logix5000 controllers controller major and minor faults controllers controller major and minor...

Programming Manual

Catalog Numbers 1756 ControlLogix, 1768 CompactLogix, 1769 CompactLogix,

1789 SoftLogix, 1794 FlexLogix, PowerFlex 700S with DriveLogix

Logix5000 Controllers Controller Major and Minor Faults

Important User InformationSolid 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://literature.rockwellautomation.com) 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.

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.

Allen-Bradley, Rockwell Automation, and TechConnect are trademarks of Rockwell Automation, Inc.

Trademarks not belonging to Rockwell Automation are property of their respective companies.

WARNINGIdentifies 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.

IMPORTANT Identifies information that is critical for successful application and understanding of the product.

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.

http://literature.rockwellautomation.com

Summary of Changes

Introduction The release of this document contains new and updated information. To find new and updated information, look for change bars, as shown next to this paragraph.

Updated Information This document contains the following changes.

Topic Page

Updated major fault codes Chapter 2

3Publication 1756-PM014B-EN-P - July 2008 3

Summary of Changes

Notes:

4 Publication 1756-PM014B-EN-P - July 2008

Table of Contents

Preface Purpose of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7How to Use this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Chapter 1Monitor Minor Faults Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Minor Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Chapter 2Handle a Major Fault Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Choose Where to Place the Fault Routine . . . . . . . . . . . . . . . . . . . 15Create a Fault Routine for a Program . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Create the Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Assign the Routine as the Fault Routine . . . . . . . . . . . . . . . . . . . . 16

Create a Routine for the Controller Fault Handler. . . . . . . . . . . . . . . . 17Create a Routine for the Power-Up Handler . . . . . . . . . . . . . . . . . . . . 17Programmatically Clear a Major Fault . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Create a Data Type to Store Fault Information . . . . . . . . . . . . . . . 18Get the Fault Type and Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Check for a Specific Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Clear the Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Clear a Major Fault During Prescan . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Identify When the Controller is in Prescan . . . . . . . . . . . . . . . . . . 21Get the Fault Type and Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Check for a Specific Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Clear the Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Test a Fault Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Create a User-Defined Major Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Create a Fault Routine for the Program . . . . . . . . . . . . . . . . . . . . . 25Configure the Program to Use the Fault Routine . . . . . . . . . . . . . 25Jump to the Fault Routine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Major Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27


Table of Contents


Preface

Purpose of this Manual This manual shows how to monitor and handle major and minor controller faults. 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 Logix 5000 Controllers Common Procedures Programming Manual, publication 1756-PM001.

The term Logix5000 controller refers to any controller that is based on the Logix5000 operating system, such as:

CompactLogix controllers ControlLogix controllers DriveLogix controllers FlexLogix controllers SoftLogix5800 controllers

How to Use this Manual Some text is formatted differently from the rest of the text.

Text that is Identifies For example Means

Italic the actual name of an item that you see on your screen or in an example

Right-click User-Defined Right-click the item that is named User-Defined.

courier information that you must supply based on your application (a variable)

Right-click name_of_program

You must identify the specific program in your application. Typically, it is a name or variable that you have defined.

enclosed in brackets a keyboard key Press [Enter]. Press the Enter key.


Summary of Changes Preface

Notes:


Chapter 1

Monitor Minor Faults

Introduction To use relay ladder logic to capture information about a minor fault:

To check for a Do this

Periodic task overlap 1. Enter a GSV instructions that gets the FAULTLOG object, MinorFaultBits attribute.

2. Monitor bit 6.

Load from nonvolatile memory

1. Enter a GSV instructions that gets the FAULTLOG object, MinorFaultBits attribute.

2. Monitor bit 7.

Problem with the serial port 1. Enter a GSV instructions that gets the FAULTLOG object, MinorFaultBits attribute.

2. Monitor bit 9.

Low battery 1. Enter a GSV instructions that gets the FAULTLOG object, MinorFaultBits attribute.

2. Monitor bit 10.

Problem with an instruction 1. 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

2. Create a tag that will store the values of the MinorFaultRecord attribute. Select the data type from step 1.

3. Monitor S:MINOR.

4. If S:MINOR is on, use a GSV instruction to get the values of the MinorFaultRecord attribute.

5. If you want to detect a minor fault that is caused by another instruction, reset S:MINOR. (S:MINOR remains set until the end of the scan.)


Chapter 1 Monitor Minor Faults

This example checks for a low battery warning.

