Logix5000 Controllers Major Minor and IO Faults
Logix5000 Controllers Major Minor and IO Faults
Logix5000 Controllers Major Minor and IO Faults
Allen-Bradley, Rockwell Automation, Rockwell Software, ControlLogix, GuardLogix, CompactLogix, DH+, PLC-5, DriveLogix, SLC 500, RSNetWorx, RSNetWorx for ControlNet, FLEX I/O, SoftLogix, FlexLogix, PowerFlex, Logix5000, RSLogix 5000, and TechConnect are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies.
Preface
Introduction
This manual shows how to monitor and handle major and minor controller faults. It also provides lists of major, minor, and I/O fault codes that can be used when troubleshooting your system. This manual is one of a set of related manuals that show common procedures for programming and operating Logix5000 controllers. For a complete list of common procedures manuals, see the Logix5000 Controllers Common Procedures Programming Manual, publication 1756-PM001. The term Logix5000 controller refers to any controller that is based on the Logix5000 operating system, including these controllers: CompactLogix ControlLogix DriveLogix FlexLogix SoftLogix5800
Additional Resources
These documents contain additional information concerning related products from Rockwell Automation.
Resource Industrial Automation Wiring and Grounding Guidelines, publication 1770.4.1. Product Certifications website, http://www.ab.com Description Provides general guidelines for installing a Rockwell Automation industrial system. Provides declarations of conformity, certificates, and other certification details.
You can view or download publications at http://www.rockwellautomation.com/ literature/. To order paper copies of technical documentation, contact your local Allen-Bradley distributor or Rockwell Automation sales representative.
Preface
Notes:
Table of Contents
Preface Summary of Changes
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 New and Updated Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Table of Contents
Summary of Changes
This manual contains new and updated information. Changes throughout this revision are marked by change bars, as shown to the right of this paragraph.
Summary of Changes
Notes:
Chapter
Major Faults
Topic Major Fault State Placement of Fault Routines Choose Where to Place the Fault Routine Create a Fault Routine for a Program Change the Fault Routine Assignment of a Program Create a Routine for the Controller Fault Handler Create a Routine for the Power-Up Handler Programmatically Clear a Major Fault Create a Data Type to Store Fault Information Get the Fault Type and Code Check for a Specific Fault Clear the Fault Clear a Major Fault During Prescan Identify When the Controller is in Prescan Get the Fault Type and Code Check for a Specific Fault Clear the Fault Test a Fault Routine 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 Major Fault Codes Page 9 13 14 14 16 17 19 22 22 23 24 24 25 25 26 26 27 27 28 28 28 29 30
If a fault condition occurs that would prevent an instruction from being able to execute, the instruction is aborted and a major fault is reported. A major fault causes logic execution to halt and the controller switches to faulted mode (the OK LED flashes red). Depending on your application, you may not want all major faults to shut down your system. If you do not want all major faults to shut down your system, create a fault routine to clear the fault and let your application continue to execute. See Create a Routine for the Controller Fault Handler on page 17 and Clear a Major Fault During Prescan on page 25.
Chapter 1
Major Faults
The process of resuming execution after a fault is cleared is known as fault recovery.
IMPORTANT Do not use fault routines to continually clear all faults on the controller. Program the fault routine to be selective in the types and number of faults cleaned. It is also a good idea to log that the fault occurred so it can be analyzed later.
IMPORTANT
When an instruction errors due to a fault, for example, a COP with an indirect addressing programming error, the instruction is skipped and not executed. This occurs with all instructions.
EXAMPLE
In a system that uses recipe numbers as indirect addresses, an incorrectly typed number could produce a major fault. To keep the entire system from shutting down in the event of this fault, a fault routine can be programmed to clear type 4, code 20, major faults.
Example 1
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A JSR instruction passes an input parameter containing an indirect address that is out of bounds. If the fault is cleared, the JSRinstruction is aborted (the subroutine is not executed) and execution resumes with the EQU.
