Maintenance and Troubleshooting
Contents
1. SPO On first scan only SP60 Acc is less than value SP1 Always ON SP61 Acc is equal to value SP3 1 minute clock SP62 Acc is greater than value SP4 1 second clock SP63 Acc result is zero SP5 100 millisecond clock SP64 Half borrow occurred SP6 50 millisecond clock SP65 Borrow occurred SP7 On alternate scans SP66 Half carry occurred CPU Status Relays SP67 Carry occurred SP11 Forced run mode SP70 Result is negative sign SP12 Terminal run mode SP71 Pointer reference error SP13 Test run mode SP73 Overflow SP14 Test hold mode SP75 Data is not in BCD SP15 Test program mode SP76 Load zero SP16 Terminal program mode Communication Monitoring Relays SP20 STOP instruction was executed SP116 Port 2 is communicating with another SP21 BREAK instruction was executed device SP22 Interrupt enabled SP117 Communication error on Port 2 System Monitoring Relays SP120 Module busy Slot 0 SP40 Critical error SP121 Communication error Slot 0 SP41 Non critical error SP122 Module busy Slot 1 SP43 Battery low SP123 Communication error Slot 1 SP46 Communications error erie Module busy Slot 2 SP47 1 0 configuration error SP125 Communication error Slot 2 SP50 Fault instruction was executed setae Module busy Slot 3 SP51 Watchdog timeout SP127 Communication error Slot 3 SP52 Syntax error SP130 Module busy Slot 4 SP53 Cannot solve the logic SP131 Communication error Slot 4 SP54 Intelligent module communication error whee Module busy Slot 5 SP2. Handheld Z Programmer Eno Koyamokoa wead X0 X2 XS X7 Y2 Insert an END statement fo Test an Output 1 1 C 2 at the beginning of the Point X1 X3 X4 program This disables 1 1 the remainder of the program 0 From a clear display use the following keystrokes 16P STATUS STAT ENT BIT REF SaoueUaIUle o 2 fe z i a fe fe a 5 Co A Y 10 Y 0 NEXT 0 Use arrow keys to select point then use ON and OFF to change the status ON lt L SHFT INS DL350 User Manual 2nd Edition 9 16 Maintenance and Troubleshooting Noise Troubleshooting fe E s o O OO ele On S2 Fa es oe SE ko z oO Electrical Noise Noise is one of the most difficult problems to diagnose Electrical noise can enter a Problems system in many different ways and fall into one of two categories conducted or radiated It may be difficult to determine how the noise is entering the system but the corrective actions for either of the types of noise problems are similar Conducted noise is when the electrical interference is introduced into the system by way of a attached wire panel connection etc It may enter through an I O module
3. RUN Mode TEST RUN Mode S TMR TO K1000 TMR TA K1000 TO Contact S is off TO Contact S is off E is on Input to Timer Current Value E is on Holding Output States The ability to hold output states is very useful because it allows you to maintain key system I O points In some cases you may need to modify the program but you do not want certain operations to stop In normal Run Mode the outputs are turned off when you return to Program Mode In TEST RUN mode you can set each individual output to either turn off or to hold its last output state on the transition to TEST PGM mode This feature is available via a menu option within DirectSOFT The following diagram shows the differences between RUN and TEST RUN modes RUN Mode to PGM Mode xo x2 Yo C X1 X3 X4 Outputs are 4 1 1 OFF Status on final scan X10 Pe C Xo x2 i i f D X1 X3 X4 Eno of vo X10 pa wow T C TEST RUN to TEST PGM eS XO x2 YO TE Eno g X1 X3 A Hold YO ON gt IZ X10 y1 C Let Y1 turn Pa OFF ED Before you decide that Test Mode is the perfect choice remember the DL350 CPU also allows you to edit the program during Run Mode The primary difference between the Test Modes and the Run Time Edit feature is you do not have to configure each individual I O point to hold the output status When you use Run Time Edits the CPU
4. E499 Invalid Text entry for Print Instruction E640 Miscompare E501 Bad entry E650 Handheld Programmer system error E502 Bad address E651 Handheld Programmer ROM error E503 Bad command E652 Handheld Programmer RAM error E504 Bad reference value E505 Invalid instruction E506 Invalid operation DL350 User Manual 2nd Edition Maintenance and Troubleshooting Program Error The following list shows the errors that can occur when there are problems with the Codes program These errors will be detected when you try to place the CPU into Run Mode or when you use AUX 21 Check Program The CPU will also turn on SP52 and store the error code in V7755 Appendix B provides a more complete description of the error codes Error Code Description Error Code Description E4 No Program in CPU E461 Stack Overflow E401 Missing END statement E462 Stack Underflow E402 Missing LBL E463 Logic Error E403 Missing RET E464 Missing Circuit E404 Missing FOR E471 Duplicate coil reference E405 Missing NEXT E472 Duplicate TMR reference E406 Missing IRT E473 Duplicate CNT reference E412 SBR LBL gt 64 E480 CV position error E413 FOR NEXT gt 64 E481 CV not connected E421 Duplicate stage reference E482 CV exceeded E422 Duplicate SBR LBL reference E483 CVJMP placement error E423 Nested loops E484 No CV E431 Invalid ISG SG address E485 No CVJMP E432 In
