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Logix5000 Controllers Controller Major and Minor Faults

1. Type Code Cause Recovery Method 4 42 JMP to a label that did not exist or was deleted Correct the JMP target or add the missing label 4 82 A sequential function chart SFC called a subroutine andthe Remove the jump back to the calling SFC subroutine tried to jump back to the calling SFC This occurs when the SFC uses either a JSR or FOR instruction to call the subroutine 4 83 The data tested was not inside the required limits This occurs Adjust the value to be within the valid range Do not exceed the array size or go beyond with array subscripts used with Boolean arrays and bit level the dimensions defined addressing 4 84 Stack overflow Reduce the subroutine nesting levels or the number of parameters passed 4 89 Ina SFR instruction the target routine does not contain the Correct the SFR target or add the missing step target step 4 90 Using a safety instruction outside a safety task Place the safety instruction inside the safety task 4 91 Equipment Phase instruction is being called from outside an Only use the instruction in an Equipment Phase program Equipment Phase program 4 990 User defined major fault See Creating a User Defined Major 7 ai Fault on page 28 for more information 4 992 4 993 4 994 4 995 4 996 4 997 4 998 4 999 6 1 Task watchdog expired Increase the task watchdog shorten the execution time make the priority of this task User task h
2. 3 Specify the properties in the New Routine dialog box Property Description Name Enter the name of the routine Description optional Enter a description of the routine Type Use the default of Ladder Diagram for creating a fault routine In Program or Phase Use the default of Main Program Open Routine Select the box if you want to immediately open the ladder logic program Assignment Choose Fault TIP If you are creating a fault routine for the Power Up Handler or Controller Fault Handler you can specify the program name of either program for the In Program or Phase property 4 Click OK Rockwell Automation Publication 1756 PM014F EN P September 2012 15 Chapter1 Major Faults Changing a Fault Routine Assignment of a Program Complete these steps to change what routine is assigned as the fault routine 1 In the Controller Organizer expand the Main Task 4J Tasks gel MainTask ts Unscheduled Programs Phases Ifa fault routine has already been created it is included in the main program Tasks a MainTask MainProgram Program Tags EE MainRoutine Current Fault A Program_Fault_Routine_1 Routine Alt_Fault_Routine_2 2 Right click MainProgram and choose Properties 3 Click the Configuration tab 4 From the Fault pull down menu choose the routine you want to be the program s fault routine Program Properties MainProgram z ol x General Configurat
3. Dest The logic inside of an Add On Instruction generates a fault While the logic ofan Add On Instruction may look like a subroutine it is not the Add On Instruction is an instruction When a fault occurs inside of an Add On Instruction the remainder of the Add On Instruction is aborted If the fault is cleared execution resumes with the MOV Important Points Regarding Add On Instructions e The Add On Instruction stops executing at the instruction that caused the fault This means that the remainder of the scan mode routine does not execute e Ifthe fault is cleared execution resumes at the instruction following the top level Add On Instruction invocation For example assume the above Add On Instruction myAoi invokes a nested Add On Instruction myNested which invokes another nested Add On Instruction inner Furthermore assume that an instruction inside of inner causes a fault If the fault is cleared execution resumes with the MOV the remainder of inner does not execute the remainder of myNested does not execute and the remainder of myAoi does not execute e During prescan e The Logic routine is executed in prescan mode e The Prescan routine is executed in normal scan mode During postscan e The Logic routine is executed in postscan mode e The Postscan routine is executed in normal scan mode Rockwell Automation Publication 1756 PM014F EN P September 2012 11 Chapter 1 Major Faults 12
4. Ifa fault occurs while processing the Logic routine the Add On Instruction aborts the remainder of the Logic routine does not execute and the pre and post scan routines do not execute If the fault is cleared execution resumes at the instruction following the top level Add On Instruction invocation Fault Handling During Prescan and Postscan The behavior of each instruction varies depending on the mode in which it is executed true false prescan or postscan For details about what a specific instruction does in each mode see the Logix5000 Controllers General Instructions Reference Manual publication number 1756 RM003 e Prescan provides a system defined initialization of the user program when the controller is switched from program mode to run mode e Postscan provides a system defined re initialization of the logic invoked from an SFC action when the action is shut down if SFCs are configured for Automatic Reset If an array index is out of range during prescan the controller could generate a major fault There are a number of ways this could happen the controller loses power encounters a major fault or the project is saved while online Since during prescan and postscan the user program is not able to make decisions or assign values to tags the only way to correct these issues would be to manually initialize the index variables using Logix Designer software or to write a fault handler to ignore the array faults durin
5. No patent liability is assumed by Rockwell Automation Inc with respect to use of information circuits equipment or software described in this manual Reproduction of the contents of this manual in whole or in part without written permission of Rockwell Automation Inc is prohibited Throughout this manual when necessary we use notes to make you aware of safety considerations WARNING Identifies information about practices or circumstances that can cause an explosion in a hazardous environment which may lead to personal injury or death property damage or economic loss ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss Attentions help you identify a hazard avoid a hazard and recognize the consequence SHOCK HAZARD Labels may be on or inside the equipment for example a drive or motor to alert people that dangerous voltage may be present BURN HAZARD Labels may be on or inside the equipment for example a drive or motor to alert people that surfaces may reach dangerous temperatures gt e eD IMPORTANT Identifies information that is critical for successful application and understanding of the product Allen Bradley Rockwell Automation Rockwell Software ControlLogix GuardLogix CompactLogix DH PLC 5 DriveLogix SLC 500 RSNetWorx RSNetWorx for ControlNet FLEX I O SoftLogix FlexLogix PowerFlex Lo
6. September 2012 1 0 Fault Codes Chapter 3 Code Interpretation 0301 One of these conditions may exist The controller is attempting to set up a connection with the module and has received an error a module in the path is out of memory The controller may be attempting to connect to a tag in a producing controller that is not marked as being produced The controller may be attempting to connect to a tag in a producing controller That tag may not be configured to allow enough consumers The size or number of connections through this module needs to be reduced e One of the network modules between the module and the controller may be out of memory Check network configuration of the system The module may be out of memory Check system configuration and capabilities of module The module in use that is the physical module is different than the module specified in the 1 0 configuration tree and is therefore causing the connection or service to fail The fault may occur even when the module passed the electronic keying test This may result when Disable Keying or Compatible Keying options were used in the module configuration instead of the Exact Match option Despite passing the electronic keying test the module being connected to does not have the same features or settings as the module specified in the 1 0 configuration tree and does not support the connection or service being attempted Check the modu
7. Multiply Source value_a pe Source B 1000000 Dest value_b pe S MINOR GSV S MINOR Get System Value Class name PROGRAM Instance name THIS Attribute Name MINORFAULTRECORD Dest minor_fault_record Time_Low pe 42373 Rockwell Automation Publication 1756 PM014F EN P September 2012 37 Chapter 2 Minor Faults Minor Fault Codes Table 4 Minor Faults Minor faults are indicated in these locations e Controller Properties dialog box Minor Faults tab e PROGRAM object MINORFAULTRECORD attribute This tables identifies the type code and suggested recovery method when applicable Type Code Cause Recovery Method 1 15 A 1769 power supply is connected directly to the controller s 1768 Remove the power supply from the 1768 CompactBus and cycle power CompactBus with an invalid configuration to the system The 1768 power supply powering the controller has failed Replace the power supply 4 4 An arithmetic overflow occurred in an instruction Fix the program by examining arithmetic operations order or adjusting values 4 5 In a GSV SSV instruction the specified instance was not found Check the instance name 4 6 In a GSV SSV instruction either Check the Class name and Attribute name e Specified Class name is not supported e Specified Attribute name is not valid 4 7 The GSV SSV destination tag was too small to hold all of the data Fix the destination so
8. STN 255 Astation number greater than 254 was encountered 9 3 The RS232 DFI Master Active Station tag is unspecified Specify a tag to be used for the Active Station Tag in the System Protocol tab of the Controller Properties 9 5 DF1 slave poll timeout Determine and correct delay for polling The poll watchdog has timed out for slave The master has not polled this controller in the specified amount of time 9 9 Modem contact was lost Correct modem connection to the controller DCD or DSR control lines are not being received in proper sequence or state 9 10 Data has been dropped or lost from the serial port Slow down the rate at which the initiator is sending data 10 10 Battery not detected or needs to be replaced Install new battery 10 11 Safety partner battery not detected or needs to be replaced Install new battery 10 12 The ESM of a 1756 L7x controller is not installed Install an ESM in the controller If the controller is powered down the WallClockTime attribute and program are not maintained 10 13 The ESM installed on the 1756 L7x controller is not compatible with the Replace the installed ESM with one that is compatible with the controller controller 10 14 The ESM needs to be replaced due to a hardware fault Replace the ESM It is not capable of maintaining the WallClockTime attribute or controller program at powerdown 10 15 The ESM cannot store enough energy in the ESM to maintain the Replace the ESM WallClockTime attrib
9. Minor Faults To check for a Do this Task overlap 1 Enter a GSV instruction that gets the FAULTLOG object MinorFaultBits attribute 2 Monitor bit 6 Load from nonvolatile memory 1 Enter a GSV instruction that gets the FAULTLOG object MinorFaultBits attribute 2 Monitor bit 7 Serial port fault 1 Enter a GSV instruction that gets the FAULTLOG object MinorFaultBits attribute 2 Monitor bit 9 Low battery or energy storage status 1 Enter a GSV instruction that gets the FAULTLOG object MinorFaultBits attribute 2 Monitor bit 10 Instruction related fault AUBAN Create a user defined data type that stores the fault information Name the data type FaultRecord and assign these members Name Data Type Style TimeLow DINT Decimal TimeHigh DINT Decimal Type INT Decimal Code INT Decimal Info DINT 8 Hex Create a tag that will store the values of the MinorFaultRecord attribute From the Data Type pull down menu in step 1 of this instruction choose the data type Monitor S MINOR Use a GSV instruction to get the values of the MinorFaultRecord attribute if S MINOR is on Reset S MINOR if you want to detect a minor fault that is cause by another instruction S MINOR remains set until the end of the scan Rockwell Automation Publication 1756 PM014F EN P September 2012 35 Chapter2 Minor Faults This example checks for a low battery warning EXAMPLE Check fo