Example 2
The logic inside of an Add-On Instruction generates a fault. While the logic of an Add-On Instruction may look like a subroutine, it is not the Add-On Instruction is an instruction. When a fault occurs inside of an Add-On Instruction, the remainder of the Add-On Instruction is aborted. If the fault is cleared, execution resumes with the MOV.
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If a fault occurs while processing the Logic routine, the Add-On Instruction aborts (the remainder of the Logic routine does not execute and the pre and post scan routines do not execute). If the fault is cleared, execution resumes at the instruction following the top-level Add-On Instruction invocation.
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Major Faults
Complete these steps to create a fault routine. 1. Open the project in the RSLogix 5000 software. 2. In the Controller Organizer, right-click the MainProgram and choose New Routine.
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Chapter 1
TIP
If you are creating a fault routine for the Power-Up Handler or Controller Fault Handler, you can specify the program name of either program for the In Program or Phase property.
4. Click OK.
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Major Faults
If a fault routine has already been created, it is included in the main program.
2. Right-click MainProgram, and choose Properties. 3. Click the Configuration tab. 4. From the Fault pull-down menu, choose the routine you want to be the programs fault routine.
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Major Faults
Chapter 1
The program you specified in 4 is now indicated as the fault routine in the main program.
This section provides steps for creating a fault routine to operate as the controller fault handler. Program tags are automatically created during this process.
IMPORTANT When you program the fault handler, remember that any instruction that is skipped as part of the fault-handling program is not executed when the main tasks and associated programs are executed. For example, if your fault handler skips a JSR instruction that is causing a major fault, then that JSR instruction, including all of the programming within the subroutine, is not executed. When a instruction errors due to a fault, for example, a COP with an indirect addressing programming error, the instruction is skipped and not executed. This occurs with all instructions.
1. In the Controller Organizer, right-click Controller Fault Handler and choose New Program.
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Major Faults
2. Enter a program name and verify that Schedule in is set to Controller Fault Handler. 3. Click OK. 4. Right-click the program you created in 2 and choose New Routine.
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Chapter 1
5. Enter a name for the routine. 6. For Assignment, leave the setting to the default of Main.
TIP Even though you can choose Fault from the Assignment pull-down menu, assigning the routine as a fault routine within the Controller Fault Handler is not necessary.
7. Click OK. The fault routine is created in the Controller Fault Handler program.
The Power-Up Handler is an optional task that executes when the controller powers up in Run or Remote Run modes.
Do this Leave the routine for the Power-Up Handler empty. When power is restored, a major fault (type 1, code 1) occurs and the controller enters the faulted state. In the Power-Up Handler fault routine, complete these steps. 1. Clear the major fault (type 1, code 1). 2. Execute the appropriate logic for the specific actions required.
IMPORTANT
Do not use fault routines to continually clear all faults on the controller. Program the fault routine to be selective in the types and number of faults cleared. When a instruction errors due to a fault, for example, a COP with an indirect addressing programming error, the instruction is skipped and not executed. This occurs with all instructions.
IMPORTANT
Complete these steps to create a fault routine for the Power-Up Handler in RSLogix 5000 software.
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Major Faults
1. In the Controller Organizer, right-click Power-Up Handler and choose New Program.
2. Type a program name and click OK. The program has been added to the Power-Up Handler.
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Chapter 1
4. Type the name of the routine. 5. For Assignment, leave the setting to the default of Main.
TIP
Even though you can choose Fault from the Assignment pull-down menu, assigning the routine as a fault routine within the Power-Up Handler is not necessary.
6. Click OK.
21
Chapter 1
Major Faults
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
IMPORTANT
Do not use fault routines to continually clear all faults on the controller. Program the fault routine to be selective in the types and number of faults cleared. When a instruction errors due to a fault, for example, a COP with an indirect addressing programming error, the instruction is skipped and not executed. This occurs with all instructions.