5. CPU is in Run Mode when the fatal error occurs the CPU will switch to Program Mode Remember in Program Mode all outputs are turned off If the fatal error is detected while the CPU is in Program Mode the CPU will not enter Run Mode until the error has been corrected Here are some examples of fatal errors e Base power supply failure e Parity error or CPU malfunction e 1 O configuration errors e Certain programming errors Non fatal Errors Non fatal errors are errors that are flagged by the CPU as requiring attention They can neither cause the CPU to change from Run Mode to Program Mode nor do they prevent the CPU from entering Run Mode There are special relays the application program can use to detect if a non fatal error has occurred The application program can then be used to take the system to an orderly shutdown or to switch the CPU to Program Mode if necessary Some examples of non fatal errors are e Backup battery voltage low e All I O module errors e Certain programming errors Finding Diagnostic Diagnostic information can be found in several places with varying levels of Information message detail e The CPU automatically logs error codes and any FAULT messages into two separate tables which can be viewed with the Handheld or DirectSOFT e The handheld programmer displays error numbers and short descriptions of the error e DirectSOFT provides the error number and an error message e Appendix B in this manual has a c
6. Forcing From a clear display use the following with Direct Access keystrokes to force Y10 ON Solid fill indicates point is on swt ws P bo J Lt Lins BIT FORCE Y10 From a clear display use the following keystrokes to force Y10 OFF No fill indicates point is off oT Pws Ea So Lt Loe BIT FORCE Y10 aoueUalule v 2a fe fa or D a 3 fe A 5 amp DL350 User Manual 2nd Edition
7. at the time you make the request If the CPU is in Run Mode mode then TEST RUN is available If the mode is Program then TEST PGM is available Once you ve selected TEST Mode you can easily switch between TEST RUN and TEST PGM DirectSOFT provides more flexibility in selecting the various modes with different menu options The following example shows how you can use the Handheld to select the Test Modes Use the MODE key to select TEST Modes example assumes Run Mode MODE CHANGE GO TO T RUN MODE MODE NEXT ENT Press ENT to confirm TEST RUN Mode Note the TEST LED on the DL205 MODE CHANGE Handheld indicates the CPU is in CPU T RUN TEST Mode fed You can return to Run Mode enter Program Mode or enter TEST PGM a Mode by using the Mode Key 5 CLR MODE NEXT NEXT ENT MODE CHANGE Sz GO TO T PGM MODE os e 68 Press ENT to confirm TEST PGM Mode Q enr Note the TEST LED on the DL205 MODE CHANGE Handheld indicates the CPU is in CPU T PGM TEST Mode DL350 User Manual 2nd Edition 9 20 Maintenance and Troubleshooting Test Displays With the Handheld Programmer you also have a more detailed display when you use TEST Mode For some instructions the TEST RUN mode display is more detailed than the status displays shown in RUN mode The following diagram shows an example of a Timer instruction display during TEST RUN mode
8. automatically maintains all outputs in their current states while the program is being updated DL350 User Manual 2nd Edition Special Instructions Maintenance and Troubleshooting 9 21 There are several instructions that can be used to help you debug your program during machine startup operations e END e PAUSE e STOP END Instruction If you need a way to quickly disable part of the program insert an END statement prior to the portion that should be disabled When the CPU encounters the END statement it assumes it is the end of the program The following diagram shows an example Normal Program New END disables X10 and Y1 XO X2 pa X0 X2 YO C C x1 X3 X4 X1 X3 X4 1 1 1 1 X10 Y1 CO ED Z X10 Al v C ED STOP Instruction Sometimes during machine startup you need a way to quickly turn off all the outputs and return to Program Mode In addition to using the Test Modes you can also use the STOP instruction When this instruction is executed the CPU automatically exits Run Mode and enters Program Mode Remember all outputs are turned off during Program Mode The following diagram shows an example of a condition that returns the CPU to Program Mode Normal Program STOP puts CPU in Program Mode XO x2 YO X20 2 CO m ED dz X1 x3 X4 xo x2 YO 32 cS S5 XX So X10 pe x1 X3