10. a fault code of 999 See the following procedures to create a user defined major fault e Creating a Fault Routine for the Program see page 28 e Configuring the Program to Use the Fault Routine see page 28 e Jumping to the Fault Routine page 29 Creating a Fault Routine for the Program Does a fault routine already exist for the program If Then Yes Go to Jumping to the Fault Routine on page 29 No Refer to the following steps 1 Inthe Controller Organizer right click the program and choose New Routine 2 Inthe name box type a name for the fault routine 3 From the Type menu choose Ladder 4 Click OK Configuring the Program to Use the Fault Routine 1 In the Controller Organizer right click the program and choose New Routine 2 Click the Configuration tab 3 From the Fault menu choose the fault routine 4 Click OK 28 Rockwell Automation Publication 1756 PM014F EN P September 2012 Major Faults Chapter 1 Conditions when the controller should shut down Jumping to the Fault Routine In the main routine of the program enter this rung JSR Jump To Subroutine Routine Name Fault_Routine Input Par 999 Where Is the Fault_Routine Name of the fault routine for the program 999 Value for the fault code EXAMPLE Creating a User Defined Major Fault When Tag_1 0 1 execution jumps to name_of_fault_routine A major fault oc
11. be indicated where multicast Ethernet packets are not returned When this fault occurs the controller usually attempts to continuously remove and remake the connection Also if you are using FLEX 1 0 modules verify that you are using the correct terminal device 0204 The controller is attempting to make a connection however the target module is not responding The device also appears to be missing from the backplane or network To recover take these actions e Verify that the module has not been removed and is still functioning and receiving power e Verify that the correct slot number has been specified e Verify that the module is properly connected to the network If you are using FLEX 1 0 modules verify that the correct terminal block is in use 0205 Either e The controller is attempting to set up a connection with the module and has received an error a parameter is in error The module in use that is the physical module is different than the module specified in the 1 0 configuration tree and is therefore causing the connection or service to fail The fault may occur even when the module passed the electronic keying test This may result when Disable Keying or Compatible Keying options were used in the module configuration instead of the Exact Match option Despite passing the electronic keying test the module being connected to does not have the same features or settings as the module specified in the 1 0 c
12. it has enough space 4 30 Bad parameters passed through to the ASCII port Verify the ASCII configuration settings 4 35 PID delta time lt 0 Adjust the PID delta time so that it is gt 0 4 36 PID setpoint out of range Adjust the setpoint so that it is within range 4 51 The LEN value of the string tag is greater than the DATA size of the string 1 Check that no instruction is writing to the LEN member of the string tag tag 2 Inthe LEN value enter the number of characters that the string contains 4 52 The output string is larger than the destination Create a new string data type that is large enough for the output string Use the new string data type as the data type for the destination 4 53 The output number is beyond the limits of the destination data type Either e Reduce the size of the ASCII value e Use a larger data type for the destination 4 56 The Start or Quantity value is invalid 1 Check that the Start value is between 1 and the DATA size of the Source 2 Check that the Start value plus the Quantity value is less than or equal to the DATA size of the Source 4 57 The AHL instruction failed to execute because the serial port is set to no Either handshaking e Change the Control Line setting of the serial port Delete the AHL instruction 6 2 Periodic task overlap Make changes such as simplifying programs lengthening the period or Periodic task has not completed before it is time to execute again raising the relative pri
13. occur even when the module passed the electronic keying test This may result when Disable Keying or Compatible Keying options were used in the module configuration instead of the Exact Match option Despite passing the electronic keying test the module being connected to does not have the same features or settings as the module specified in the 1 0 configuration tree and does not support the connection or service being attempted Check the module in use and verify that it exactly matches the module specified in the 1 0 configuration tree of the Logix Designer application For more information about electronic keying see the user manual for the module you are using The controller may be attempting to connect to a nonexistent tag in a producing controller Rockwell Automation Publication 1756 PM014F EN P September 2012 45 Chapter 3 1 0 Fault Codes Code 0118 Interpretation An invalid configuration format is used One of these conditions exists The configuration class specified does not match the class supported by the module The connection instance is not recognized by the module e The path specified for the connection is inconsistent The module in use that is the physical module is different than the module specified in the 1 0 configuration tree and is therefore causing the connection or service to fail The fault may occur even when the module passed the electronic keying test This may result when Disable K
14. the connections are used try to free some of the used connections or add another module to route the errant connection through The 1 0 memory limits of the controller are exceeded Check the 1 0 memory available and make program or tag changes if needed e Thel 0 module targeted does not have enough connections available Check the number of controllers making a connection to this 1 0 module and verify that the number of connections is within the limits of the 1 0 module 0005 The controller is attempting to make a connection to the module and has received an error Either The configured address for the connection to the module is incorrect The module in use that is the physical module is different than the module specified in the 1 0 configuration tree and is therefore causing the connection or service to fail The fault may occur even when the module passed the electronic keying test This may result when Disable Keying or Compatible Keying options were used in the module configuration instead of the Exact Match option Despite passing the electronic keying test the module being connected to does not have the same features or settings as the module specified in the 1 0 configuration tree and does not support the connection or service being attempted Check the module in use and verify that it exactly matches the module specified in the 1 0 configuration tree of Logix Designer application For more information about electronic keying see the
15. this revision are marked by change bars as shown in the margin of this page This table contains the changes made to this revision Fault Handling During Prescan and Postscan Major Fault Codes Rockwell Automation Publication 1756 PM014F EN P September 2012 Summary of Changes Notes 4 Rockwell Automation Publication 1756 PM014F EN P September 2012 Table of Contents Preface Studio 5000 Engineering and Design Environment and Logix Designer Application msieticusrens concn teas nak aur yivele Be 7 AA i aan all eg SB Sicee Bat So a8 ons CRBS 556 Te oh ae alee cna oes 7 Additional REsOUtCesicicichouengca dacs hunate niche ooeekeantadeuakow be 8 Chapter 1 Major Faults Major Fault States i waeea ie era ne aisiak nu eie sas ata 9 Recovering From a Major Fault iiss cndenacdereveks vane ewenentns 10 Fault Handling During Prescan and Postscan 0 065 12 Placement of Fault Routines 4 2 8 0 ccedodew ese ah en AS ae oes 13 Choosing Where to Place the Fault Routine 0 14 Creating a Fault Routine for a Program ccs pei iccwdnceeserei artes 14 Changing a Fault Routine Assignment of a Program 16 Creating a Routine for the Controller Fault Handler 17 Creating a Routine for the Power Up Handler 08 19 Programmatically Clear a Major Fault tooth sh coaeaneya cents 22 Creating a Data Type to Store Fault Information 22 Getting the Fault Type
16. you are using FE06 The input force pointer has not been set FE07 The output connection point has not been set FE08 The controller is attempting to set up a connection with the module and has received an error FE09 Either e The controller is attempting to set up a connection with the module and has received an error The module in use that is the physical module is different than the module specified in the 1 0 configuration tree and is therefore causing the connection or service to fail The fault may occur even when the module passed the electronic keying test This may result when Disable Keying or Compatible Keying options were used in the module configuration instead of the Exact Match option Despite passing the electronic keying test the module being connected to does not have the same features or settings as the module specified in the 1 0 configuration tree and does not support the connection or service being attempted Check the module in use and verify that it exactly matches the module specified in the 1 0 configuration tree of the Logix Designer application For more information about electronic keying see the user manual for the module you are using FEOA A connection has been opened without the output force pointer being set FEOB Either The tag to be consumed on this module is invalid Verify that the tag is marked as being produced The module in use that is the physical module is different than the module specified
17. 107 A connection being accessed was not found 0108 An invalid connection type was used One of these conditions exists The controller is requesting a connection type not supported by the module The module in use that is the physical module is different than the module specified in the 1 0 configuration tree and is therefore causing the connection or service to fail The fault may occur even when the module passed the electronic keying test This may result when Disable Keying or Compatible Keying options were used in the module configuration instead of the Exact Match option Despite passing the electronic keying test the module being connected to does not have the same features or settings as the module specified in the 1 0 configuration tree and does not support the connection or service being attempted Check the module in use and verify that it exactly matches the module specified in the 1 0 configuration tree of the Logix Designer application For more information about electronic keying see the user manual for the module you are using You have configured a consumed tag or module to use a Unicast connection over EtherNet IP network but the producer does not support Unicast connections Rockwell Automation Publication 1756 PM014F EN P September 2012 1 0 Fault Codes Chapter 3 Code 0109 Interpretation The connection size is inconsistent with that expected Either The controller is attempting to set
18. 1756 Backplane 1756 410 Faulted 0 pe i Bl 2 1756 IF61 analog input a woffa 7 1756 L75 10_contral e A module fault code and description is indicated in the Connection tab of the Module Properties dialog box E Module Properties Local 8 1756 0B16D 3 1 w x General Connection Module Info Configuration Diagnostics Pulse Test Backplane Requested Packet Interval RPI 20 04 ms 0 2 750 0 ms T Inhibit Module I Major Fault On Controller If Connection Fails While in Run Mode Module Fault Code 16 0116 Electronic Keying Mismatch Major and or Minor revision invalid or incorrect Rockwell Automation Publication 1756 PM014F EN P September 2012 1 0 Fault Codes Chapter 3 0 Fault Codes Depending on where the fault code is indicated the code format contains either the full Hexidecimal number for example 16 000A or the last characters of the code for example 000A This table lists commonly experienced I O fault codes and a corresponding description and recovery method when applicable Each code is listed by the last characters of the full Hexidecimal number that is XXXX Code Interpretation 0001 A connection to a module failed 0002 Either There are not enough connections available either for the controller or for the communication module being used to connect through Check the connection use of the controller or communication module If all of
