655CBLSO1 YO Expander Cable 3 feet 1 0 m IC655CBL502 V O Expander Cable 15 feet 5 meters IC655CBL503 T O Expander Cable 30 feet 10 meters 1C655CBL504 I O Expander Cable 80 feet 25 meters IC655CBLS505 YO Expander Cable 160 feet 50 meters 1C655CBL540 OTU to CPU Cable 5 feet 1 5 m 1C655CBL5341 OIU to CPU Cable 10 feet 3 0 m IC655PWRS500 AC Power Supply 115 230 V ac Input 6 amps maximum IC655PWRS501 AC Power Supply 115 230 V ac Input 12 amps maximum IC6SSPWR514 DC Power Supply 24 V dc Input 6 amps maximum 1C655CHS590 VO Rack Terminator Plug IC655ACC551 Oversized Faceplate 1IC655ACCS52 Filler Module 1C655ACC553 1
18. cle power If problem persists replace and OIU faulty unit OIU or CPU No reply or NAK from the CPU to an Check link between the OIU and the CPU OIU ENQ Cycle power If problem persists re place the CPU Reassign the intelligent module address either in the user logic program or through sub menu 47 on the OTU E321 OTU CPU COMM E350 MODULE ADDR A base unit and slot address has been specified that does not contain an intelli gent module when attempting commu nications between intelligent modules or between OIU to intelligent modules Invalid communications ID number speci fied for an intelligent module during communications between intelligent modules Syntax error occurred during background communications Communications time out during commu nications session between two intelligent modules During communications between a per sonal computer and OIU the personal computer did not respond to an enquiry Communications problems between CPU and OIU Mode keyswitch turned to RUN with no program in the CPU memory cartridge Invalid key sequence attempted before ENT PREV or NEXT keys Reference number or value entered is out of range Attempt made to perform an operation which is illegal when the CPU is in the RUN mode l Attempt made to perform an operation which is illegal when the CPU is in the RUN w OUTPUTS DISABLED mode Attempt made to perform
19. d replace and tighten the screw Before turning on power ensure that the CPU mode keyswitch is in the STOP position 5 14 Maintenance 7 GFK 0122 Before turning power on reinstall the memory cartridge in the CPU The memory will be blank or have random data in it you will need to execute an INIT CPU Initialize CPU function from the Scratch Pad screen Reapply power to the system and check the system for proper operation Replacing a CPU Backup Battery 1 Ensure that power has been applied to the system at least one minute before changing the battery Remove AC or DC power as applicable from the CPU base unit Access the battery by opening the large hinged door on the front of the CPU module The battery is mounted on the inside of the door Remove the battery connector from the socket in the CPU by grasping it and pulling it straight out until it is free of the socket To ensure that the wires in the battery do not pull out of the connector it may be necessary to use a pair of needle nose pliers to grasp and remove the connector Pull the battery out of the mounting clips on the door Replacement batteries come with the connector prewired to the battery To install the new battery insert it into the mounting clips and push the battery connector firmly into the socket on the CPU until it is securely in place Turn on power to the base unit Reinitialize the CPU This will cause the CPU system para
20. e sub menu 45 to select the former or the new config or change I O config to its previous configuration Use sub Menu 46 to change one of the modules address to a avoid duplication E251 I O BUS PARITY Parity error on I O bus due to electrical noise or other type of interference E252 NEW O CONFIG Current I O configuration is different than the one stored in CPU memory cartridge E261 I O ADDR CONFLICT Attempt made to force a module to an address already assigned to another module Attempt made to force a module address to an invalid address A non existent operation code was includ ed during a CCM communications ses sion E262 YO OUT OF RANGE Use sub menu 46 to re enter a valid ad dress Key in CLR to retry the communications E311 COMM ERROR 1 E312 COMM ERROR 2 A non existent operation code included during communications with a program mer A non existent address was included dur ing communications with a programmer A non existent mode was included during communications with a programmer Key in CLR to retry the communications E313 COMM ERROR 3 Key in CLR to retry the communications E316 COMM ERROR 6 Key in CLR to retry the communications 5 8 Maintenance GFK 0122 Table 5 5 Error Code Definitions Operator Interface Unit Continued Action to Clear Error E320 OIU CPU TOUT Communications time out between CPU Cy
21. isplay and look at registers 4078 4079 and 4080 These registers will display an error code number Then refer to table 5 2 for error code definition and the action to take to clear the problem The flow chart on the following page shows the recommended troubleshooting procedure for the Series Five PLC Maintenance GFK 0122 242408 System Malfunction Turn power on to power supply Connect power supply source voltage wiring LED ON No Ensure that jumper is configured correctly for 115 or 230 VAC for AC supplies Replace power supply YES Read error message in LM5 Scratch Pad See Table 5 1 below for messages and action to clear error Are Status LEDs ON Look at Registers 4078 4079 and 4080 in Hexadecimal display mode Error codes are read from these registers If contents are non zero refer to Table 5 4 for error code definition If not enough information to solve problem refer to table 5 2 for definition of special bits Correct cause of error by taking corrective action as listed under ACTION TO CLEAR ERROR in Table 5 4 Enough information to clear error YES SYSTEM OPERATION IS NORMAL Figure 5 1 Recommended Troubleshooting Sequence Flow Chart Maintenance 5 3 GFK 0122 Table 5 1 Scratch Pad Error Messages and Corrective Action Scratch Pad Error Message Corrective Action Compilation Error Store program to CPU again