9. flashing to indicate RUNTIME EDITS Run Time Edits are enabled Find the instruction you want to change X0 X A SHFT FD REF SHET SET 0 FIND 00000 STR X0 Press the arrow key to move to the X Then enter the new contact C10 5 5 a e P M E RUNTIME EDIT STR C10 Press ENT to confirm the change ent Note once you press ENT the next address is displayed OR CO aoueUalUle o Q fe z 2 o 3 fa fe 5 Co DL350 User Manual 2nd Edition 9 24 Maintenance and Troubleshooting Forcing I O Points There are many times especially during machine startup and troubleshooting D E s o O OO ale On S2 To es oe SE ke oO wee D an where you need the capability to force an I O point to be either on or off Before you use a programming device to force any data type it is important to understand how the DL350 CPU processes the forcing requests WARNING Only authorized personnel fully familiar with all aspects of the application should make changes to the program Make sure you thoroughly consider the impact of any changes to minimize the risk of personal injury or damage to equipment e Regular Forcing This type of forcing can temporarily change the status of a discrete bit For example you may want to force an input on even though it
10. the application program unless the CPU has a fatal error If a fatal error has occurred the CPU LED should be on You can use a programming device to determine the cause of the error If you are using a DL350 and you are trying to change the modes with a programming device make sure the mode switch is in the TERM position Both of the programming devices Handheld Programmer and DirectSOFT will return a error message describing the problem Depending on the error there may also be an AUX function you can use to help diagnose the problem The most common programming error is Missing END Statement All application programs require an END statement for proper termination A complete list of error codes can be found in Appendix B CPU Indicator If the CPU indicator is on a fatal error has occurred in the CPU Generally this is not a programming problem but an actual hardware failure You can power cycle the system to clear the error If the error clears you should monitor the system and determine what caused the problem You will find this problem is sometimes caused by high frequency electrical noise introduced into the CPU from an outside source Check your system grounding and install electrical noise filters if the grounding is suspected If power cycling the system does not reset the error or if the problem returns you should replace the CPU BATT Indicator If the BATT indicator is on the CPU battery is either disconnected or
11. 133 Communication error Slot 5 SP134 Module busy Slot 6 SP135 Communication error Slot 6 SP136 Module busy Slot 7 SP137 Communication error Slot 7 DL350 User Manual 2nd Edition ouL LusuUeN o 2 fe E i a i fa a 5 Co 9 6 Maintenance and Troubleshooting D E s o O OO ale On S2 To es oe SE Oo oO Error Message Tables The DL350 CPU will automatically log any system error codes and any custom messages you have created in your application program with the FAULT instructions The CPU logs the error code the date and the time the error occurred There are two separate tables that store this information e Error Code Table the system logs up to 32 errors in the table When an error occurs the errors already on the table are pushed down and the most recent error is loaded into the top slot If the table is full when an error occurs the oldest error is pushed erased from the table e Message Table the system logs up to 16 messages in this table When a message is triggered the messages already stored in the table are pushed down and the most recent message is loaded into the top slot If the table is full when an error occurs the oldest message is pushed erased from the table The following diagram shows an example of an error table for messages Date Time Message 1993 05 26 08 41 51 11 Conveyor 2 stopped 1993 04 30 17 01 11 56 C
12. Maintenance and Troubleshooting In This Chapter Hardware Maintenance Diagnostics CPU Indicators PWR Indicator RUN Indicator CPU Indicator BATT Indicator Communications Problems O Module Troubleshooting Noise Troubleshooting Machine Startup and Program Troubleshooting 9 2 Maintenance and Troubleshooting Hardware Maintenance fe E s o O OO ale On S2 To es oe SE ko S Standard Maintenance Air Quality Maintenance Low Battery Indicator CPU Battery Replacement The DL305 is a low maintenance system requiring only a few periodic checks to help reduce the risks of problems Routine maintenance checks should be made regarding two key items e Air quality cabinet temperature airflow etc e CPU battery The quality of the air your system is exposed to can affect system performance If you have placed your system in an enclosure check to see the ambient temperature is not exceeding the operating specifications If there are filters in the enclosure clean or replace them as necessary to ensure adequate airflow A good rule of thumb is to check your system environment every one to two months Make sure the DL305 is operating within the system operating specifications The CPU has a battery LED that indicates the battery voltage is low You should check this indicator periodically to determine if the battery needs replacing