19. Check the controllers that are using the connection and verify that all the configurations are identical The connection requested is not a listener or a controlling connection type 031E The controller is attempting to connect to a tag in a producing controller and has received an error The controller is attempting to connect to a tag in a producing controller and that tag has already been used by too many consumers Increase the maximum number of consumers on the tag 031F No SC servicing controller connection object was found that corresponds to a symbol instance 0800 No interpretation available 0801 No interpretation available 0814 Invalid connection status information was found FD01 1 0 map object attributes were found to be invalid A fault has occurred while clearing memory FD02 No error code is supplied by an 1 0 module to describe an 1 0 fault FD03 The controller is attempting to set up a connection with the module and has received an error this module requires a particular set of connections and connection types and one of those connection types is missing FD04 The module requires a CST master in the chassis Configure a module typically a controller in this chassis to be the CST master FD05 The module requires an axis or group table assigned Assign a Group or Axis FD06 The controller command to transition the SERCOS ring to a new phase returned an error from the module Check for duplicate Drive Nodes FD07 An atte
20. M is removable or replace the controller if the ESM is not ESM does not contain enough charge to save the user program removable on power down e Ifthe problem persists contact Rockwell Automation Support 1 60 For a controller with no memory card installed the controller 1 Clear the fault Detected a non recoverable fault 2 Download the project Cleared the project from memory 3 Change to Remote Run or Run mode Follow these steps if the fault persists 1 Before you cycle power to the controller record the state of the OK and RS232 status indicators 2 Contact Rockwell Automation support See the back of this publication for contact information 1 61 For a controller with a memory card installed the controller 1 Clear the fault Detected a non recoverable fault 2 Download the project Wrote diagnostic information to the memory card 3 Change to Remote Run or Run mode Cleared the project from memory If the fault persists contact Rockwell Automation support See the back of this publication for contact information 1 62 For a controller with a Secure Digital SD card installed the 1 Clear the fault controller 2 Download the project e Detected a nonrecoverable fault 3 Change to Remote Run or Run mode e Wrote diagnostic information to the memory card If the fault persists contact Rockwell Automation Technical Support See the back of this When in this state the controller will not open any connections publicatio
21. Programming Manual Allen Bradley Logix5000 Controllers Major Minor and 1 0 Faults Catalog Numbers 1756 ControlLogix 1756 GuardLogix 1768 Compact GuardLogix 1768 CompactLogix 1769 CompactLogix 1789 SoftLogix PowerFlex with DriveLogix Allen Bradley Rockwell Software Automation Important User Information Solid state equipment has operational characteristics differing from those of electromechanical equipment Safety Guidelines for the Application Installation and Maintenance of Solid State Controls publication SGI 1 1 available from your local Rockwell Automation sales office or online at http www rockwellautomation com literature describes some important differences between solid state equipment and hard wired electromechanical devices Because of this difference and also because of the wide variety of uses for solid state equipment all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable In no event will Rockwell Automation Inc be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment The examples and diagrams in this manual are included solely for illustrative purposes Because of the many variables and requirements associated with any particular installation Rockwell Automation Inc cannot assume responsibility or liability for actual use based on the examples and diagrams
22. an Owner of this module because it is attempting to establish a Listen Only connection which requires no module configuration It cannot connect until an Owner configures and connects to the module first 0111 Either The Requested Packet Interval RPI specified is invalid for this module or for a module in the path to this module The module in use that is the physical module is different than the module specified in the 1 0 configuration tree and is therefore causing the connection or service to fail The fault may occur even when the module passed the electronic keying test This may result when Disable Keying or Compatible Keying options were used in the module configuration instead of the Exact Match option Despite passing the electronic keying test the module being connected to does not have the same features or settings as the module specified in the 1 0 configuration tree and does not support the connection or service being attempted Check the module in use and verify that it exactly matches the module specified in the 1 0 configuration tree of the Logix Designer application For more information about electronic keying see the user manual for the module you are using For Listen Only connections the RPI set by the owner of this module is slower than the one requested Either increase the requested RPI or decrease the RPI the owner controller is using See the Connection tab for valid RPI values 0114 The Product Cod
23. and Codeirias sccm ederanusteasdvdnsrulears 23 Checking fora Specific Fault sc sows cis poudespeeneeeceed ends 24 Clearing the Fault cveivsden ta tie rien neue gdaeaearasaneiced 24 Clearing a Major Fault During Prestattsaiwiccke cod uss aches Peceses 25 Identifying When the Controller is in Prescan 25 Getting the Fault Type and Code vias eens aceon vineesuerncewed 26 Checking for a Specific Fault sa142 3 44 45 14 sake denee eases 26 Clearing th Fault cicate tis men od pie ranmase ati ehea 27 Testing a Fault Routines soudi eiea e a aa hae 27 Creating a User Defined Major Fault cwicasubpsecavieveccavaniness 28 Creating a Fault Routine for the Program 00000 28 Configuring the Program to Use the Fault Routine 28 Jumping to the Fault Routine wis winders hone ee ies Gee ate ghacere 29 Major Fault Codesissassaiassagreceriaws tava aa talus Giga esas 30 Chapter 2 Minor Faults Identifying Minor Faults s cimeciieoseet chcuese ean kee amedordds 35 Minor Fault Codes 723 Acca dase Ans atau wae ciate N TN 38 Chapter 3 1 0 Fault Codes Indications of I O Failte sca iecdnc deve Sieract es wets Relishes neers l LOD E E E E E EEE E E E E E ee EEE 43 Index Rockwell Automation Publication 1756 PM014F EN P September 2012 5 Table of Contents 6 Rockwell Automation Publication 1756 PM014F EN P September 2012 Preface Studio 5000 Engineering and The Studio 5000 Engineering and Design Environment combi
24. as not completed in the specified period of time A higher simplify higher priority tasks or move some code to another controller program error caused an infinite loop or the program is too complex to execute as quickly as specified or a higher priority task is keeping this task from finishing 7 40 Store to nonvolatile memory failed 1 Try again to store the project to nonvolatile memory 2 Ifthe project fails to store to nonvolatile memory replace the memory card If you are using a 1756 L7x controller verify that the SD card is unlocked 7 41 Load from nonvolatile memory failed due to controller type Change to a controller of the correct type or download the project and store it on the mismatch memory card 7 42 Load from nonvolatile memory failed because the firmware Update the controller firmware to the same revision level as the project that is in revision of the project in nonvolatile memory does not match nonvolatile memory the firmware revision of the controller 7 43 Load from nonvolatile memory failed due to bad checksum Contact Rockwell Automation support See the back of this publication 7 44 Failed to restore processor memory Contact Rockwell Automation support See the back of this publication 8 1 Attempted to place controller in Run mode with keyswitch Wait for the download to complete and clear fault during download 11 1 Actual position has exceeded positive overtravel limit Move axis in negative direction until position
25. atus information about a program you access the PROGRAM object e For fault information you access these attribute of the PROGRAM object Attribute Data Type Instruction Description MajorFaultRecord DINT 11 22 Records major faults for this program SSV Specify the program name to determine which PROGRAM object you want Or specify THIS to access the PROGRAM object for the program that contains the GSV or SSV instruction Rockwell Automation Publication 1756 PM014F EN P September 2012 Major Faults Chapter 1 To simplify access to the MajorFaultRecord attribute create this user defined data type 1 In the organizer of Logix Designer software right click User Defined and choose New Data Type Motion Groups Ungrouped Axes Add On Instructions Data Types TE User Defined E Add On Defin Import Data Types a O Predefined E Module Defin Cut Ctrl x Trends E Ba Cams Mrla i 2 Enter the data type information as shown in this table Data Type FAULTRECORD Name FAULTRECORD Description Stores the MajorFaultRecord attribute or MinorFaultRecord attribute of the PROGRAM object Members Name Data Type Style Description Time_Low DINT Decimal Lower 32 bits of the fault timestamp value Time_High DINT Decimal Upper 32 bits of the fault timestamp value Type INT Decimal Fault type program 1 0 and so forth Code INT Decimal Unique code for the
26. being connected to does not have the same features or settings as the module specified in the 1 0 configuration tree and does not support the connection or service being attempted Check the module in use and verify that it exactly matches the module specified in the 1 0 configuration tree of the Logix Designer application For more information about electronic keying see the user manual for the module you are using 0317 The controller is attempting to set up a ControlNet connection with the module and has received an error Use RSNetWorx for ControlNet software to schedule or reschedule the connection to this module 0318 The controller is attempting to set up a connection with the module and has received an error the link address is invalid Verify that the associated ControlNet module has the correct slot or node number selected 0319 The controller is attempting to set up a connection with the module and has received an error the redundant module does not have the necessary resources to support the connection Reduce the size or number of connections through this module or add another controller or ControlNet module to the system Rockwell Automation Publication 1756 PM014F EN P September 2012 47 Chapter3 1 0 Fault Codes Code Interpretation 0322 A connection point mismatch has occurred Either Anew connection requested does not match the existing connection
27. cannot be changed 000F A MSG instruction has been configured to delete a map object that cannot be deleted 0010 The state of the device prevents a service request from being handled 0011 The reply to a message has a data size that is too large for the destination Change the destination to a tag that can handle the data size and type being returned 0013 The configuration for the module is invalid not enough configuration data was sent Verify that the correct module is being targeted 0014 AMSG instruction is configured to change an attribute that does not exist 0015 The configuration for the module is invalid too much configuration data was sent Verify that the correct module is being targeted 0100 The connection being accessed is already in use Either The controller is attempting to make a specific connection to a module and the module cannot support more than one of these connections The target of a connection recognizes that the owner is attempting to remake a connection that is already running 0103 Either The controller is requesting services not supported by the module The module in use that is the physical module is different than the module specified in the 1 0 configuration tree and is therefore causing the connection or service to fail The fault may occur even when the module passed the electronic keying test This may result when Disable Keying or Co
