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© ABB Group – Version 3.2 (2012-04)Technical Guides
AC500 CPUDiagnosisBasic module
Scalable PLC AC500
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© ABB Group October 10, 2012 | Slide 2
Diagnosis System
Local diagnosis at the CPU
Local diagnosis at the modules
Diagnosis in Control Builder Plus
PS501 tools and status bar
PS501 PLC-Browser
Diagnosis by use of library SysInt_AC500_Vxx.LIB
Diagnosis by use of library Diag_AC500_Vxx.LIB
Extended diagnosis for fieldbus slaves
DiagnosisContents
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© ABB Group October 10, 2012 | Slide 3
Diagnosis System
Local diagnosis at the CPU
Local diagnosis at the modules
Diagnosis in Control Builder Plus
PS501 tools and status bar
PS501 PLC-Browser
Diagnosis by use of library SysInt_AC500_Vxx.LIB
Diagnosis by use of library Diag_AC500_Vxx.LIB
Extended diagnosis for fieldbus slaves
DiagnosisComing up
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DiagnosisDiagnosis Sources and Tools
Control Builder Plus Programming tool CoDeSys
PLC:•LEDs•LCD display
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DiagnosisSummary
Diagnosis functions of PS501are available offline or online and as Function Blocks
Diagnosis is used in following cases:
Hardware configuration (fieldbus check)
Program creation (compiler: syntax, semantic, variable mapping)
Testing the logic without PLC (simulation mode and online functions)
Testing the logic with PLC and commissioning on site
Setup/check for ETH-addresses
Wiring test, logic test
Trouble shooting: configuration errors, logic errors, PLC errors, wiring errors, sensor/actor errors, fieldbus
/network errors…
Optimizing the cycle time for the task, check the file sizes in the memory
Exploitation
Check of the firmware versions, check the PLC error buffer, check the project tree, check the project info and
load
Check and trouble shooting: see commissioning
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© ABB Group October 10, 2012 | Slide 6
DiagnosisDiagnosis System of AC500
Up to 100 error messages are managed in a circular buffer LIFOEach message is provided with the time stamp and attribute:
ComeGoneAcknowledgement
The time stamp is generated by Real Time Clock (RTC) of the PLC
If the RTC was not set or there is no battery in the PLC the time after power on is counted starting with:
01. Januar 1970, 00:00 AM
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© ABB Group October 10, 2012 | Slide 7
DiagnosisTrouble Shooting: Error Indication
The trouble shooting can be done by use of:
HardwareThe CPU‘s LED „ERR“ „ and CPU‘s display after pushing the „DIAG“ keyLEDs at IO modules, communication modules, FieldbusPlugs
Engineering tools:Error cause in plain text in Control Builder PlusFieldbus and Ethernet diagnosis in Control Builder PlusA message in the status line of the CoDeSys project in online modeThe command „diagshow all“ and further commands of PLC browser in online mode (Control Builder Plus and CoDeSys)
User programFBs from ABB library SysInt_AC500_Vxx.lib integrated in user programFBs from ABB library Diag_AC500_Vxx.lib integrated in user programFBs from ABB library of the appropriate fieldbus integrated in user program
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© ABB Group October 10, 2012 | Slide 8
DiagnosisError Number
Each error message has a unique error number providing the following information:
State (come, gone, acknowledged)
Error class
Faulty component
Faulty device
Faulty module
Faulty channel
Error identifier
Error number
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© ABB Group October 10, 2012 | Slide 9
DiagnosisThe Error Classes
For more details see CoDeSys Help
The error classes:
E1 fatal the operating system is insecure: PLC is STOPPEDE2 severe the program execution is insecure: PLC is STOPPEDE3 light PLC behavior is defined by project configurationE4 warning PLC behavior is defined by project configuration
Error class
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© ABB Group October 10, 2012 | Slide 10
DiagnosisError Lists: Example Battery Error
For more details see CoDeSys Help
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© ABB Group October 10, 2012 | Slide 11
Diagnosis System
Local diagnosis at the CPU
Local diagnosis at the modules
Diagnosis in Control Builder Plus
PS501 tools and status bar
PS501 PLC-Browser