13. X4 Tz C Yi 33 X10 Y1 Eno C D Co Gs In the example shown above you could trigger X20 which would execute the STOP instruction The CPU would enter Program Mode and all outputs would be turned off DL350 User Manual 2nd Edition fe s o O OO ale On S2 To es oe Sk ko S Maintenance and Troubleshooting Run Time Edits The DL350 CPU allows you to make changes to the application program during Run Mode These edits are not bumpless Instead CPU scan is momentarily interrupted and the outputs are maintained in their current state until the program change is complete This means if the output is off it will remain off until the program change is complete If the output is on it will remain on application should make changes to the program Changes during Run Mode become effective immediately Make sure you thoroughly consider the impact of any changes to minimize the risk of personal injury or damage to equipment There are some important operations sequence changes during Run Time Edits 1 If there is a syntax error in the new instruction the CPU will not enter the Run Mode 2 Ifyou delete an output coil reference and the output was on at the time the output will remain on until it is forced off with a programming device 3 Input point changes are not acknowledged during Run Time Edits So if you re using a high speed operation and a critical input comes on the CPU may not se
14. You can also detect low battery voltage from within the CPU program SP43 is a special relay that comes on when the battery needs to be replaced The CPU battery is used to retain program V memory and the system parameters The life expectancy of this battery is five years NOTE Before installing or replacing your CPU battery back up your V memory and system parameters You can do this by using DirectSOFT to save the program V memory and system parameters to hard floppy disk on a personal computer To install the D3 BAT 1 CPU battery in the DL350 CPU 1 Press the retaining clip on the battery door down and swing the battery door open 2 Place the battery into the coin type slot 3 Close the battery door making sure that it locks securely in place 4 Make a note of the date the battery was installed WARNING Do not attempt to recharge the battery or dispose of an old battery by fire The battery may explode or release hazardous materials DL350 User Manual 2nd Edition Maintenance and Troubleshooting 9 3 Diagnostics Diagnostics Your DL305 system performs many pre defined diagnostic routines with every CPU scan The diagnostics have been designed to detect various types of failures for the CPU and I O modules There are two primary error classes fatal and non fatal Fatal Errors Fatal errors are errors the CPU has detected that offer a risk of the system not functioning safely or properly If the
15. a power supply connection the communication ground connection or the chassis ground connection Radiated noise is when the electrical interference is introduced into the system without a direct electrical connection much in the same manner as radio waves Reducing While electrical noise cannot be eliminated it can be reduced to a level that will not Electrical Noise affect the system Most noise problems result from improper grounding of the system A good earth ground can be the single most effective way to correct noise problems If a ground is not available install a ground rod as close to the system as possible Insure all ground wires are single point grounds and are not daisy chained from one device to another Ground metal enclosures around the system A loose wire is no more than a large antenna waiting to introduce noise into the system therefore you should tighten all connections in your system Loose ground wires are more susceptible to noise than the other wires in your system Review Chapter 2 Installation Wiring and Specifications if you have questions regarding how to ground your system Electrical noise can enter the system through the power source for the CPU and I O Installing a isolation transformer for all AC sources can correct this problem DC sources should be well grounded good quality supplies Switching DC power supplies commonly generate more noise than linear supplies Separate input wiring from output wiri
16. blem could be in one of the modules To isolate which module is causing the problem disconnect the system power and remove one module at a time until the PWR LED operates normally Follow the procedure below e Turn off power to the base e Remove a module from the base e Reapply power to the base Bent base connector pins on the module can cause this problem Check to see the connector is not the problem Power Budget If the machine had been operating correctly for a considerable amount of time prior Exceeded to the indicator going off the power budget is not likely to be the problem Power budgeting problems usually occur during system start up when the PLC is under operation and the inputs outputs are requiring more current than the base power supply can provide WARNING The PLC may reset if the power budget is exceeded If there is any doubt about the system power budget please check it at this time Exceeding the power budget can cause unpredictable results which can cause damage and injury Verify the modules in the base operate within the power budget for the chosen base You can find these tables in Chapter 4 System Design and Configuration VA TANA aoueUalUle v 2 fe z or D 2 3 fe A 5 amp DL350 User Manual 2nd Edition 9 12 Maintenance and Troubleshooting RUN Indicator If the CPU will not enter the Run mode the RUN indicator is off the problem is usually in