EXAMPLE Check for a minor fault

Minor_fault_check times for 1 minute (60000 ms) and then automatically restarts itself.

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.

If minor_fault_bits.10 is on, then the battery is low.

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Monitor Minor Faults Chapter 1

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.

To make sure that a previous instruction did not produce the fault, the rung first clears S:MINOR. The rung then executes the multiply instruction. If the instruction produces a minor fault, the controller sets S:MINOR. If S:MINOR is set, the GSV instruction gets information about the fault and resets S:MINOR.

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Minor Fault Codes The type and code correspond to the type and code displayed in these locations.

Controller Properties dialog box, Minor Faults tab PROGRAM object, MINORFAULTRECORD attribute

Type Code Cause Recovery Method

4 4 An arithmetic overflow occurred in an instruction. Fix 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:

specified Class name is not supported specified Attribute name is not valid

Check the Class name and Attribute name.

4 7 The GSV/SSV destination tag was too small to hold all of the data.

Fix the destination so it has enough space.

4 35 PID delta time 0. Adjust the PID delta time so that it is > 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 tag.

1. Check that no instruction is writing to the LEN member of the string tag.

2. In the 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:

Reduce the size of the ASCII value. 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 handshaking.

Either:

Change the Control Line setting of the serial port. Delete the AHL instruction.

6 2 Periodic task overlap.

Periodic task has not completed before it is time to execute again.

Simplify program(s), or lengthen period, or raise relative priority, etc.

7 49 Project loaded from nonvolatile memory.

9 0 Unknown error while servicing the serial port. Contact Rockwell Automaiton Technical Support.


Monitor Minor Faults Chapter 1

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.

A problem was detected with the DF1 masters poll list, such as specifying more stations than the size of the file, specifying more then 255 stations, trying to index past the end of the list, or polling the broadcast address (STN #255).

Check for the following errors in the poll list:

total number of stations is greater than the space in the poll list tag

total number of stations is greater than 255 current station pointer is greater than the end of the

poll list tag

a station number greater than 254 was encountered

9 5 DF1 slave poll timeout.

The poll watchdog has timed out for slave. The master has not polled this controller in the specified amount of time.

Determine and correct delay for polling.

9 9 Modem contact was lost.

DCD and/or DSR control lines are not being received in proper sequence and/or state.

Correct modem connection to the controller.

10 10 Battery not detected or needs to be replaced. Install new battery.




Notes:


Chapter 2

Handle a Major Fault

Introduction If a fault condition occurs that is severe enough for the controller to shut down, the controller generates a major fault and stops the execution of logic.

Depending on your application, you may not want all major faults to shut down your entire system.

In those situations, you can use a fault routine to clear a specific fault and let at least some of your system continue to operate.

Choose Where to Place the Fault Routine

A fault routine lets you program logic to take specific action after a fault, such as clear the fault and resume execution. Where you place the routine depends on the type of fault that you want to handle:

EXAMPLE Use a fault routine

In a system that uses recipe numbers as indirect addresses, a miss-typed number could produce a major fault, such as type 4, code 20.

To keep the entire system from shutting down, a fault routine clears any type 4, code 20, major faults.

If you want take specific action/clear the fault when Do this Page

Condition Fault Type

The execution of an instruction faults 4 Create a Fault Routine for a Program 16

Communication with an I/O module fails 3 Create a Routine for the Controller Fault Handler 17

Watchdog time for a task expires 6

While a project is downloading to the controller, the keyswitch is placed in RUN

8

A motion axis faults 11

The controller powers up in run/remote run mode

1 Create a Routine for the Power-Up Handler 17


Chapter 2 Handle a Major Fault

Create a Fault Routine for a Program

Create the Routine

Assign the Routine as the Fault Routine

1. Right-click the program and choose New Routine.

2. Define the routine.

1. Right-click the program and choose Properties.

2. Specify the fault routine.

16

Publication 1756-PM014B-EN-P - July 2008

Handle a Major Fault Chapter 2

Create a Routine for the Controller Fault Handler

Create a Routine for the Power-Up Handler

The power-up handler is an optional task that executes when the controller powers up in run/remote run mode. Use the power-up handler when you want to accomplish either of the following after power is lost and then restored:

1. Create a program for the Controller Fault Handler.

2. Create a routine for the program.

3. Configure the routine as the main routine for the program.

To Do this

Prevent the controller from returning to run/remote mode

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 mode.