Diagnosis by use of library SysInt_AC500_Vxx.LIB
Diagnosis by use of library Diag_AC500_Vxx.LIB
Extended diagnosis for fieldbus slaves
DiagnosisComing up
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© ABB Group October 10, 2012 | Slide 12
DiagnosisLocal Diagnosis by Means of CPU‘s LCD Display
Errors are indicated by:
The CPU’s LED ERR
The CPU’s display:Error class / error number
For each detail information push repeatedly the DIAG key:
detail information 1 = component detail information 2 = devicedetail information 3 = moduledetail information 4 = channel
Exit display by pushing:ESC without error acknowledgement or OK with error acknowledgement
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© ABB Group October 10, 2012 | Slide 13
DiagnosisExample: CPU display in case no battery/low battry voltage
<OK>
Note: Diagnosis of AC500 PM55x and PM56x can only be shown by LED ERR at CPU
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© ABB Group October 10, 2012 | Slide 14
Diagnosis System
Local diagnosis at the CPU
Local diagnosis at the modules
Diagnosis in Control Builder Plus
PS501 tools and status bar
PS501 PLC-Browser
Diagnosis by use of library SysInt_AC500_Vxx.LIB
Diagnosis by use of library Diag_AC500_Vxx.LIB
Extended diagnosis for fieldbus slaves
DiagnosisComing up
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© ABB Group October 10, 2012 | Slide 15
DiagnosisS500 I/O Modules: General
Local diagnosis by means of LEDs on moduleDiagnosis over I/O-Bus or fieldbusError description always to find in the documentation of the module
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© ABB Group October 10, 2012 | Slide 16
DiagnosisExample AX521/AX522: LED Indication at Module
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© ABB Group October 10, 2012 | Slide 17
DiagnosisExample AX521/AX522: Diagnosis (1)
Diagnosis evaluation for module and channel errors:
S500 modules at I/O-Bus: AC500 display S500 modules connected via fieldbus : FBP diagnosis block (by means of Function Blocks)
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© ABB Group October 10, 2012 | Slide 18
DiagnosisExample AX521/AX522: Diagnosis (2)
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© ABB Group October 10, 2012 | Slide 19
DiagnosisCS31 Bus Module DC551-CS31: Local Diagnosis
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© ABB Group October 10, 2012 | Slide 20
DiagnosisFBP Interface Module DC505-FBP (1)
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© ABB Group October 10, 2012 | Slide 21
DiagnosisFBP Interface Module DC505-FBP (2)
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© ABB Group October 10, 2012 | Slide 22
DiagnosisFieldBusPlug FBP: Example PDP22
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© ABB Group October 10, 2012 | Slide 23
Diagnosis System
Local diagnosis at the CPU
Local diagnosis at the modules
Diagnosis in Control Builder Plus
PS501 tools and status bar
PS501 PLC-Browser
Diagnosis by use of library SysInt_AC500_Vxx.LIB
Diagnosis by use of library Diag_AC500_Vxx.LIB
Extended diagnosis for fieldbus slaves
DiagnosisComing up
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New features of PS501 Control Builder PlusNew diagnosis features – Online access in CBP
• The Online diagnostics consists of a set
of partly animated, mostly read only
views.
Online mode activated.
1
2
3
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New features of PS501 Control Builder PlusNew diagnosis features – Online Monitoring I/O in CBP
In Online mode, I/O component mapping tables are showing animated live values which are updated every second. No forcing available.
Online mode activated.
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New features of PS501 Control Builder PlusNew diagnosis features – Online for CPU, I/O bus and CS31
Overview of the actual contents of the CPU diagnosis buffer
12
Online mode activated.
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New features of PS501 Control Builder PlusNew diagnosis features – Online/Show CPU statistics
• Actual resource run & battery load states are shown
• Information about the number of application tasks
• Information about the locally connected I/O Modules
1
2
Online mode activated.
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New features of PS501 Control Builder PlusNew protocols and parameters – Clock Synchronization
• Synchronize PLC RTC with PC clock
1
2
3Online mode activated.