17. defective BATT on 1 CPU battery low 2 CPU battery missing or disconnected TX1 1 Transmitting data from Port 1 RX1 1 Receiving data at Port 1 TX2 1 Transmitting data from Port 2 RX2 1 Receiving data at Port 2 fed J az F Status Indicators oo DL350 BD D3 350 CPU oke Port 1 eal M E p oD o OS BB BS H 0 Mode Switch PORT Hel ino Battery Slot 20 ig 38 Port 2 LTS DL350 User Manual 2nd Edition 9 10 Maintenance and Troubleshooting PWR Indicator fe o O OO SiE On S2 Fa es oe SE ko z oO Incorrect Base Power Sk Faulty CPU There are four general reasons for the CPU power status LED PWR to be OFF 1 2 3 4 Power to the base is incorrect or is not applied Base power supply is faulty Other component s have the power supply shut down Power budget for the base has been exceeded If the voltage to the power supply is not correct the CPU and or base may not operate properly or may not operate at all Use the following guidelines to correct the problem WARNING To minimize the risk of electrical shock always disconnect the system power before inspecting the physical wiring ali 2 First disconnect the system power and check all incoming wiring for loose connections If you are using a separate termination panel check those connections to make sure the wiring is connected to the proper location If the connections are acceptab
18. e the change VA TENN WARNING Only authorized personnel fully familiar with all aspects of the Not all instructions can be edited during a Run Time Edit session The following list shows the instructions that can be edited Mnemonic Descriptor remore Description Load data constant TMRA Accumulating timer Load data double constant TMRAF Accumulating fast timer ADDD Add data double constant ow e Subtract data double constant Up Down counter Multiply constant SGCNT Stage counter Z STR STAN AND ANDN And And not OR ORN Or Or not STRE STRNE Store equal Store not equal ANDE ANDNE And equal And not equal ORE ORNE Or equal Or not equal STR STRN Store greater than or equal Store less than AND ANDN And greater than or equal And less than ORO i oema e Output accumulator to discrete points CMPD Compare accumulator constant DL350 User Manual 2nd Edition Maintenance and Troubleshooting 9 23 Use the program logic shown to describe how this process works In the example XO X1 Yo change X0 to C10 Note the example as sumes you have already placed the CPU in Run Mode CO Use the MODE key to select Run Time Edits MODE CHANGE MODE NEXT NEXT ENT RUN TIME EDIT Press ENT to confirm the Run Time Edits Note the RUN LED on the DL205 MODE CHANGE Handheld starts
19. ect the problem and continue running the Duplicate Reference check until no duplicate references are found NOTE You can use the same coil in more than one location especially in programs using the Stage instructions and or the OROUT instructions The Duplicate Reference check will find these outputs even though they may be used in an acceptable fashion DL350 User Manual 2nd Edition Maintenance and Troubleshooting 9 19 TEST PGM and Test Mode allows the CPU to start in TEST PGM mode enter TEST RUN mode run TEST RUN Modes a fixed number of scans and return to TEST PGM mode You can select from 1 to 65 525 scans Test Mode also allows you to maintain output status while you switch between Test Program and Test Run Modes You can select Test Modes from either the Handheld Programmer by using the MODE key or from DirectSOFT via a PLC Modes menu option The primary benefit of using the TEST mode is to maintain certain outputs and other parameters when the CPU transitions back to Test program mode Also the CPU will maintain timer and counter current values when it switches to TEST PGM mode not supported on the Handheld Programmer However you can use the Handheld to z322 NOTE You can only use DirectSOFT to specify the number of scans This feature is switch between Test Program and Test Run Modes With the Handheld the actual mode entered when you first select Test Mode depends on the mode of operation