When power is restored, take specific actions and then resume normal operation

In the routine for the Power-Up Handler:

1. Clear the major fault (type 1, code 1).

2. Enter the logic for the actions.

1. Create a program for the Power-Up Handler.

2. Create a routine for the program.

3. Configure the routine as the main routine for the program.

Publication 1756-PM014B-EN-P - July 2008

17


Programmatically Clear a Major Fault

To clear a major fault that occurs during the execution of your project, complete these actions in the appropriate routine.

Create a Data Type to Store Fault Information Get the Fault Type and Code Check for a Specific Fault Clear the Fault

Create 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.

To access system information, you use a Get System Value (GSV) or Set System Value (SSV) instruction.

For status information about a program, you access the PROGRAM object.

For fault information, you access these attribute of the PROGRAM object.

To simplify access to the MajorFaultRecord attribute, create this user-defined data type.

Attribute Data Type Instruction Description

MajorFaultRecord DINT[11] GSV

SSV

Records major faults for this program

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.)

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, I/O, etc)

Code INT Decimal unique code for the fault

Info DINT[8] Hex fault specific information

To create a new data type:

Controller Your_Project

Tasks

Motion Groups

Trends

Data Types

User-Defined

Right-click and choose New Data Type.

+

+

+



Get the Fault Type and Code

1. The GSV instruction accesses the MAJORFAULTRECORD attribute of this program. This attribute stores information about the fault.

2. The GSV instruction 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.

Check for a Specific Fault

1. The first EQU instruction checks for a specific type of fault, such as program, I/O. 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.

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1. 2.1 Equal

Source A major_fault_record.Type 0Source B fault_type

EqualSource A major_fault_record.Code 0Source B fault_code

MoveSource 0 Dest major_fault_record.Type 0

MOVMoveSource Dest major_fault_record

MOV

2 Set system valueCIP Object class PRCIP Object nameAttribute name MAJORFAULTR

j f l d i

SSV

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3. 4.



Clear the Fault

1. The SSV instruction writes new values to the MAJORFAULTRECORD attribute of this program.

2. The SSV instruction writes the values contained in the major_fault_record tag. Since the Type and Code member are set to zero, the fault clears and the controller resumes execution.

Clear a Major Fault During Prescan

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.

To clear a major fault that occurs during prescan:

Identify When the Controller is in Prescan Get the Fault Type and Code Check for a Specific Fault Clear the Fault

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If your controller is revision

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).

IMPORTANT It is a good programming practice to check for a specific fault before clearing the fault.



Identify 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.

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.

During prescan, this bit is off. (During prescan, the controller resets all bits that are referenced by OTE instructions.)

Once the controller begins to execute the logic, the CPU_scanning bit is always on.

Get the Fault Type and Code

Enter this rung in the fault routine for the program.

1. The GSV instruction accesses the MAJORFAULTRECORD attribute of this program. This attribute stores information about the fault.

2. The GSV instruction 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.

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43064



Check for a Specific Fault


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.

1. 3.2.

43064

4. 5.



Clear the Fault


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 SSV instruction writes new values to the MAJORFAULTRECORD attribute of this program.

3. The SSV instruction writes the values contained in the major_fault_record tag. Since the Type and Code member are set to zero, the fault clears and the controller resumes execution.

Test 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:

43064

where: is the:

aaa tag that you will use to initiate the fault

bbb fault routine of the program



3. To simulate a fault, set the input condition.

Create a User-Defined Major Fault

If you want to suspend (shut down) the controller based on conditions in your application, create a user-defined major fault. With a user-defined major fault:

The fault type = 4. You define a value for the fault code. Choose a value between 990 to

999. These codes are reserved for user-defined faults. The controller handles the fault the same as other major faults:

The controller changes to the faulted mode (major fault) and stops executing the logic.

Outputs are set to their configured state or value for faulted mode.

To create a user-defined major fault: Create a Fault Routine for the Program Configure the Program to Use the Fault Routine Jump to the Fault Routine

EXAMPLE Test a fault routine

When test_fault_routine is on, a major fault occurs and the controller executes Fault_Routine.

EXAMPLE User-defined major fault

When Tag_1.0 = 1, produce a major fault and generate a fault code of 999.



Create a Fault Routine for the Program

Does a fault routine already exist for the program?