28. clearing that fault Identifying When the Controller is in Prescan In the main routine of your program enter this rung as the first rung in the main routine of the program CPU_scanning 0 pC i The fault routine of this program uses the status of this bit to determine if the fault occurred during prescan or normal scan of the logic e During prescan this bit is off During prescan the controller resets all bits that are referenced by OTE instructions e Once the controller begins to execute the logic the CPU_scanning bit is always on Rockwell Automation Publication 1756 PM014F EN P September 2012 25 Chapter1 Major Faults Getting the Fault Type and Code Enter this rung in the fault routine for the program GSW 0 Get System Value Class name PROGRAM Instance name THIS Attribute Name MAJORFAULTRECORD Dest major_fault_record Time_Low oe The GSV instruction e Accesses the MAJORFAULTRECORD attribute of this program This attribute stores information about the fault Stores the fault information in the major_fault_record of type FAULTRECORD tag When you enter a tag that is based on a structure enter the first member of the tag Checking for a Specific Fault Enter this rung in the fault routine for the program 1 2 3 CPU_scanning 1 Equal Equal Source major_fault_record Type Source major_fault_record Code 0e 0e Source B 4 Source B 20 CLR LF Cl
29. curs and the controller enters the faulted mode Outputs go to the faulted state The Controller Properties dialog box Major Faults tab displays the code 999 Tag_1 0 JSR Jump To Subroutine Rockwell Automation Publication 1756 PM014F EN P September 2012 Routine Name Fault_Routine Input Par 999 29 Chapter1 Major Faults Major Fault Codes The type and code correspond to the type and code displayed in these locations e Controller Properties dialog box Major Faults tab e PROGRAM object MAJORFAULTRECORD attribute Table 2 Major Fault Codes Type Code Cause Recovery Method 1 1 The controller powered on in Run mode Execute the power loss handler 1 16 1 0 communication configuration fault detected Reconfigure the number of communication modules on the 1768 bus side of the CompactLogix 1768 L4x controllers only controller e 1768 L43 has a maximum of two modules e 1768 L45 has a maximum of four modules Up to four Sercos modules Up to two NetLinx communication modules 1 40 If the controller uses a battery then the battery does not For controllers that use a battery replace the battery contain enough charge to save the user program on power For controllers that use an ESM Energy Storage Module down e Allow the ESM to fully charge before powering down the controller If the controller uses an ESM Energy Storage Module then the Replace the ESM if the ES
30. d synchronize the system 12 34 Just after a switchover occurs the keyswitch positions of the Either primary and secondary controllers are mismatched e Change the keyswitches from Run to Program to Run mode twice to clear the fault The old primary controller is in Program mode and the new Use the Logix Designer application to go online with the controllers Then clear the primary controller is in Run mode faults and change both the controllers modes to Run 14 1 Safety Task watchdog expired Clear the fault User task has not completed in a specified period of time A Ifa safety task signature exists safety memory is re initialized and the safety task begins program error caused an infinite loop the program is too executing complex to execute as quickly as specified a higher priority If a safety task signature does not exist you must re download the program to allow the task is keeping this task from finishing or the safety partner safety task to run has been removed Reinsert the safety partner if it was removed 14 2 An error exists in a routine of the safety task Correct the error in the user program logic 14 3 Safety partner is missing Install a compatible safety partner 14 4 Safety partner is unavailable Install a compatible safety partner 14 5 Safety partner hardware is incompatible Install a compatible safety partner 14 6 Safety partner firmware is incompatible Update the safety partner so that the firmware major and minor rev
31. e number call the phone number above to obtain one to your distributor to complete the return process Outside United States Please contact your local Rockwell Automation representative for the return procedure Documentation Feedback Your comments will help us serve your documentation needs better If you have any suggestions on how to improve this document complete this form publication RA DU002 available at http www rockwellautomation com literature Rockwell Otomasyon Ticaret A S Kar Plaza Is Merkezi E Blok Kat 6 34752 erenk y stanbul Tel 90 216 5698400 www rockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Furope Middle East Africa Rockwell Automation Vorstlaan Boulevard du Souverain 36 1170 Brussels Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication 1756 PM014F EN P September 2012 Supersedes Publication 1756 PM014E EN P November 2011 Copyright 2012 Rockwell Automation Inc All rights reserved Printed in the U S A
32. e of the actual module hardware does not match the Product Code of the module created in the software Electronic Keying failed for this module You may have a mismatch between the module created in the software and the actual module hardware 0115 The Product Type of the actual module hardware does not match the Product Type of the module created in the software Electronic Keying failed for this module You may have a mismatch between the module created in the software and the actual module hardware 0116 The Major or Minor revisions of the module do not match the Major or Minor revisions of the module created in the software Verify that you have specified the correct Major and Minor Revision if you have chosen Compatible Module or Exact Match keying Electronic Keying failed for this module You may have a mismatch between the module created in the software and the actual module hardware 0117 The connection is to an invalid port or port that is already in use One of these conditions exists Another controller owns this module and has connected with a Communications Format different than the one chosen by this controller Verify that the Communications Format chosen is identical to that chosen by the first owner controller of the module The module in use that is the physical module is different than the module specified in the 1 0 configuration tree and is therefore causing the connection or service to fail The fault may
33. ear Clear Dest major_fault_record Type Dest major_fault_record Code 0e 0e CPU_scanning lacus 3 2 7 Set Sustem Value Item Description 1 During prescan the bits of all OTE instructions are off and this instruction is true Once the controller begins to execute the logic this instruction is always false 2 The first EQU instruction checks for a fault of type 4 which means that an instruction in this program caused the fault 3 The second EQU instruction checks for a fault of code 20 which means that either an array subscript is too large or a POS or LEN value of a CONTROL structure is invalid 4 The first CLR instruction sets to zero the value of the fault type in the major_fault_record tag 5 The second CLR instruction sets to zero the value of the fault code in the major_fault_record tag 26 Rockwell Automation Publication 1756 PM014F EN P September 2012 Major Faults Chapter 1 Clearing the Fault Enter this rung in the fault routine for the program CPU_scanning 2 Set System Value Class name PROGRAM Instance name THIS Attribute Name MAJORFAULTRECORD Source major_fault_record Time_Low oe The SSV instruction e Begins during prescan with the bits of all OTE instructions off and this instruction is true Once the controller begins to execute the logic this instruction is always false e Writes new values to the MAJORFAULTRECORD attribute of this program e Writes the values contai
34. ered the fault For more information about the APR Fault attributes see the ntegrated Motion on the Ethernet IP Network Configuration and Startup User Manual publication MOTION UM003 18 10 An Absolute Position Recovery APR fault has occurred and the To determine the corrective action see the APR Fault Mfg attributes to determine the absolute position of the axis cannot be recovered cause of the fault This fault is indicated when a manufacturer specific APR fault For more information about the APR Fault Mfg attributes see the ntegrated Motion on has occurred the Ethernet IP Network Configuration and Startup User Manual publication MOTION UM003 18 128 A fault specific to the Guard Motion safety function has To determine the corrective action see the Guard Motion attributes and Guard Status occurred bits to determine the cause of the fault This fault is applicable only when a drive with Guard Safety For more information about the Guard Motion attributes and Guard Status bits see the functionality is used Integrated Motion on the Ethernet IP Network Configuration and Startup User Manual publication MOTION UM003 34 Rockwell Automation Publication 1756 PM014F EN P September 2012 Chapter 2 Identifying Minor Faults Minor Faults Identifying Minor Faults 35 Minor Fault Codes 38 The table explains how to use relay ladder logic to monitor information about common minor faults Table 3 Methods of Monitoring for
35. eying or Compatible Keying options were used in the module configuration instead of the Exact Match option Despite passing the electronic keying test the module being connected to does not have the same features or settings as the module specified in the 1 0 configuration tree and does not support the connection or service being attempted Check the module in use and verify that it exactly matches the module specified in the 1 0 configuration tree of the Logix Designer application For more information about electronic keying see the user manual for the module you are using 0119 The controlling connection is not open Where a Listen Only connection is requested the controlling connection is not open 011A The controller is attempting to set up a connection with the module and cannot resources required are unavailable Ifthe module is a 1756 ControlNet module up to five controllers can make Rack Optimization connections to the module Verify that this number has not been exceeded If the module is a 1794 ACN15 1794 ACNR15 or 1797 ACNR15 adapter only one controller can make a Rack Optimization connection to the module Verify that this number has not been exceeded 0203 The owner or originator recognizes that the target device is on the network or backplane however 1 0 data and messages are not being responded to In other words the target can be reached but its response is not as expected For example this fault may
36. fault Info DINT 8 Hex Fault specific information Getting the Fault Type and Code Get System Value Class name PROGRAM Instance name THIS Attribute Name MAJORFAULTRECORD Dest major_fault_record Time_Low oe The GSV instruction e Accesses the MAJORFAULTRECORD attribute of this program This attribute stores information about the fault e Stores the fault information in the major_fault_record tag of type FAULTRECORD When you enter a tag that is based on a structure enter the first member of the tag Rockwell Automation Publication 1756 PM014F EN P September 2012 23 Chapter1 Major Faults Checking for a Specific Fault o wis jor_fault_record Type 5 jor_fault_record Code wo A oo l Item Description 1 The first EQU instruction checks for a specific type of fault such as program 1 0 In Source B enter the value for the type of fault that you want to clear 2 The second EQU instruction checks for a specific fault code In Source B enter the value for the code that you want to clear 3 The first CLR instruction sets to zero the value of the fault type in the major_fault_record tag 4 The second CLR instruction sets to zero the value of the fault code in the major_fault_record tag Clearing the Fault Set System Value Class name PROGRAM Instance name THIS Attribute Name MAJORFAULTRECORD Source major_fault_record Time_Low 0e The SSV instruction write
37. fault has occurred See the DriveFaults axis tag for more information 11 11 Motor thermal fault has occurred See the DriveFaults axis tag for more information 11 12 Drive thermal fault has occurred See the DriveFaults axis tag for more information 11 13 SERCOS ring fault has occurred Verify the integrity of the SERCOS fiber optic ring network and the devices on it 11 14 Drive enable input fault has occurred Re enable the drive enable input and clear the fault 11 15 Drive phase loss fault has occurred Restore full power connection to the drive and clear the fault 11 16 Drive guard fault has occurred See the GuardFaults axis tag for more information 11 32 The motion task has experienced an overlap The group s course update rate is too high to maintain correct operation Clear the group fault tag raise the group s update rate and then clear the major fault 12 32 A disqualified secondary controller cycled power and no Verify that partner chassis or controller was found upon powerup e A partner chassis is connected e Power is applied to both redundant chassis e Partner controllers have the same Catalog number Slot number Firmware revision 12 33 An unpartnered controller has been identified in in the new Either primary chassis after a switchover e Remove the unpartnered controller and troubleshoot the cause of the switch over Adda partner controller to the secondary chassis troubleshoot the cause of the switch over an