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New features of PS501 Control Builder PlusNew diagnosis features – Online/Show Devices version info
• CPU firmware versions, display, boot and FW
• All internal / external communication module firmware versions
• All versions figures of configured / mounted local I/O –modules
1
2
Online mode activated.
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New features of PS501 Control Builder PlusNew diagnosis features – PLC Browser in CBP
• All supported PLC Browser commands can be entered.
• Via “Save content to file” the contents of window can be saved to a
text file.
1
2
Online mode activated.
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New features of PS501 Control Builder PlusNew diagnosis features – Online for Onboard-ETH & CM577
• Diagnosis on internal
and external ETH couplers
Online mode activated.
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New features of PS501 Control Builder PlusNew diagnosis features – Online for Profibus Master/Slaves
• Different diagnosis available for Profibus-DP Master / Slaves
Online mode activated.
Master Slave
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New features of PS501 Control Builder PlusNew diagnosis features – Online for Profinet Master/Slaves
• Different diagnosis available for Profinet Master / Slaves
Online mode activated.
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New features of PS501 Control Builder PlusNew diagnosis features – Online for Canopen Master/Slaves
• Different diagnosis available for CanOpen Master / Slaves
Online mode activated.
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© ABB Group October 10, 2012 | Slide 35
Diagnosis System
Local diagnosis at the CPU
Local diagnosis at the modules
Diagnosis in Control Builder Plus
PS501 tools and status bar
PS501 PLC-Browser
Diagnosis by use of library SysInt_AC500_Vxx.LIB
Diagnosis by use of library Diag_AC500_Vxx.LIB
Extended diagnosis for fieldbus slaves
DiagnosisComing up
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© ABB Group October 10, 2012 | Slide 36
DiagnosisDiagnosis tools in CoDeSys Project
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© ABB Group October 10, 2012 | Slide 37
DiagnosisDiagnosis tools in CoDeSys Project
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© ABB Group October 10, 2012 | Slide 38
DiagnosisStatus Line in PS501: Connection and PLC status
Visible in the right down corner of the screen.
Name of the communication profile
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© ABB Group October 10, 2012 | Slide 39
Error number One of the attributes: + come- gonex acknowledgement
Time stamp Error class and description
DiagnosisStatus Line in PS501: Example Battery Error
The error text is read from the file Errors.ini located in the directory..\Targets\ABB_AC500 or ..\Targets\ABB_AC500\AC500_V12
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New features of PS501 Control Builder PlusNew diagnosis features – Watch & Receipt Manager
• Due to activate the new features set the check in “Project/Options/Desktop/Tabular watch editor“
• The watch window displays the values in a table oriented view
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New features of PS501 Control Builder PlusNew diagnosis features – Cross references functions
• The cross reference list is extended with:• Open cross reference list from the watch window
and list from language editor• Including the visualization to the cross reference list• Including arrays, structures and addresses
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New features of PS501 Control Builder PlusNew diagnosis features – Online/Show file information
• Display sizes of
programs &
Visualization
1 2
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© ABB Group October 10, 2012 | Slide 43
Diagnosis System
Local diagnosis at the CPU
Local diagnosis at the modules
Diagnosis in Control Builder Plus
PS501 tools and status bar
PS501 PLC-Browser
Diagnosis by use of library SysInt_AC500_Vxx.LIB
Diagnosis by use of library Diag_AC500_Vxx.LIB
Extended diagnosis for fieldbus slaves
DiagnosisComing up
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© ABB Group October 10, 2012 | Slide 44
DiagnosisPLC- Browser: Commands for Diagnosis
diagshow all: Shows all errors
diagshow X: Shows all errors of the class X (with X= 1...4)
diagack all: Acknowledges all errors (except errors that have to be quit exclusively)
diagack X: Acknowledges all errors of the class X (with X= 1...4)
diagreset: Resets the diagnosis system (clears error buffer)
1. Login into PLC2. Click at “Resources“/
“PLC-Browser“3. Click at “…“ button and select a
command4. Press <Enter> key
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© ABB Group October 10, 2012 | Slide 45
DiagnosisPLC- Browser: Example Battery Error (1)
Error number
Error appearance
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DiagnosisPLC- Browser: Example Battery Error (2)
Error acknowledge
Error vanished
Error acknowledged
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© ABB Group October 10, 2012 | Slide 47
Diagnosis System
Local diagnosis at the CPU
Local diagnosis at the modules
Diagnosis in Control Builder Plus
PS501 tools and status bar
PS501 PLC-Browser
Diagnosis by use of library SysInt_AC500_Vxx.LIB
Diagnosis by use of library Diag_AC500_Vxx.LIB
Extended diagnosis for fieldbus slaves
DiagnosisComing up
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© ABB Group October 10, 2012 | Slide 48
DiagnosisLibrary SysInt_AC500_Vxx.LIB
POUs Diagnosis
Represent PLC- Browser commands in the PLC program and more Example: DIAG_RESET: Reset of the error buffer by means of external signal DIAG_EVENT for creating user defined error indication at CPU displayRead the description before use!