22. loose cables or screw connections all major faults can be corrected by replacing modules There are usually no special tools required other than a screwdriver and a voltmeter Series Five Diagnostic Aids The diagnostic features of the Series Five PLC provide the user with a powerful easy to use troubleshooting tool These diagnostic features not only tell you that an error has occurred they also lead you to the location of the problem These diagnostic features are status indicators on the CPU and all other modules special purpose internal coils that turn on to reflect error conditions reserved registers that indicate an error code number or other informative information the CPU ERROR FLAGS display in the Scratch Pad screen in Logicmaster 5 and the error display in the OIU Logicmaster 5 provides the tools for displaying and interpreting error messages and leading you to the cause of the problem When a failure occurs a bit or bits will be set in the CPU ERROR FLAGS line at the bottom of the Scratch Pad display and an error message will be displayed In most cases the cause of the problem is indicated If additional information about the problem is needed by accessing a HELP screen you are directed to an explanation of the bit or bits that are set i e the nature of the error You can then display the reference table for the special contacts 11 000 to 11 512 to see which of the contacts has been set to a logic 1 or access the register d
23. meters to be reset to their default conditions and will clear Logicmaster 5 memory and Series Five CPU memory Verify that system operation is correct a42415 INSERT BATTERY CONNECTOR INTO BOARD CONNECTOR O 0000000000000 0000000000000 O Figure 5 4 CPU Battery Mounting and Connection Maintenance 5 15 GFK 0122 Replacing I O Modules 1 Turn off AC or DC power as applicable to the base unit in which the I O module to be replaced is contained and from the I O system 2 Remove the faceplate from the module to be replaced There is no need to remove field wiring from the terminal block since the block is removable Disconnect the removable terminal block from the module by removing the two captive screws holding the terminal block to the module s circuit board assembly a42416 OUTAUT DOC Ma TPT AS SERO se PA NY bd bd bd bw EA wa Y O bona bread Y NY REMOVE CAPTIVE SCREWS Y y wed hd ed Y bid bd bd bd NINA MOO REMOVE FACEPLATE COVER Figure 5 5 Removal of Terminal Block From Module 3 Loosen the two captive screws holding the module in place and remove the module from its slot by pulling it towards you 4 Install the new module in the slot by lining it up with the backplane connector for its slot and firmly pushing the module into the connectors until it is securely seated then tighten the two captive screws 5 Place the terminal
24. n Erase contents of UVEPROM cartridge with an ultra violet lamp or use another UVEPROM cartridge E622 NO MC IN OIU Attempt made to transfer data to or from a memory cartridge in the OIU with no memory cartridge installed in the OIU Insert an appropriate memory cartridge in to the OIU E623 SYSTEM MC Attempt made to transfer user logic from OIU memory cartridge to CPU memory cartridge when OIU memory cartridge contains other than user logic Remove memory cartridge from OTU and insert one that contains user logic E624 REGS ONLY Attempt made to transfer user logic from OIU memory cartridge to CPU memory cartridge when OIU memory cartridge contains register data Remove memory cartridge from OIU and insert one that contains user logic or select register option from sub menu 72 E625 PROG ONLY Attempt made to transfer registers from the OIU memory cartridge to the CPU memory cartridge when the OIU memo ry cartridge contains user logic Remove memory cartridge from OIU and insert one that contains register data or select program option from sub menu E626 EPROM MC Attempt made to copy data onto an EPROM memory cartridge installed in the CPU RAM or EEPROM cartridge in OIU is write protected or UVEPROM cartridge in OIU has not been erased or CPU has detected a mismatch of data while copy ing data with sub menu 71 or 72
25. nter examine the logic that is controlling the reset first then the count signal Follow steps 2 through 5 Replacing Components The following procedures provide information on replacement of various components of a Series Five PLC system Replacing a Power Supply 1 Turn off AC or DC power as applicable to the supply 2 Disconnect field wiring from the power supply terminal block 242666 RUN RUN C SIGNAL GROUND C SIGNAL GROUND G CHASSIS GROUND G CHASSIS GROUND AC HOT 24 VDC POS AC NEUTRAL 24 VDC NEG AAA NO CONNECTION NO JUMPER NO CONNECTION L IC655PWR500 ____________ IC655PWR514 IC655PWR501 Figure 5 2 Power Supply Terminal Block Connections 5 12 Maintenance 6 GFK 0122 Remove the power supply by loosening the two captive screw fasteners that are holding the supply in place Install the new power supply by placing it over the connector on the backplane and pushing down on the module until it is firmly seated Reconnect field wiring to the power supply terminal block and verify that the jumper for 115 or 230 V ac is properly configured if the supply is an AC supply Apply power to the system and check for proper system operation Replacing a CPU Module 1 2 Place the CPU mode switch in the STOP position Turn off AC or DC power as applicable to the power supply Disconnect any cables that may be attached to the CPU Remove the memory cartridge installed in