38. for the module is invalid e The module in use that is the physical module is different than the module specified in the 1 0 configuration tree and is therefore causing the connection or service to fail The fault may occur even when the module passed the electronic keying test This may result when Disable Keying or Compatible Keying options were used in the module configuration instead of the Exact Match option Despite passing the electronic keying test the module being connected to does not have the same features or settings as the module specified in the 1 0 configuration tree and does not support the connection or service being attempted Check the module in use and verify that it exactly matches the module specified in the 1 0 configuration tree of the Logix Designer application For more information about electronic keying see the user manual for the module you are using FFOE The controller is attempting to set up a connection with the module and has received an error 50 Rockwell Automation Publication 1756 PM014F EN P September 2012 check specific fault 24 CIP Motion major fault codes 33 clear major fault 9 22 codes 1 0 faults 41 43 major fault 30 minor fault 38 controller shut down 28 status in RSLogix 5000 42 suspend 28 when in prescan 25 create data type store fault information 22 fault routine 14 routine for Fault Handler 17 routine for Power Up Handler 19 fault clear 9 codes 1 0 43 codes major 30 codes
39. g prescan To ease this burden an internal fault handler has been provided This handler is only used during prescan and only clears array faults type 4 fault codes of 20 of 83 Note Array faults are not ignored during postscan as the user program has total control of index tag values when an action is shut down Rockwell Automation Publication 1756 PM014F EN P September 2012 Major Faults Chapter 1 Placement of Fault Routines A fault routine lets you program logic to take specific action after a fault such as clearing the fault and resuming execution Fault routines can be configured specific to a program controller or to the Power Up Handler Program Fault Routine Tasks 8 MainTask 3 8 MainProgram A Program Tags E MainRoutine p Fault_Routine_1 B Alt_Fault_Routine B Other_Routine Controller Fault Routine a Controller L 5_101 Controller Tags SS Controller Fault Handler oy amp Program_for_Fault_Handler_1 A Program Tags amp B Fault_Handler_Routine_1 Power Up Fault Handler Routine 3 8 Controller L75_101 Controller Tags Controller Fault Handler 3 6 Power Up Handler a PowerUp_Program_1 Program Tags D PowerUp_Program_1 Rockwell Automation Publication 1756 PM014F EN P September 2012 Chapter1 Major Faults Choosing Where to Place the Fault Routine Where you place the routine depends on the type of fault tha
40. g the routine as a fault routine within the Power Up Handler is not necessary 6 Click OK Rockwell Automation Publication 1756 PM014F EN P September 2012 21 Chapter1 Major Faults Programmatically Clear a Major Fault The fault routine is added to the Power Up Handler g Controller L75_101 Controller Tags Controller Fault Handler Power Up Handler PowerUp_Program_1 Program Tags Ey PowerUp_Program_1 7 Double click the newly created routine to edit it To clear a major fault that occurs during the execution of your project see the following sections and complete these actions in the appropriate routine e Creating a Data Type to Store Fault Information e Getting the Fault Type and Code e Checking for a Specific Fault e Clearing the Fault IMPORTANT Do not use fault routines to continually clear all faults on the controller Program the fault routine to be selective in the types and number of faults cleared IMPORTANT When a instruction errors due to a fault for example a COP with an indirect addressing programming error the instruction is skipped and not executed This occurs with all instructions Creating a Data Type to Store Fault Information Logix5000 controllers store system information in objects Unlike PLC 5 or SLC 500 controllers there is no status file e To access system information you use a Get System Value GSV or Set System Value SSV instruction e For st
41. gix5000 RSLogix 5000 Studio 5000 and TechConnect are trademarks of Rockwell Automation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies Summary of Changes This manual contains new and updated information IMPORTANT RSLogix 5000 programming software is now known as Studio 5000 Logix Designer application a component of Studio 5000 Engineering and Design The following controllers are no longer supported in Logix Designer application version 21 Catalog Number Description 1756 L61 ControlLogix 5561 Controller 1756 L61S ControlLogix 5561S Controller 1756 L62 ControlLogix 5562 Controller 1756 L62S ControlLogix 55625 Controller 1756 L63 ControlLogix 5563 Controller 1756 L63S ControlLogix 5563S Controller 1756 L64 ControlLogix 5564 Controller 1756 L65 ControlLogix 5565 Controller 1768 L43 CompactLogix 5343 Controller 1768 L43S CompactLogix 53435 Controller 1768 145 CompactLogix 5345 Controller 1768 L45S CompactLogix 5345S Controller 1769 L23E QBF1 CompactLogix 5323E QB1 Controller 1769 L23E QBFC1 CompactLogix 5323E QBFC1 Controller 1769 L23 QBFC1 CompactLogix 5323 QBFC1 Controller 1769 131 CompactLogix 5331 Controller 1769 L32C CompactLogix 5332C Controller 1769 L32E CompactLogix 5332E Controller 1769 L35CR CompactLogix 5335CR Controller 1769 L35E CompactLogix 5335E Controller Changes throughout
42. in the 1 0 configuration tree and is therefore causing the connection or service to fail The fault may occur even when the module passed the electronic keying test This may result when Disable Keying or Compatible Keying options were used in the module configuration instead of the Exact Match option Despite passing the electronic keying test the module being connected to does not have the same features or settings as the module specified in the 1 0 configuration tree and does not support the connection or service being attempted Check the module in use and verify that it exactly matches the module specified in the 1 0 configuration tree of the Logix Designer application For more information about electronic keying see the user manual for the module you are using FEOC The controller is attempting to set up a connection with the PLC 5 controller and has received an error Verify that the instance number specified has been properly specified in the PLC 5 controller FEOD The symbol instance number was found to not be set FEOE The module is currently being updated FEOF Firmware supervisor has attempted to update an unsupported module FE10 The firmware file to update the module cannot be found FE11 The firmware file is corrupted FE12 An error has occurred while updating the module FE13 An active connection could not be made to the target module FE14 The firmware file is currently being read FE22 The target to originator netparams connect
43. ion Monitor Assigned Routines Main E MainPoutine Fault fProgram_Fault_Routine_1 De lt none gt Inhibit PEPE M Synchr in EA Cancel Apply Help 5 Click Apply and OK 16 Rockwell Automation Publication 1756 PM014F EN P September 2012 Major Faults Chapter 1 The program you specified in step 4 is now indicated as the fault routine in the main program 8 Tasks MainTask 3 88 MainProgram Program Tags Ed MainRoutine New Fault Routine for B gt ff Alt_Fault_Routine_2 Program Program_Fault_Routine_1 Creating a Routine for the ha DT lie steps for creating a v a as the controller Controller Fault Handler ault handler Program tags are automatically created during this process IMPORTANT When you program the fault handler remember that any instruction that is skipped as part of the fault handling program is not executed when the main tasks and associated programs are executed For example if your fault handler skips a JSR instruction that is causing a major fault then that JSR instruction including all of the programming within the subroutine is not executed When a instruction errors due to a fault for example a COP with an indirect addressing programming error the instruction is skipped and not executed This occurs with all instructions 1 In the Controller Organizer right click Controller Fault Handler and choose New Program a 8 Con
44. ion type is invalid FE23 The target to originator netparams connection does not specify whether unicast is allowed Rockwell Automation Publication 1756 PM014F EN P September 2012 49 Chapter3 1 0 Fault Codes Code Interpretation FF00 The controller is attempting to set up a connection with the module and has received an error Verify that the physical module is the same module type or is a compatible module as created in the software If the module is a 1756 DHRIO module in a remote chassis connected via a ControlNet network verify that the network has been scheduled with RSNetWorx software Even after the network has been scheduled with RSNetWorx for ControlNet software if you are online and if the 1756 DHRIO module is configured for DH network only a ff00 Module Fault no connection instance may occur The module is properly communicating even though Faulted is displayed as its Status on the Module Properties dialog box Disregard the error message and fault status and continue FFO1 The controller is attempting to set up a connection with the module and has received an error Verify that the path to this module is a valid length FFO4 The controller s map instance attempted to access a connection while being in an invalid state FF08 The controller is attempting to set up a connection with the module and has received an error Verify that the path to this module is a valid length FFOB Either The configuration
45. is within overtravel limit and then execute Motion Axis Fault Reset 11 2 Actual position has exceeded negative overtravel limit Move axis in positive direction until position is within overtravel limit and then execute Motion Axis Fault Reset Rockwell Automation Publication 1756 PM014F EN P September 2012 31 Chapter1 Major Faults Table 2 Major Fault Codes Type Code Cause Recovery Method 11 3 Actual position has exceeded position error tolerance Move the position within tolerance and then execute Motion Axis Fault Reset 11 4 Encoder channel A B or Z connection is broken Reconnect the encoder channel then execute Motion Axis Fault Reset 11 5 Encoder noise event detected or the encoder signals are notin Fix encoder cabling then execute Motion Axis Fault Reset quadrature 11 6 Drive Fault input was activated Clear Drive Fault then execute Motion Axis Fault Reset 11 7 Synchronous connection incurred a failure First execute Motion Axis Fault Reset If that does not work pull servo module out and plug back in If this does not work replace servo module 11 8 Servo module has detected a serious hardware fault Replace the module 11 9 Configuration fault has occurred See the AttributeErrorCode or AttributeErrorlD axis tags to identify which attribute was The motion module or drive has rejected the update of one of rejected and why the axis attributes 11 10 Motor
46. ision matches the primary controller 32 Rockwell Automation Publication 1756 PM014F EN P September 2012 Major Faults Chapter 1 Table 2 Major Fault Codes Type Code Cause Recovery Method 14 7 Safety task is inoperable Clear the fault This fault occurs when the safety logic is invalid For example a Ifa safety task signature exists safety memory is re initialized via the safety task mismatch in logix exists between the primary controllerand signature and the safety task begins executing safety partner a watchdog timeout occurred or memory is Ifa safety task signature does not exist you must download the program again to allow corrupt the safety task to run 14 8 Coordinated system time CST not found Clear the fault Configure a device to be the CST master 14 9 Safety partner nonrecoverable controller fault Clear the fault and download the program If the fault persists replace the safety partner 18 1 The CIP Motion drive has not initialized correctly To determine corrective action see the CIP Initialization attribute for details about the type of fault that occurred For more information about the CIP Initialization attribute see the Integrated Motion on the Ethernet IP Network Configuration and Startup User Manual publication MOTION UM003 18 2 The CIP Motion drive has not initialized correctly To determine the corrective action see the CIP Initiali