POUs I/O-Bus
I/O-Bus and module diagnosis
Further information
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© ABB Group October 10, 2012 | Slide 49
DiagnosisExample Battery Error
Function Block DIAG_GET:
0-1 edge on EN input reads the oldest not read error
The next 0-1 edge on EN reads the next one
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© ABB Group October 10, 2012 | Slide 50
Diagnosis System
Local diagnosis at the CPU
Local diagnosis at the modules
Diagnosis in Control Builder Plus
PS501 tools and status bar
PS501 PLC-Browser
Diagnosis by use of library SysInt_AC500_Vxx.LIB
Diagnosis by use of library Diag_AC500_Vxx.LIB
Extended diagnosis for fieldbus slaves
DiagnosisComing up
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© ABB Group October 10, 2012 | Slide 51
DiagnosisLibrary Diag_AC500_Vxx.LIB
The library enables a direct access to following diagnosis with integrated visualisation:
Reading the AC500 diagnosis buffer and CPU capacity utilizationDiagnosis of the communication modulesDiagnosis of S500 I/O modules mounted at I/O-Bus (central extension)Diagnosis of S500 I/O modules at CS31-Bus (decentral extension)Diagnosis of the FBP slave interface
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© ABB Group October 10, 2012 | Slide 52
DiagnosisImport of the Prepared Diagnosis into a User Program (1)
Step 1 Import the diagnosis program and visualization into your project:
Select menu item “Project/Import“ and select the file PLC_DIAGNOSIS.EXP from the PS501 installation CD
Step 2Insert the library DIAG_AC500_Vxx.LIB to your project:
Select “Resources/Library Manager/ Insert/Additional library…“
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© ABB Group October 10, 2012 | Slide 53
DiagnosisImport of the Prepared Diagnosis into a User Program (2)
Step 3 The program PLC_Diagnosis has to be called in the task (here PLC_PRG)
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© ABB Group October 10, 2012 | Slide 54
DiagnosisImport of the Prepared Diagnosis into a User Program (3)
Step 4In the tab “Visualizations” there is a POU PLC_VISUUse this start screen to enable and switch to 4 different diagnosis screens as:
CPU loadCPU diagCS31 diagFBP diag
Use for each diagnosis a template from the library
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© ABB Group October 10, 2012 | Slide 55
DiagnosisVisualization Template CPU Load
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© ABB Group October 10, 2012 | Slide 56
DiagnosisVisualization Template CPU Diagnosis (1)
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© ABB Group October 10, 2012 | Slide 57
DiagnosisVisualization Template CPU Diagnosis (2)
Define the message language by click at the template and selecting “Extras/Settings…”
Select the path of Errors.xml for dynamic texts as of C:\Program Files\3S Software\CoDeSys V2.3\Errors.xml
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© ABB Group October 10, 2012 | Slide 58
DiagnosisVisualization Template CS31-Bus
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© ABB Group October 10, 2012 | Slide 59
DiagnosisVisualization Template FBP Slave Interface
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DiagnosisError messages: Example Battery Error
Error: Come Gone Acknowledge
Error class Message text
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© ABB Group October 10, 2012 | Slide 61
DiagnosisAX522 at I/O-Bus (1)
Warning from I/O-Bus module 2 (second module right to the CPU) type 1 (1 = analog input), channel 4
Error cause: Broken wire at input channel 4 (configured as 4.. 20 mA)
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© ABB Group October 10, 2012 | Slide 62
DiagnosisAX522 at I/O-Bus (2)