20. ethod to determine if a module has failed is to replace it if you have a spare However if you suspect another device to have caused the failure in the module that device may cause the same failure in the replacement module as well As a point of caution you may want to check devices or power supplies connected to the failed module before replacing it with a spare module DL350 User Manual 2nd Edition Maintenance and Troubleshooting 9 15 Testing Output If you want to do an I O check out independent of the application program for the Points DL350 follow the procedure below Step Action Use a handheld programmer or DirectSOFT to communicate online to the PLC 2 Change to Program Mode 3 Go to address 0 Insert an END statement at address 0 This will cause program 4 execution to occur only at address 0 and prevent the application pro gram from turning the I O points on or off 5 _ Change to Run Mode 1 Use the programming device to set turn on or off the points you wish i to test 7 When you finish testing I O points delete the END statement at address 0 wee TER WARNING Depending on your application forcing I O points may cause unpredictable machine operation that can result in a risk of personal injury or equipment damage Make sure you have taken all appropriate safety precautions prior to testing any I O points
21. is really off This allows you to change the point status that was stored in the image register This value will be valid until the image register location is written to during the next scan This is primarily useful during testing situations when you need to force a bit on to trigger another event The following diagrams show a brief example of how you could use the xO Yo Handheld Programmer to force an I O OUT point The image register will not be updated with the status from the input CO module Also the solution from the application program will not be used to update the output image register The example assumes you have already placed the CPU into Run Mode From a clear display use the following keystrokes 16P STATUS STAT ENT BIT REF X Use the PREV or NEXT keys to select the Y data type Once the Y appears press 0 to start at YO A Y 10 Y 0 0 ENT NEXT Use arrow keys to select point then use Y2 is now on ON and OFF to change the status ON lt lt SHFT NS DL350 User Manual 2nd Edition Maintenance and Troubleshooting 9 25 Regular
22. le reconnect the system power and measure the voltage at the base terminal strip to insure it is within specification If the voltage is not correct shut down the system and correct the problem If all wiring is connected correctly and the incoming power is within the specifications required the base power supply should be returned for repair There is not a good check to test for a faulty CPU other than substituting a known good one to see if this corrects the problem If you have experienced major power surges it is possible the CPU and power supply have been damaged If you suspect this is the cause of the power supply damage a line conditioner which removes damaging voltage spikes should be used in the future DL350 User Manual 2nd Edition Maintenance and Troubleshooting 9 11 Device or Module Itis possible a faulty module or external device using the system 5V can shut down causing the Power the power supply This 5V can be coming from the base or from the CPU Supply to communication ports Shutdown To test for a device causing this problem 1 Turn off power to the CPU 2 Disconnectall external devices i e communication cables from the CPU 3 Reapply power to the system If the power supply operates normally you may have either a shorted device or a shorted cable If the power supply does not operate normally then test for a module causing the problem by following the steps below If the PWR LED operates normally the pro
23. needs replacing The battery voltage is continuously monitored while the system voltage is being supplied Communications Problems If you cannot establish communications with the CPU check these items e The cable is disconnected e The cable has a broken wire or has been wired incorrectly e The cable is improperly terminated or grounded e The device connected is not operating at the correct baud rate 9600 baud for the top port Use AUX 56 to select the baud rate for the bottom port on a DL350 e The device connected to the port is sending data incorrectly e A grounding difference exists between the two devices e Electrical noise is causing intermittent errors e The CPU has a bad comm port and the CPU should be replaced e If you are using DirectSOFT refer to the troubleshooting section of the Quick Start Manual If an error occurs the indicator will come on and stay on until a successful communication has been completed fe S o O OO ale On S2 To es oe SE ko oO DL350 User Manual 2nd Edition Maintenance and Troubleshooting 9 13 I O Module Troubleshooting Things to Check If you suspect an I O error there are several things that could be causing the problem e A blown fuse e A loose terminal block e The 24 VDC supply has failed e The module has failed e The I O configuration check detects a change in the I O configuration I O Diagnostics If the modules are not providing any clues to the