47. izer right click Power Up Handler and choose New Program aS Controller L 5_101 a Controller Fault Handler fia S Tasks C New Program iG MainTask Import Program E Unschedule The New Program dialog box appears New Program Name PowerUp_Program 1 Description Cancel r Help Schedule in Power Up Handier J Inhibit Program M Synchronize Redundancy Data after Execution 2 Type a program name and click OK The program has been added to the Power Up Handler a Controller L75_101 i Controller Tags m Controller Fault Handler 6 Power Up Handler EERE Powerl p_Program_1 Rockwell Automation Publication 1756 PM014F EN P September 2012 Major Faults Chapter 1 3 Right click the program you created in step 2 and choose New Routine New Routine X Import Routine Controller Organi Controller L75_101 A Controller Tags a Controller Fault Handler m E Power Up Handler copy Spe PowerUp Program_1 Paste A Program Tags Delet Cut T The New Routine dialog box appears E Name Power p_Program_1 Description Cancel Type E Ladder Diagram z Help In Program or Phase E PowerUp_Program_ 1 Assignment a Main Open Routine 4 Type the name of the routine 5 For Assignment leave the setting to the default of Main TIP Even though you can choose Fault from the Assignment pull down menu assignin
48. le in use and verify that it exactly matches the module specified in the 1 0 configuration tree of the Logix Designer application For more information about electronic keying see the user manual for the module you are using 0302 The controller is attempting to set up a connection with the module and has received an error a module in the path has exceeded its communication bandwidth capacity Increase the Requested Packet Interval RPI and reconfigure your network with RSNetWorx software Distribute the load on another bridge module 0303 The controller is attempting to set up a connection with the module and has received an error a module in the path has exceeded its communication bandwidth capacity Distribute the load on another bridge module 0304 The ControlNet module is not scheduled to send data Use RSNetWorx for ControlNet software to schedule or reschedule the ControlNet network 0305 The ControlNet configuration in the controller does not match the configuration in the bridge module This may occur because a ControlNet module was changed after the network was scheduled or because a new control program has been loaded into the controller Use RSNetWorx for ControlNet software to reschedule the connections 0306 The ControlNet Configuration Master CCM cannot be found The 1756 CNB module and PLC 5 ControlNet processor are the only devices capable of being a CCM and the CCM must be node number 1 Verify that a 1756 CNB modules or PLC 5 Co
49. minor 38 create user defined 28 develop routine to clear fault 9 during prescan 25 1 0 43 indirect address 25 monitor minor 35 routine create 14 shown in Module Properties 42 test a fault routine 27 Fault Handler create routine 17 fault handling during prescan and postscan 12 1 0 43 configuration warning 42 1 0 faults indication of 41 indicator 1 0 fault 41 indirect address 25 instruction causing minor fault 37 L Logix Designer application 7 low battery Index warning 36 M major fault codes 30 create user defined 28 develop fault routine 9 how to cleare 22 major faults CIP Motion 33 minor fault codes 38 logic 35 Module Properties fault in 42 motion major faults 33 P Power Up Handler create a routine 19 prescan clear a major fault 25 program create fault routine 14 recovering from a major fault 10 important points regarding Add On Instructions 11 routine 14 create fault 14 Fault Handler 17 Power Up Handler create 19 S shut down the controller 28 status controller in RSLogix 5000 42 store faults create data type 22 Studio 5000 Engineering and Design Environment 7 suspend controller 28 T test a fault routine 27 W warning low battery 36 Rockwell Automation Publication 1756 PM014F EN P September 2012 51 Index 52 Rockwell Automation Publication 1756 PM014F EN P September 2012 Rockwell Automation Support Rockwell Automation provide
50. mpatible Keying options were used in the module configuration instead of the Exact Match option Despite passing the electronic keying test the module being connected to does not have the same features or settings as the module specified in the 1 0 configuration tree and does not support the connection or service being attempted Check the module in use and verify that it exactly matches the module specified in the 1 0 configuration tree of Logix Designer application For more information about electronic keying see the user manual for the module you are using 0106 An ownership conflict occurred for the connection One of these conditions exists The Connection Request to this module has been rejected due to an Ownership conflict with another Owner for example another Controller This may occur with modules such as output modules that allow only a single Owner to configure and control its outputs This fault may also occur if the module is configured as Listen Only and supports only one connection If the Owner is connected to the module with a Unicast connection over EtherNet IP network other connections to the module may fail because the Owner controls the one connection If the Owner is connected to the module with a Multicast connection over EtherNet IP network Unicast connections to the module may fail because the Owner controls the one connection Configure both the Owner and the Listen Only connection as Multicast 0
51. mpt to configure the SERCOS ring failed The baud rate for all devices must be the same and supported by the drives and the SERCOS module FD08 Mainly two sets of faults may cause this fault physical and interface faults Possible sources of physical faults include these conditions e Broken ring e Loose connector Fiber optics not clean Electrical noise due to improper drive grounding e Too many nodes on the ring e Interface errors are encountered when you are configuring third party drives Potential interface errors include the following No SERCOS MST Protocol Error Missed AT drive did not send data when expected SERCOS timing error in phase 3 Error in drive data returned to SERCOS module FD09 An attempt by the controller to configure the node for cyclic operation returned an error FDOA Abad response was received from a motion module FD1F An error occurred adding the safety network segment to a route FD20 No safety task appears to be running FD22 Verify the number of physical expansion 1 0 modules configured for the controller and then update the number of modules selected from the Expansion 1 0 list on the General page in the Controller Properties dialog FD23 To verify the number of physical expansion 1 0 the controller supports open the Controller Properties dialog and expand the Expansion 1 0 list on the General page Configure the number of physical expansion 1 0 modules to match the selection in the Expansi
52. n for contact information or allow a transition to Run mode 3 16 A required 1 0 module connection failed Check the e 1 0 module is in the chassis Electronic keying requirements e Controller properties Major Fault tab and the Module Properties Connection tab for more information about the fault 3 20 Possible fault with the chassis Not recoverable replace the chassis 21 3 23 At least one required connection was not established before Wait for the controller 1 0 light to turn green before changing to Run mode going to Run mode 4 16 Unknown instruction encountered Remove the unknown instruction This probably happened due to a program conversion process 4 20 Array subscript too big control structure POS or LEN is invalid Adjust the value to be within the valid range Do not exceed the array size or go beyond dimensions defined 4 21 Control structure LEN or POS lt 0 Adjust the value so it is gt 0 4 31 The parameters of the JSR instruction do not match those of Pass the appropriate number of parameters If too many parameters are passed the the associated SBR or RET instruction extra ones are ignored without any error 4 34 A timer instruction has a negative preset or accumulated value Fix the program to not load a negative value into timer preset or accumulated value 30 Rockwell Automation Publication 1756 PM014F EN P September 2012 Major Faults Chapter 1 Table 2 Major Fault Codes
53. nd Startup User Manual publication MOTION UM003 18 6 ACIP Motion Drive fault has occurred Reconfigure the faulted motion module to correct the fault Usually the fault affects all the axis associated with the module For more information about the Module Fault attribute and Module Fault bits see the and all of the associated axes are shutdown Integrated Motion on the Ethernet IP Network Configuration and Startup User Manual publication MOTION UM003 18 7 A motion group fault has occurred Reconfigure the entire motion subsystem to correct the fault Usually the fault affects all of the axes associated with a motion See the Group Fault attribute if details about the fault are needed group 18 8 A fault has occurred during the configuration of a CIP Motion To determine the corrective action see the Configuration Fault in the Attribute Error Code Drive and Attribute Error ID attributes associated with the motion or 1756 ENxT module Typically this fault occurs after an attempt to update an axis configuration attribute of a CIP Motion Drive was unsuccessful Rockwell Automation Publication 1756 PM014F EN P September 2012 33 Chapter 1 Major Faults Table 2 Major Fault Codes Type Code Cause Recovery Method 18 9 An Absolute Position Recovery APR fault has occurred and the To determine the corrective action see the APR Fault attributes to determine the cause of absolute position of the axis cannot be recov
54. ned in the major_fault_record tag Because the Type and Code member are set to zero the fault clears and the controller resumes execution Testing a Fault Routine You can use a JSR instruction to test the fault routine of a program without creating an error simulate a fault 1 Create a BOOL tag that you will use to initiate the fault 2 In the main routine or a subroutine of the program enter this rung EXAMPLE Test a fault routine When test_fault_routine is on a major fault occurs and the controller executes Fault_Routine JSR Jump to Subroutine Routine name Fault_Routine test_fault_routine Where Is the test_fault_routine Tag that you will use to initiate the fault Fault_Routine Fault routine of the program Rockwell Automation Publication 1756 PM014F EN P September 2012 27 Chapter1 Major Faults Creating a User Defined If m want to suspend ore the ail aes anni ae Major Fault app ication create a user derine major ault ith a user derine major ault e The fault type 4 e You define a value for the fault code Choose a value between 990 999 These codes are reserved for user defined faults e The controller handles the fault the same as other major faults The controller changes to the Program mode and stops executing the logic Outputs are set to their configured state or value for faulted mode EXAMPLE ATTENTION When Tag_1 0 1 produce a major fault and generate
55. nes engineering Design Environment and Logix Designer Application In This Manual and design elements into a common environment The first element in the Studio 5000 environment is the Logix Designer application The Logix Designer application is the rebranding of RSLogix 5000 software and will continue to be the product to program Logix5000 controllers for discrete process batch motion safety and drive based solutions r 7 Rockwell Software Studio 5000 Create Open Explore New Project Existing Project Help From Import Sample Project Release Notes From Sample Project From Upload About Recent Projects g Sepi Test g Integeates_Motion_Co 8 August 2012 The Studio 5000 environment is the foundation for the future of Rockwell Automation engineering design tools and capabilities It is the one place for design engineers to develop all the elements of their control system This manual shows how to monitor and handle major and minor controller faults It also provides lists of major minor and I O fault codes that can be used when troubleshooting your system This manual is one of a set of related manuals that show common procedures for programming and operating Logix5000 controllers For a complete list of common procedures manuals see the Logix5000 Controllers Common Procedures Programming Manual publication 1756 PMO001 The term Logix5000 controller refers to any controller tha