26. perator Interface Unit The informa tion in the tables is as follows ERROR CODE MESSAGE Error code number and message message with OTU CAUSE OF ERROR Action or problem that caused the error ACTION TO CLEAR ERROR Action required to clear the error Table 5 4 Error Code Definitions Logicmaster 5 Error Code Cause of Error Action to Clear Error Scan time exceeds Preset time of Watchdog timer Check user logic or increase watchdog timer preset Cycle power Store program again Replace CPU battery within one week Install back up battery in CPU Replace battery in memory cartridge within one week Contents of memory cartridge must be copied before you change the battery or data will be lost Install battery in memory cartridge With power off install memory cartridge in CPU With power off insert user program MC in the CPU With power off insert user program MC in the CPU Change register reference Store program again Change user logic program to have fewer stack levels With power off install terminal block With power off install I O module in correct slot With power off remove output module and install new fuse or replace module Adjust voltage of external power supply CPU memory parity error detected Voltage of CPU back up battery too low No back up battery in CPU Voltage of back up battery installed in memory cartridge too low No batte
27. ry or dead battery in memory cartridge No memory cartridge in CPU Memory cartridge contains only CPU parameters Memory cartridge contains only registers Register reference is greater than maximum register size Memory parity error in user logic Rung too complex to execute Terminal block removed from I O module I O configuration change since last power up or I O module removed from slot Blown fuse or no fuse in an output module FU indicator on output module will also be on Voltage of external 24 V dc power to output module too low No power applied to Series Three PLC s I O base unit connected through a Series Three PLC I O Interface module A problem exists in the Series Three PLC s I O system Apply power to the Series Three PLC s I O base unit Troubleshoot the Series Three PLC s I O system and replace defective module s Recycle power or push CPU reset pushbutton or replace base unit or device Error on 1 O bus or device connected to 1 O bus 5 6 Maintenance GFK 0122 Table 5 4 Error Code Definitions Logicmaster 5 Continued I O bus parity error noise Cycle power Replace base unit or device on I O bus Key in NEW CONFIG command or OLD CONFIG command from LMS or edit I O map and do a STORE TO CPU Reassign addresses with no duplication Correct user logic Specify correct target address Reassign correct target ID
28. ssory kit location guide GFJ 011 which is packed with each accessory kit This guide shows the location and lists the quantity of each item in the kit GE Fanuc 244260 GFJ 011 SERIES FIVE ACCESSORY KIT IC655ACC520 1 Fuses all sizes used 2 Dust cover for I O 3 Dust cover for I O module CD QTY Sof each QTY 10 of each QTY 10 of each e En 5 Power supply faceplate 6 I O module faceplate 7 Module sideplate 8 CPU door complete with CCM door and OIU port lid 9 Memory cartridge labels auos ran QTY 2 of each CMOS RAM EPROM EEPROM CMOS RAM Eprom ee Figure 5 6 Accessory Kit Location Guide 10 Plastic chain for I O faceplate to module 11 Terminal screws washers all sizes 12 CPU key 2 sets of 2 keys each 13 Terminal block keys 16 32 pt 14 Power supply terminal jumper 15 Register size jumper Ring and Spade Lugs The following list of ring and spade lugs have been tested and can be used for connecting field wiring to the terminal blocks on Series Five I O modules Most ring or spade lugs will fit the terminals Table 5 9 Recommended Lugs for Field Wiring Connections Type of Lug Wire Size Awg mm AMP Catalog Number 22 16 0 38 1 2 mm 16 14 1 2 1 9 mm 12 10 3 0 5 2 mm 16 14 1 2 1 9 mm 22 18 0 38 1 0 mm
29. to the base unit and verify proper system operation Maintenance 5 13 GFK 0122 Replacing a Memory Cartridge Backup Battery 1 Before replacing a memory cartridge battery the memory contents should be saved since the memory in the cartridge will be lost when a battery is changed 2 Remove the memory cartridge as described previously 3 Remove the phillips head screw that attaches the top cover to the case containing the memory cartridge a42417 Figure 5 3 Memory Cartridge Battery Location 4 You do not have to remove the circuit board from the case to remove and replace the battery The battery is mounted on the circuit board and can be removed by very gently pulling up on the bottom of the battery until it is completely free of the socket It is recommended that you use your fingers or a non conductive tool for pulling the battery out of the socket CAUTION Be very careful when removing the battery from its mounting holes to ensure that the circuit board is not damaged Be careful not to short runs or components on the circuit board when using a screwdriver 5 Notice that the holes into which the battery is inserted are offset to one side this ensures that proper battery polarity is observed Insert the new battery into the mounting holes by placing it over the holes then gently pushing down on the battery case until it is firmly seated in place Do not bend the two leads on the battery 6 Replace the cover an
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