24. ng Never run I O wiring close to high voltage wiring DL350 User Manual 2nd Edition Maintenance and Troubleshooting 9 17 Machine Startup and Program Troubleshooting The DL350 CPU provides several features to help you debug your program before and during machine startup This section discusses the following topics which can be very helpful e Program Syntax Check e Duplicate Reference Check e Test Modes e Special Instructions e Run Time Edits e Forcing I O Points Syntax Check Even though the Handheld Programmer and DirectSOFT provide error checking during program entry you may want to check a modified program Both programming devices offer a way to check the program syntax For example you can use AUX 21 CHECK PROGRAM to check the program syntax from a Handheld Programmer or you can use the PLC Diagnostics menu option within DirectSOFT This check will find a wide variety of programming errors The following example shows how to use the syntax check with a Handheld Programmer Use AUX 21 to perform syntax check 5 m AUX 21 CHECK PRO Cc CLR 2 1 1 SYN 2 DUP REF Select syntax check default selection You may not get the busy display BUSY if the program is not very long ENT One of two displays will appear Error Display example SaoueUaIUle 00050 E401 v 2a z fa z ior D a fe 5 amp MISSING END shows location in q
25. omplete list of error messages sorted by error number fed Qa 5S OS e oT 03 no 33 o0 Ko Many of these messages point to supplemental memory locations which can be referenced for additional related information These memory references are in the form of V memory and SPs special relays The following two tables name the specific memory locations that correspond to certain types of error messages The special relay table also includes status indicators which can be used in programming For a more detailed description of each of these special relays refer to Appendix D DL350 User Manual 2nd Edition Maintenance and Troubleshooting V memory Error Category Diagnostic Vmemory Locations i User Defined Error code used with FAULT instruction Corresponding to ETE aE P T cor aglo faeere e Grammatical Address where syntax error occurs V7763 Error Code found during syntax check V7764 CPU Scan Number of scans since last Program to Run V7765 Mode transition Current scan time ms V7775 Minimum scan time ms V7776 Maximum scan time ms V7777 D Z o OO ec OO GS Fa es wo 2 SE xe Z 40 DL350 User Manual 2nd Edition Special Relays SP Corresponding Error Codes to Startup and Real time Relays Maintenance and Troubleshooting Accumulator Status Relays
26. onveyor 1 stopped 1993 04 30 170121112 Limit SW1 failed 1993 04 28 03 25 14 31 Saw Jam Detect You can access the error code table and the message table through DirectSOFT s PLC Diagnostic sub menus or from the Handheld Programmer Details on how to access these logs are provided in the DirectSOFT and D2 HPP manual The following examples show you how to use the Handheld and AUX Function 5C to show the error codes The most recent error or message is always displayed You can use the PREV and NXT keys to scroll through the messages Use AUX 5C to view the tables AUX 5C HISTORY D sHFT AUX ENT ERROR MESAGE Use the arrow key to select Errors or Messages gt ENT AUX 5C HISTORY D ERROR MESAGE Example of an error display E252NEW I O CFG 93 09 21 10 11 15 Year Month Day Time DL350 User Manual 2nd Edition 9 7 Maintenance and Troubleshooting System Error The System error log contains 32 of the most recent errors that have been detected Codes The errors that are trapped in the error log are a subset of all the error messages which the DL305 systems generate These errors can be generated by the CPU or by the Handheld Programmer depending on the actual error Appendix B provides a more complete description of the error codes The errors can be detected at various times However most of them are detected at power up on entry to R
27. output modules cannot detect shorted or open output points If you suspect one or more points on a output module to be faulty you should measure the voltage drop from the common to the suspect point Remember when using a Digital Volt Meter leakage current from an output device such as a triac or a transistor must be considered A point which is off may appear to be on if no load is connected the the point The I O point status indicators on the modules are logic side indicators This means the LED which indicates the on or off status reflects the status of the point in respect to the CPU On an output module the status indicators could be operating normally while the actual output device transistor triac etc could be damaged With an input module if the indicator LED is on the input circuitry should be operating properly To verify proper functionality check to see the LED goes off when the input signal is removed Leakage current can be a problem when connecting field devices to I O modules False input signals can be generated when the leakage current of an output device is great enough to turn on the connected input device To correct this install a resistor in parallel with the input or output of the circuit The value of this resistor will depend on the amount of leakage current and the voltage applied but usually a 10K to 20KQ resistor will work Insure the wattage rating of the resistor is correct for your application The easiest m