1. In the controller organizer, right-click the program and choose New Routine.

2. In the name box, type a name for the fault routine.

3. From the Type drop-down list, choose Ladder.

4. Click OK.

Configure the Program to Use the Fault Routine

1. In the controller organizer, right-click the program and choose New Routine.

2. Select the Configuration tab.

3. From the Fault drop-down list, choose the fault routine.

4. Click OK.

If Then

Yes Go to Jump to the Fault Routineon page 26

No Create a fault routine for the program:



Jump to the Fault Routine

In the main routine of the program, enter this rung:

conditions when the controller should shut down

Where Is

Fault_Routine name of the fault routine for the program

999 value for the fault code

EXAMPLE Create a User-Defined Major Fault

When Tag_1.0 = 1, execution jumps to name_of_fault_routine. A major fault occurs 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.



Major Fault Codes The type and code correspond to the type and code displayed in these locations.

Controller Properties dialog box, Major Faults tab PROGRAM object, MAJORFAULTRECORD attribute


1 1 The controller powered on in Run mode. Execute the power-loss handler.

1 15 A 1769 power supply is connected directly to the controllers 1769 CompactBus, with an invalid configuration.

The 1768 power supply powering the controller has failed.

Remove the power supply from the 1769 CompactBus and cycle power to the system.

Replace the power supply.

1 60 For a controller with no CompactFlash card installed, the controller: detected a non-recoverable fault cleared the project from memory

1. Clear the fault.2. Download the project.3. Change to remote run/run mode.

If the problem persists:1. Before you cycle power to the controller, record the state of the

OK and RS232 LEDs.2. Contact Rockwell Automation support. See the back of this

publication.

1 61 For a controller with a CompactFlash card installed, the controller: detected a non-recoverable fault wrote diagnostic information to the

CompactFlash card

cleared the project from memory

1. Clear the fault.2. Download the project.3. Change to remote run/run mode.

If the problem persists, contact Rockwell Automation support. See the back of this publication.

3 16 A required I/O module connection failed. Check that the I/O module is in the chassis. Check electronic keying requirements.

View the controller properties Major Fault tab and the module properties Connection tab for more information about the fault.

3 20 Possible problem with the ControlBus chassis. Not recoverable - replace the chassis.

3 23 At least one required connection was not established before going to Run mode.

Wait for the controller I/O light to turn green before changing 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. Dont exceed the array size or go beyond dimensions defined.

4 21 Control structure .LEN or .POS < 0. Adjust the value so it is > 0.

4 31 The Parameters of the JSR instruction do not match those of the associated SBR or RET instruction.

Pass the appropriate number of Parameters. If too many Parameters are passed, the 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.

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 and the subroutine tried to jump back to the calling SFC. Occurs when the SFC uses either a JSR or FOR instruction to call the subroutine.

Remove the jump back to the calling SFC.

4 83 The data tested was not inside the required limits.

Modify value to be within limits.

4 84 Stack overflow. Reduce the subroutine nesting levels or the number of Parameters passed.

4 89 In a SFR instruction, the target routine does not contain the target step.

Correct the SFR target or add the missing step.

6 1 Task watchdog expired.

User task has not completed in specified period of time. A 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.

Increase the task watchdog, shorten the execution time, make the priority of this task higher, simplify higher priority tasks, or move some code to another controller.

7 40 Store to nonvolatile memory failed. 1. Try again to store the project to nonvolatile memory.

2. If the project fails to store to nonvolatile memory, replace the memory board.

7 41 Load from nonvolatile memory failed due to controller type mismatch.

Change to a controller of the correct type or download the project and store it on the CompactFlash card.

7 42 Load from nonvolatile memory failed because the firmware revision of the project in nonvolatile memory does not match the firmware revision of the controller.

Update the controller firmware to the same revision level as the project that is in nonvolatile memory.

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 during download.

Wait for the download to complete and clear fault.

11 1 Actual position has exceeded positive overtravel limit.

Move axis in negative direction until position 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.

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 not in quadrature.

Fix encoder cabling then execute Motion Axis Fault Reset.

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 doesnt work, pull servo module out and plug back in. If all else fails replace servo module.

11 8 Servo module has detected a serious hardware fault.

Replace the module.

11 9 Configuration fault has occurred.

The motion module or drive has rejected the update of one of the axis attributes.

See the AttributeErrorCode or AttributeErrorID axis tag fields to identify which attribute was rejected and why.

11 10 Motor 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 groups course update rate is too high to maintain correct operation. Clear the group fault tag, raise the groups update rate, and then clear the major fault.




Notes:


Publication 1756-PM014B-EN-P - July 2008 32Supersedes Publication 1756-PM014A-EN-P - July 2007 Copyright 2008 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.