56. nown as fault recovery IMPORTANT Do not use fault routines to continually clear all faults on the controller Program the fault routine to be selective in the types and number of faults cleaned It is also a good idea to log that the fault occurred so it can be analyzed later IMPORTANT When an instruction errors due to a fault for example a COP with an indirect addressing programming error the instruction is skipped and not executed This occurs with all instructions EXAMPLE In a system that uses recipe numbers as indirect addresses an incorrectly typed number could produce a major fault To keep the entire system from shutting down in the event of this fault a fault routine can be programmed to clear type 4 code 20 major faults Recovering From a Major Fault If the fault is cleared the faulted instruction does not continue executing Example 1 SR Jump To Subroutine Routine Name subroutine Input Par array bad_index Return Par returnValue Rockwell Automation Publication 1756 PM014F EN P September 2012 Major Faults Chapter 1 AJSR instruction passes an input parameter containing an indirect address that is out of bounds If the fault is cleared the JSRinstruction is aborted the subroutine is not executed and execution resumes with the EQU Example 2 y AO myAoi myAoiTag input q 0e input2 r 0e output1 S 0e output2 t 0e ov Move Source x
57. ntrolNet processor is at node number 1 and is functioning properly This fault may temporarily occur when the system is powered up and will be cleared when the CCM is located 0311 The controller is attempting to set up a connection with the module and has received an error Verify that all modules in the 1 0 Configuration tree are the correct modules 0312 The controller is attempting to set up a connection with the module and has received an error an invalid link address has been specified A link address can be a slot number a network address or the remote 1 0 chassis number and starting group Verify that the chosen slot number for this module is not greater than the size of the rack Verify that the ControlNet node number is not greater than the maximum node number configured for the network in RSNetWorx for ControlNet software 0315 The segment type or route is invalid Either The controller is attempting to set up a connection with the module and has received an error the connection request is invalid The module in use that is the physical module is different than the module specified in the 1 0 configuration tree and is therefore causing the connection or service to fail The fault may occur even when the module passed the electronic keying test This may result when Disable Keying or Compatible Keying options were used in the module configuration instead of the Exact Match option Despite passing the electronic keying test the module
58. on 1 0 list FEO1 An invalid configuration format was encountered FEO2 The Requested Packet Interval RPI specified is invalid for this module See the Connection tab for valid RPI values FE03 The input connection point has not been set FE04 The controller is attempting to set up a connection with the module and has received an error 48 Rockwell Automation Publication 1756 PM014F EN P September 2012 1 0 Fault Codes Chapter 3 Code Interpretation FE05 Either e The controller is attempting to set up a connection with the module and has received an error The module in use that is the physical module is different than the module specified in the 1 0 configuration tree and is therefore causing the connection or service to fail The fault may occur even when the module passed the electronic keying test This may result when Disable Keying or Compatible Keying options were used in the module configuration instead of the Exact Match option Despite passing the electronic keying test the module being connected to does not have the same features or settings as the module specified in the 1 0 configuration tree and does not support the connection or service being attempted Check the module in use and verify that it exactly matches the module specified in the 1 0 configuration tree of the Logix Designer application For more information about electronic keying see the user manual for the module
59. onfiguration tree and does not support the connection or service being attempted Check the module in use and verify that it exactly matches the module specified in the 1 0 configuration tree of the Logix Designer application For more information about electronic keying see the user manual for the module you are using 0206 46 Either The controller is attempting to set up a connection with the module and has received an error the request size is too large Verify that the path to this module is sufficiently close to the controller The module in use that is the physical module is different than the module specified in the 1 0 configuration tree and is therefore causing the connection or service to fail The fault may occur even when the module passed the electronic keying test This may result when Disable Keying or Compatible Keying options were used in the module configuration instead of the Exact Match option Despite passing the electronic keying test the module being connected to does not have the same features or settings as the module specified in the 1 0 configuration tree and does not support the connection or service being attempted Check the module in use and verify that it exactly matches the module specified in the 1 0 configuration tree of the Logix Designer application For more information about electronic keying see the user manual for the module you are using Rockwell Automation Publication 1756 PM014F EN P
60. ority 6 3 Event task overlap Make changes such as simplifying programs lengthening the period Event task has not completed before it is time to execute again raising the relative priority or slowing the triggering event 6 4 Virtual adapter task overlap CompactLogix 1769 L2x and 1769 L3x Increase the RPI for the CompactBus controllers only Virtual adapter has not completed running at the rate specified by the RPI when it executed again 7 49 Project loaded from nonvolatile memory 9 0 Unknown error while servicing the serial port Contact Rockwell Automation Technical Support See the back of this publication 38 Rockwell Automation Publication 1756 PM014F EN P September 2012 Minor Faults Chapter 2 Table 4 Minor Faults Type Code Cause Recovery Method 9 1 The CTS line is not correct for the current configuration Disconnect and reconnect the serial port cable to the controller Make sure the cable is wired correctly 9 2 Poll list error Check for these errors in the poll list A fault was detected with the DF1 master s poll list such as specifying Total number of stations is greater than the space in the poll list tag more stations than the size of the file specifying more then 255 stations e Total number of stations is greater than 255 trying to index past the end of the list or polling the broadcast address e Current station pointer is greater than the end of the poll list tag
61. p Handler 19 Programmatically Clear a Major Fault 22 Creating a Data Type to Store Fault Information 22 Getting the Fault Type and Code 2 Checking for a Specific Fault 24 Clearing the Fault 24 Clearing a Major Fault During Prescan 25 Identifying When the Controller is in Prescan 25 Getting the Fault Type and Code 26 Checking for a Specific Fault 26 Clearing the Fault 27 Testing a Fault Routine 27 Creating a User Defined Major Fault 28 Creating a Fault Routine for the Program 28 Configuring the Program to Use the Fault Routine 28 Jumping to the Fault Routine 29 Major Fault Codes 30 Ifa fault condition occurs that would prevent an instruction from being able to execute the instruction is aborted and a major fault is reported A major fault causes logic execution to halt and the controller switches to faulted mode the OK LED flashes red Depending on your application you may not want all major faults to shut down your system If you do not want all major faults to shut down your system create a fault routine to clear the fault and let your application continue to execute See Creating a Routine for the Controller Fault Handler on page 17 and Clearing a Major Fault During Prescan on page 25 Rockwell Automation Publication 1756 PM014F EN P September 2012 9 Chapter 1 Major Faults 10 Equal Source A returnValue 0 123 Source B QU The process of resuming execution after a fault is cleared is k
62. r a minor fault Minor_fault_check times for 1 minute 60000 ms and then automatically restarts itself minor_fault_check DN TON i Timer On Delay Timer minor_fault_check h gt Preset 60000 Accum Every minute minor_fault_check DN turns on for one scan When this occurs the GSV instruction gets the value of the FAULTLOG object MinorFaultBits attribute and stores it in the minor_fault_bits tag Because the GSV instruction only executes once every minute the scan time of most scans is reduced minor_fault_check DN GSV Get System Value Class name FAULTLOG Instance name Attribute Name MinorFaultBits Dest minor_fault_bits pe If minor_fault_bits 10 is on then the battery is low or ESM minor fault minor_fault_bits 10 battery_low_warning 36 Rockwell Automation Publication 1756 PM014F EN P September 2012 Minor Faults Chapter 2 This example checks for a minor fault that is caused by a specific instruction EXAMPLE Check for a minor fault that is caused by an instruction Multiply value_a by 1000000 and check for a minor fault such as a math overflow e To make sure that a previous instruction did not produce the fault the rung first clears S MINOR e The rung then executes the multiply instruction e Ifthe instruction produces a minor fault the controller sets S MINOR e IfS MINOR is set the GSV instruction gets information about the fault and resets S MINOR S MINOR UL
63. ry 7 Click OK The fault routine is created in the Controller Fault Handler program Controller L75_101 A Controller Tags a Controller Fault Handler aS Program_for_Fault_Handler_1 Program Tags E Fault _Handler_Routine_1 8 Double click the newly created routine to edit it The Power Up Handler is an optional task that executes when the controller powers up in Run or Remote Run modes Do this Leave the routine for the Power Up Handler empty When power is restored a major fault type 1 code 1 occurs and the controller enters the faulted state Have the controller take specific actions then resume normal operation when power is restored In the Power Up Handler fault routine complete these steps 1 Clear the major fault type 1 code 1 2 Execute the appropriate logic for the specific actions required IMPORTANT Do not use fault routines to continually clear all faults on the controller Program the fault routine to be selective in the types and number of faults cleared IMPORTANT When a instruction errors due to a fault for example a COP with an indirect addressing programming error the instruction is skipped and not executed This occurs with all instructions Rockwell Automation Publication 1756 PM014F EN P September 2012 19 Chapter 1 20 Major Faults Complete these steps to create a fault routine for the Power Up Handler in Logix Designer software 1 In the Controller Organ
64. s e New values to the MAJORFAULTRECORD attribute of this program e The values contained in the major_fault_record tag Because the Type and Code member are set to zero the fault clears and the controller resumes execution 24 Rockwell Automation Publication 1756 PM014F EN P September 2012 Major Faults Chapter 1 Clearing a Major Fault During Prescan If controller is revision If the controller faults immediately after you switch it to the Run mode then examine the prescan operation for the fault Depending on the revision of your controller an array subscript that is beyond the range of the array out of range during prescan may or may not produce a fault Then 11 x or earlier During prescan an array subscript that is beyond the range of the array out of range produces a major fault 12 x See the release notes for the firmware of your controller 13 0 or later During prescan the controller automatically clears any faults due to an array subscript that is beyond the range of the array out of range See the following procedures to clear a major fault that occurs during prescan e Identifying When the Controller is in Prescan see page 25 e Getting the Fault Type and Code see page 26 e Checking for a Specific Fault see page 26 e Clearing the Fault see page 27 IMPORTANT It is good programming practice to check for a specific fault before