28. problem run AUX 42 from the handheld programmer or I O diagnostics in DirectSOFT Both options will provide the base number the slot number and the problem with the module Once the problem is corrected the indicators will reset An I O error will not cause the CPU to switch from the run to program mode however there are special relays SPs available in the CPU which will allow this error to be read in ladder logic The application program can then take the required action such as entering the program mode or initiating an orderly shutdown The following figure shows an example of the failure indicators cme QO E252 Program Control Information NEW I O CFG V7752 0020 Desired module ID code V7753 0021 Current module ID code V7754 0002 Location of conflict V7755 0252 Fatal error code SP47 1 0 Configuration Error aoueUElUle je Qa 4 al e iS fey o 2 J je ie A J co DL350 User Manual 2nd Edition ELS Maintenance and Troubleshooting Some Quick Steps When troubleshooting the DL305 series I O modules there are a few facts you should be aware of These facts may assist you in quickly correcting an I O problem fe E s o O OO ale On S2 Fa es oe SE ko z oO The
29. uestion Syntax OK display NO SYNTAX ERROR See Appendix B for a complete listing of programming error codes If you get an error press CLR and the Handheld will display the instruction where the error occurred Correct the problem and continue running the Syntax check until the NO SYNTAX ERROR message appears DL350 User Manual 2nd Edition 9 18 Maintenance and Troubleshooting D E s o O OO ale On S2 To es oe SE Oo oO Duplicate Reference Check You can also check for multiple uses of the same output coil Both programming devices offer a way to check for this condition For example you can AUX 21 CHECK PROGRAM to check for duplicate references from a Handheld Programmer or you can use the PLC Diagnostics menu option within DirectSOFT The following example shows how to perform the duplicate reference check with a Handheld Programmer Use AUX 21 to perform syntax check AUX 21 CHECK PRO B Cc CLR 2 1 AUX ENT 1 SYN 2 DUP REF Select duplicate reference check gt ent You may not get the busy BUSY display if the program is not very long One of two displays will appear Error Display example 00024 E471 DUP COIL REF shows location in question Syntax OK display NO DUP REFS If you get an error press CLR and the Handheld will display the instruction where the duplicate reference occurred Corr
30. un Mode or when a Handheld Programmer key sequence results in an error or an illegal request Error Description Error Description Code Code E003 Software time out E520 Bad operation CPU in Run E004 Invalid instruction RAM parity error E521 Bad operation CPU in Test Run E041 CPU battery low E523 Bad operation CPU in Test Program E043 Memory cartridge battery low E524 Bad operation CPU in Program E099 Program memory exceeded E525 Mode switch not in TERM E101 CPU memory cartridge missing E526 Unit is offline E104 Write fail E527 Unit is online E151 Invalid command E528 CPU mode E155 RAM failure E540 CPU locked E201 Terminal block missing E541 Wrong password E202 Missing I O module E542 Password reset E203 Blown fuse E601 Memory full E206 User 24V power supply failure E602 Instruction missing E210 Power fault E604 Reference missing E250 Communication failure in the I O chain E610 Bad I O type E251 I O parity error E611 Bad Communications ID 9 E252 New I O configuration E620 Out of memory E262 1 O out of range E621 EEPROM Memory not blank S5 E312 Communications error 2 E622 No Handheld Programmer EEPROM E E313 Communications error 3 E624 V memory only 33 E316 Communications error 6 E625 Program only E320 Time out E627 Bad write operation iss E321 Communications error E628 Memory type error should be EEPROM
31. valid jump GOTO address E486 BCALL placement error E433 Invalid SBR address E487 No Block defined E434 Invalid RTC address E488 Block position error E435 Invalid RT address E489 Block CR identifier error E436 Invalid INT address E490 No Block stage a E437 Invalid IRTC address E491 ISG position error of E438 Invalid IRT address E492 BEND position error es E440 Invalid Data Address E493 BEND error Sa E441 ACON NCON E494 No BEND 595 E451 Bad MLS MLR E452 X input used as output coil E453 Missing T C E454 Bad TMRA E455 Bad CNT E456 Bad SR DL350 User Manual 2nd Edition Maintenance and Troubleshooting 9 9 CPU Indicators The DL350 CPU has indicators on the front to help you diagnose problems with the system The table below gives a quick reference of potential problems associated with each status indicator Following the table will be a detailed analysis of each of these indicator problems Indicator Status Potential Problems PWR off 1 System voltage incorrect 2 Power supply CPU is faulty 3 Other component such an I O module has power supply shorted 4 Power budget exceeded for the base being used RUN 1 CPU programming error will not come on 2 Switch in TERM position 3 Switch in STOP position RUN flashing 1 CPU in firmware upgrade mode CPU on 1 Electrical noise interference 2 CPU
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