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Logix5000 Controllers Controller Major and Minor Faults Programming Manual, 1756-PM014B-EN-PSummary of ChangesIntroductionUpdated Information

Table of ContentsPrefacePurpose of this ManualHow to Use this Manual

Monitor Minor FaultsIntroductionMinor Fault Codes

Handle a Major FaultIntroductionCreate a Fault Routine for a ProgramCreate a Routine for the Controller Fault HandlerCreate a Routine for the Power-Up HandlerProgrammatically Clear a Major FaultClear a Major Fault During PrescanTest a Fault RoutineCreate a User-Defined Major FaultMajor Fault Codes

Back Cover

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/SyntheticBoldness 1.000000 /Description >>> setdistillerparams> setpagedevice

IN, RN pub type specs

dPrint?Content/Comp #Split Shipment Indicator FlagWCSS Item NumberCustomer Item NumberItem DescriptionProducing PlantJob NumberReplenishing PlantPlant CodeProduct CodePackaging/Ordering UOMQty per Packaging/Ordering UOMList Price Per EaTransfer Cost per EaSell Price per EaStandard Cost (per Ea)Min Order Qty (in eaches)Multiple Order Qty (in EachesChargeback PriceItem Reference #1Item Reference #2Revision FieldMax Order Qty (in eaches)Sequentially Numbered Item?Sequentially Numbered Item - DetailsPriced for Digital or OffsetContent File LocationItem Category Form (F) Book (B)Item SubtypeOrientationSides PrintedCSS/JLS Stock ComponetPaper Size WidthPaper Size LengthNo of Forms to a SheetPage QtySheets QtyCSS/JLS Production StockPaper Stock TypePaper Stock WeightPaper Stock ColorStack OffsetTab Size# of TabsBinder SizeBinder ColorBinder Ring TypeBinder Transparency (clearview or matt)Thermal Tape ColorTrim Size WidthTrim Size LengthStitching LocationDrilling SizeDrilling LocationGlue Location# / PadFold TypeFold At# / Poly# / BoxCommentsCross Reference Item Number 1

Publication NumberPublication TitlePackaging/Ordering Unit Of MeasureQty per Packaging/Ordering Unit of MeasureMin Order QtyMultiple Order QtyBusiness GroupCost CenterRevision DateMax Order QtyBlack & Whiteor ColorItem CategoryForm (F) or Book (B)Binding/StitchingOrientationSides PrintedPrinting Paper Size WidthPrinting Paper Size LengthNumber of Forms to a SheetPage Count of PublicationNumber of Sheets Required to PrintCSS/JLS Production StockPaper Stock TypePaper Stock WeightPaper Stock ColorStack OffsetTab SizeNumber of Tabs NeededBinder SizeBinder ColorBinder Ring TypeBinder TransparencyThermal Tape ColorFinished Trim Size WidthFinished Trim Size LengthStitching LocationDrill Hole SizeNumber and Location of Drill HolesGlue LocationNumber of Pages per PadFold TypeFold AtNumber of Pieces per Poly wrapNumber of Pieces per BoxCommentsPart Number

Are these items being setup on dPrint? (Yes or No). If yes, Inv Mgmt to check "Print Management" flag on item setup.The content/Comp # will be provided by the CSC once the spec files are loaded to the DAS (the files must be named with the WCSS item #). The content/comp# must be hardcoded to the Item message Field in WCSS. Must be a 10 Digit number that starts with an 8.Required. Setting this to yes will allow warehouse product to ship out before the JIT item is completed. Setting this to no will hold all warehoused items until the printing of this item is complete. Please indicate Y or N.** Note: Each item with a Y will always ship separately even if produced at the same time as like items.Optional. 15 Characters Max. If the WCSS number provided already exists in the system, then Inventory Management will assign a random WCSS number.30 characters maximum.Cannot use quote symbol, that is--"--.Required. Which plant/Print Center will produce this item?Required. To be provided from the producing plant for JIT s/uRequired: What is the plant code of the plant that has owning rights to the dPrint files? If produced at multiple plants there can be only one owning plant.Required. What is the plant code of the facility that will produce this item? (see "Plant and Whse Codes" tab below)Required. Enter one of the applicable product.Method of packaging for publication shipment

Click here for explanation of each value in the pull-downRequired. This field auto-calculates (transfer cost divided by .5). Used to determine Standard Cost on WCSS (which is 50% of the list price for these product codes).Required. Transfer Cost per ordering/packaging unit of measure.Required. Price that will be billed to customer upon order. If Price Breaks, enter "Price Breaks" and note them on separate spreadsheet.Required. Replacement Cost per Packaging/ordering UOM.Click here for an explanation of this field; otherwise, type NA.Optional. Used to assist customer with internal Chargebacks to end users. (per packaging/ordering UOM)IMPORTANT: This information must match the DocMan record.