65. s technical information on the Web to assist you in using its products At http www rockwellautomation com support you can find technical manuals a knowledge base of FAQs technical and application notes sample code and links to software service packs and a MySupport feature that you can customize to make the best use of these tools For an additional level of technical phone support for installation configuration and troubleshooting we offer TechConnect support programs For more information contact your local distributor or Rockwell Automation representative or visit http www rockwellautomation com support Installation Assistance If you experience a problem within the first 24 hours of installation review the information that is contained in this manual You can contact Customer Support for initial help in getting your product up and running United States or Canada _ 1 440 646 3434 Outside United States or Use the Worldwide Locator at http www rockwellautomation com support americas phone_en html or Canada contact your local Rockwell Automation representative New Product Satisfaction Return Rockwell Automation tests all of its products to ensure that they are fully operational when shipped from the manufacturing facility However if your product is not functioning and needs to be returned follow these procedures United States Contact your distributor You must provide a Customer Support cas
66. t is based on the Logix5000 operating system including these controllers e CompactLogix e ControlLogix DriveLogix e FlexLogix e SoftLogix5800 Rockwell Automation Publication 1756 PM014F EN P September 2012 7 Preface Additional Resources These documents contain additional information concerning related products from Rockwell Automation Resource Description Industrial Automation Wiring and Grounding Guidelines publication 1770 4 1 Product Certifications website http www ab com Provides general guidelines for installing a Rockwell Automation industrial system Provides declarations of conformity certificates and other certification details You can view or download publications at http www rockwellautomation com literature To order paper copies of technical documentation contact your local Allen Bradley distributor or Rockwell Automation sales representative Rockwell Automation Publication 1756 PM014F EN P September 2012 Chapter 1 Major Fault State Major Faults Topic Page Major Fault State 9 Placement of Fault Routines 13 Choosing Where to Place the Fault Routine 14 Creating a Fault Routine for a Program 14 Changing a Fault Routine Assignment of a Program 16 Creating a Routine for the Controller Fault Handler pr Creating a Routine for the Power U
67. t you want to handle Use this table to determine where in the project your fault routine should be configured Table 1 Determine Response to Major Faults If you want take specific action or clear the fault when See this section Page Condition Fault Type The execution of an instruction faults 4 Creating a Fault Routine for a Program 14 Communication with an 1 0 module fails 3 Creating a Routine for the Controller Fault Handler Pd Watchdog timer for a task expires 6 A motion axis faults 11 The controller powers up in Run or Remote Run mode 1 Creating a Routine for the Power Up Handler 19 Creating a Fault Routine for a Program Complete these steps to create a fault routine 1 Open the project in the Logix Designer software 2 In the Controller Organizer right click the MainProgram and choose New Routine B E Controller L63_New_Controller IA Controller Tags Controller Fault Handler Power Up Handler H S Tasks MainTask A MainProgram F unscheduled Prox Motion Groups Import Routine _ Ungrouped Axes BE Add An tnecbeichinne BERA CIE 14 Rockwell Automation Publication 1756 PM014F EN P September 2012 Major Faults Chapter 1 The New Routine dialog box appears x l C Description Cancel Type E Ladder Diagram v Help In Program or Phase C MainProgram v Assignment knone gt v lt none gt J Open Routine Fault he
68. troller L75_101 Controller Tags Controller Fault Handler Ca New Program New Program I Power Up Handler 2 t Tasks Import Prog be 3 48 MainTask Rockwell Automation Publication 1756 PM014F EN P September 2012 17 Chapter 1 18 Major Faults The New Program dialog box appears New Program a j M Synchronize Redundancy Data after Execution 2 Enter a program name and verify that Schedule in is set to Controller Fault Handler 3 Click OK 4 Right click the program you created in step 2 and choose New Routine Controller Organizer Import Routine I Controller L75_101 A Controller Tags 8 Controller Fault Handler ao Program_for_Fault_Handler_1 A Program Tags Power Up Handler Cut Copy Paste Delete The New Routine dialog box appears New Routine Routine_Fault_Handler_1 B Ladder Diagram E Program_tor Fault_Handler_1 Rockwell Automation Publication 1756 PMO14F EN P September 2012 Major Faults Chapter 1 Creating a Routine for the Power Up Handler To Prevent the controller from returning to Run or Remote mode 5 Enter a name for the routine 6 For Assignment leave the setting to the default of Main TIP Even though you can choose Fault from the Assignment pull down menu assigning the routine as a fault routine within the Controller Fault Handler is not necessa
69. ule Properties dialog box for the additional fault code The additional fault code indicates the configuration parameter that is causing the fault You may have to correct multiple parameters before this fault is cleared and connection is properly established Verify that the configuration is valid by using the module configuration software to validate your configuration Consult the module documentation for a list of fault codes to determine the configuration parameter that is in error 000A Either e A connection is being created where the connection type is invalid An object attribute or tag value is invalid If an object attribute or tag is invalid export the Logix Designer file then re import it Reschedule the ControlNet network after re importing if applicable Rockwell Automation Publication 1756 PM014F EN P September 2012 43 Chapter 3 Code 000C 1 0 Fault Codes Interpretation The controller is attempting to request a service from the module and has received an error First verify that the module is not faulted For an 1 0 module this may indicate that the module has one of these conditions Limited communication but has a Major Fault A firmware update needs to be completed or is currently being completed Refer to the Module Info tab to determine the exact cause 000D An 1 0 map instance is created where the instance is already in use 000E A MSG instruction is configured to change an attribute that
70. up a connection with the module and cannot the size of the connection is invalid The controller may be attempting to connect to a tag in a producing controller whose size does not match the tag in this controller The module in use that is the physical module is different than the module specified in the 1 0 configuration tree and is therefore causing the connection or service to fail The fault may occur even when the module passed the electronic keying test This may result when Disable Keying or Compatible Keying options were used in the module configuration instead of the Exact Match option Despite passing the electronic keying test the module being connected to does not have the same features or settings as the module specified in the 1 0 configuration tree and does not support the connection or service being attempted Check the module in use and verify that it exactly matches the module specified in the 1 0 configuration tree of the Logix Designer application For more information about electronic keying see the user manual for the module you are using If the module is a 1756 ControlNet module verify that the chassis size is correct For remote 1 0 adapters verify that the rack size and rack density is correct 0110 The controller is attempting to set up a Listen Only connection with the module and cannot the module has not been configured and connected to by an Owner for example another controller This controller is not
71. user manual for the module you are using If you are using a 1756 DHRIO module verify that the Channel type selected in the software DH or remote 1 0 network matches the module s rotary switch settings 0006 Either The response buffer is too small to handle the response data e The module in use that is the physical module is different than the module specified in the 1 0 configuration tree and is therefore causing the connection or service to fail The fault may occur even when the module passed the electronic keying test This may result when Disable Keying or Compatible Keying options were used in the module configuration instead of the Exact Match option Despite passing the electronic keying test the module being connected to does not have the same features or settings as the module specified in the 1 0 configuration tree and does not support the connection or service being attempted Check the module in use and verify that it exactly matches the module specified in the 1 0 configuration tree of Logix Designer application For more information about electronic keying see the user manual for the module you are using 0007 A service request is unconnected but should be connected 0008 The controller has requested a service which is not implemented on the target module 0009 The configuration for the module is invalid The module configuration may have been changed in the Data Monitor or programmatically Access the Connections tab of the Mod
72. ute or the controller program at powerdown 17 1 1 An internal controller diagnostic has failed Contact Rockwell Automation Technical Support with the fault type and fault code logged See the back of this publication Rockwell Automation Publication 1756 PM014F EN P September 2012 39 Chapter2 Minor Faults Notes 40 Rockwell Automation Publication 1756 PM014F EN P September 2012 Chapter 3 1 0 Fault Codes Topic Page Indications of 1 0 Faults 41 1 0 Fault Codes 43 Indications of 1 0 Faults I O faults are indicated by these means e The I O indicator of the controller shown in examples below flashes green or red Figure 1 175 FORCE E ok 0 ORCEC CARS232 BATT DCHO A BATO CAOK RUN REM PROG I O fault messages are indicated on the controller status display Figure 2 175 Status Display Rockwell Automation Publication 1756 PM014F EN P September 2012 41 Chapter 3 42 1 0 Fault Codes e The I O status indicator and message in the controller status area of the Logix Designer application Rem Prog Ao Program Mode No Forces gt E Controller OK F Battery OK No Edits Redundan cy Bo 1 0 indicator flashes green or red and the corresponding status message indicates an error 1 0 Not Responding e A yellow warning symbol appears on the module in the I O Configuration tree of the Logix Designer application B Sa KO Configuration
73. zation Fault Mfg attributes for This fault is indicated when a manufacturer specific details about the fault that occurred initialization fault has occurred For more information about the CIP Initialization Fault Mfg attribute see the ntegrated Motion on the Ethernet IP Network Configuration and Startup User Manual publication MOTION UMO003 18 3 The Physical Axis Fault bit is set indicating a fault on the To determine corrective action see the CIP Axis Fault attributes for details about the fault physical axis that occurred For more information about the CIP Axis Fault attributes see the ntegrated Motion on the Ethernet IP Network Configuration and Startup User Manual publication MOTION UMO003 18 4 The Physical Axis Fault bit is set indicating a fault on the To determine corrective action see the CIP Axis Fault Mfg attributes for details about physical axis the fault that occurred This fault is indicated when a manufacturer specific axis fault For more information about the CIP Axis Fault Mfg attributes see the ntegrated Motion has occurred on the Ethernet IP Network Configuration and Startup User Manual publication MOTION UM003 18 5 A motion fault occurred To determine corrective action see the Motion Fault attribute and Motion Fault bits for details about the fault that occurred For more information about the Motion Fault attribute and Motion Fault bits see the Integrated Motion on the Ethernet IP Network Configuration a

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