Error indication also by means of:
CPU LCD displayPLC browserStatus line of PS501
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© ABB Group October 10, 2012 | Slide 63
Diagnosis System
Local diagnosis at the CPU
Local diagnosis at the modules
Diagnosis in Control Builder Plus
PS501 tools and status bar
PS501 PLC-Browser
Diagnosis by use of library SysInt_AC500_Vxx.LIB
Diagnosis by use of library Diag_AC500_Vxx.LIB
Extended diagnosis for fieldbus slaves
DiagnosisComing up
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© ABB Group October 10, 2012 | Slide 64
DiagnosisFieldbus Diagnosis by means of LEDs of a Communication Module
Example
Indication: Connection error between the PROFIBUS DP Master and Slave 2
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© ABB Group October 10, 2012 | Slide 65
DiagnosisFieldbus Diagnosis by means of the Diagnosis System
Indication by means of:
CPU display
Visualization
Status line
PLC- Browser
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© ABB Group October 10, 2012 | Slide 66
DiagnosisExtended Diagnosis by Means of Function Blocks
For more details see the Function Blocks in the appropriate fieldbus library
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DiagnosisExample: PROFIBUS DP Communication Error to Slave 2
Configuration:Master: CM572 mounted in slot 2 Slave: Dezentral extension with DC505 and
PDP22. Address 2
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© ABB Group October 10, 2012 | Slide 68
DiagnosisExample: AX522 Module Error of the Slave 2
Error is not indicated by means of :
CPU display
Visualization
Status line
PLC- Browser
Error is indicated by means of:
Local LEDs by decentral extension
Diagnosis FBs from fieldbus library
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© ABB Group October 10, 2012 | Slide 69
DiagnosisLocal diagnosis by means of LEDs
DC505-FBP:
LED S-ERR on
LED I/O-Bus flashing
AX522:
LED CH-ERR4 flashing
Error in group 1 (slot 0)
Error cause: Broken wire at input channel 4 (configured as 4.. 20 mA)
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© ABB Group October 10, 2012 | Slide 70
DiagnosisAX522: Broken wire at an Input Channel
FBP diagnosis block has to be analyzed
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© ABB Group October 10, 2012 | Slide 71
DiagnosisFunction Block DPM_SLV_DIAG: AX522 of Slave 2 (1)
Use the slave description to evaluate the diagnosis block!
For decentral extension use the DC505-FBP description for the diagnosis bytes
Fixed value for DC505Communication with DC505 OKThe fifth module right to DC505Module type; 1 = analog inputChannel 4
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© ABB Group October 10, 2012 | Slide 72
DiagnosisFunction Block DPM_SLV_DIAG: AX522 of the Slave 2 (2)
Bit 0 to 5: Error number = 7
For decentral extension use the module description to find the error cause by means of error number!
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© ABB Group October 10, 2012 | Slide 73
DiagnosisFunction Block DPM_SLV_DIAG: AX522 of the Slave 2 (3)
Bit 6 and bit 7 + 1: Error class
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© ABB Group October 10, 2012 | Slide 74
DiagnosisCross-References to Documentation (1)
For more details see CoDeSys Help
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© ABB Group October 10, 2012 | Slide 75
DiagnosisCross-References to Documentation (2)
1. CoDeSys Help\Target System\AC500 / S500\System Technology\System Technology of the AC500 CPUs\The diagnosis system in the AC500
2. CoDeSys Help\Target System\AC500 / S500\Function Block Libraries AC500
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© ABB Group October 10, 2012 | Slide 76