Click here for explanation of each value in the pull-down menu.IMPORTANT: This information must match the DocMan record.IMPORTANT: This information must match the DocMan record.

Date on the publication.Click here for explanation of each value in the pull-down menu.Indicate Yes or No. Enter Yes if the item is a sequentially numbered item.Describe the details behind the sequentially numbered item, such as:- Record Sequence Shipped: whse will record the sequence numbers that shipped- Ship in Sequence Record: required to ship products in particular sequence and the whse records the numbersRequired: If PDF is to be retained in the DAS enter DAS in this field, if item is part of eCreate or Custom Docs put CUSTOM in this field.Typically a Book.

Click here for explanation of each value in the pull-down menu.Click here for explanation of each value in the pull-downClick here for explanation of each value in the pull-down menu.Optional: Use when finished product stored in the warehouse is to be inserted into the construction of a JIT book.IMPORTANT: Not Trim Size width

This is the width of the paper on which the publication is printed.IMPORTANT: Not Trim Size length

This is the length of the paper on which the publication is printed.Click here for explanation of how to determine the information required.Click here for explanation of how to determine the information required.Optional: Use when product is being printed on Shell Stock. Provide warehoused WCSS Item nu,mber of product to be used in the production of JIT item.Click here for explanation of how to determine the information required.The pull-down menu lists the most common choices.

Click here for a full list of the available choices.

If you use a choice not in the pull-down list, type the value in the cell below the pull-down menu.If item uses tabs; otherwise, NA.If needed; otherwise type NA.If item used in a binder; otherwise, NA.If item used in a binder; otherwise, NA.If item used in a binder; otherwise, NA.If item used in a binder; otherwise, NA.If publication is thermal tape bound; otherwise, NA.Click here to see the available finished trim sizes.

The sizes are listed - width x length.Click here to see the available finished trim sizes.

The sizes are listed - width x length.If publication is Book [B] and stapled; otherwise, NA.Click here for a list of possible drill locationsIf publication uses padding; otherwise, NA.If publication is a notepad or message pad; otherwise, NA.Click here for explanation of each value in the pull-down menu. Folding of final document optionalThe location(s) of the foldClick here for explanation of each value in the pull-down menu.Use this column to list:- Cover Stock- Text Stock- Cover Ink- Text Ink- Spine, if necessary

Also use to indicate any other production or finishing requirements not provided in previous columns

Click here for an explanation of the available Cover Stock, Cover Ink and Text Ink values.List only if pubication is used in manufacturing; otherwise, leave blank.

1756-PM014B-EN-PLogix5000 Controllers Major and Minor Faults Programming ManualEA11Marketing CommercialCMKMAY IA Control/Vis/Net - 1902107/01/20085Black & WhiteBSADDLEPORTRAITHEAD2HEADRRD must provide this informationRRD must provide this information4328PLAIN20#WhiteRRD must provide this informationNANANANANANANA8.511SIDENANANANAHALF8.5 x 1150RRD must provide this informationText Stock = 20# White Opaque BondText Ink = BlackCover Stock = 90# White IndexCover Ink = Black

Click here for explanation of each value in the pull-down

Method of packaging for publication shipment

Click here for explanation of each value in the pull-down

IMPORTANT: This information must match the DocMan record.

Click here for explanation of each value in the pull-down menu.


Typically a Book.



Click here for explanation of how to determine the information required.



The pull-down menu lists the most common choices.

Click here for a full list of the available choices.

If you use a choice not in the pull-down list, type the value in the cell below the pull-down menu.

Click here to see the available finished trim sizes.

The sizes are listed - width x length.

Click here to see the available finished trim sizes.

The sizes are listed - width x length.

Click here for a list of possible drill locations


Use this column to list:- Cover Stock- Text Stock- Cover Ink- Text Ink- Spine, if necessary

Also use to indicate any other production or finishing requirements not provided in previous columns

Click here for an explanation of the available Cover Stock, Cover Ink and Text Ink values.

Click here for an explanation of this field; otherwise, type NA.

Click here for explanation of each value in the pull-down menu. Folding of final document optional

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