IMPORTANT
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Chapter 1
To simplify access to the MajorFaultRecord attribute, create this user-defined data type. 1. In the organizer of RSLogix 5000 software, right-click User-Defined and choose New Data Type.
42372
The GSV instruction: accesses the MAJORFAULTRECORD attribute of this program. This attribute stores information about the fault. stores the fault information in the major_fault_record tag (of type FAULTRECORD). When you enter a tag that is based on a structure, enter the first member of the tag.
Rockwell Automation Publication 1756-PM014E-EN-P - November 2011 23
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Major Faults
Item 1 2 3 4
Description 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. The second EQU instruction checks for a specific fault code. In Source B, enter the value for the code that you want to clear. The first CLR instruction sets to zero the value of the fault type in the major_fault_record tag. The second CLR instruction sets to zero the value of the fault code in the major_fault_record tag.
42372
The SSV instruction writes: new values to the MAJORFAULTRECORD attribute of this program. the values contained in the major_fault_record tag. Because the Type and Code member are set to zero, the fault clears and the controller resumes execution.
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Chapter 1
If the controller faults immediately after you switch it to the Run mode, then examine the prescan operation for the fault. Depending on the revision of your controller, an array subscript that is beyond the range of the array (out of range) during prescan may or may not produce a fault.
Then During prescan, an array subscript that is beyond the range of the array (out of range) produces a major fault. See the release notes for the firmware of your controller. During prescan, the controller automatically clears any faults due to an array subscript that is beyond the range of the array (out of range).
Complete these procedures to clear a major fault that occurs during prescan. Identify When the Controller is in Prescan, see page 25. Get the Fault Type and Code, see page 26. Check for a Specific Fault, see page 26. Clear the Fault, see page 27.
IMPORTANT It is good programming practice to check for a specific fault before clearing that fault.
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.
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The GSV instruction: accesses the MAJORFAULTRECORD attribute of this program. This attribute stores information about the fault. stores the fault information in the major_fault_record (of type FAULTRECORD) tag. When you enter a tag that is based on a structure, enter the first member of the tag.
Item 1 2 3 4 5
Description 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. The first EQU instruction checks for a fault of type 4, which means that an instruction in this program caused the fault. 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. The first CLR instruction sets to zero the value of the fault type in the major_fault_record tag. The second CLR instruction sets to zero the value of the fault code in the major_fault_record tag.
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Chapter 1
The SSV instruction: begins during prescan with the bits of all OTE instructions off and this instruction is true. Once the controller begins to execute the logic, this instruction is always false. writes new values to the MAJORFAULTRECORD attribute of this program. writes the values contained in the major_fault_record tag. Because the Type and Code member are set to zero, the fault clears and the controller resumes execution.
You can use a JSR instruction to test the fault routine of a program without creating an error (simulate a fault). 1. Create a BOOL tag that you will use to initiate the fault. 2. In the main routine or a subroutine of the program, enter this rung.
EXAMPLE
When test_fault_routine is on, a major fault occurs and the controller executes Fault_Routine.
Is the Tag that you will use to initiate the fault Fault routine of the program
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Major Faults
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 990999. These codes are reserved for user-defined faults. the controller handles the fault the same as other major faults: The controller changes to the Program mode and stops executing the logic. Outputs are set to their configured state or value for faulted mode.
EXAMPLE ATTENTION: When Tag_1.0 = 1, produce a major fault and generate a fault code of 999.
Complete these procedures to create a user-defined major fault: Create a Fault Routine for the Program, see page 28. Configure the Program to Use the Fault Routine, see page 28. Jump to the Fault Routine, page 29.
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 menu, choose Ladder. 4. Click OK.
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Chapter 1
Is the Name of the fault routine for the program Value for the fault code
EXAMPLE
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.
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Chapter 1
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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
60
For a controller with no memory card installed, the controller: detected a non-recoverable fault. cleared the project from memory.
61
For a controller with a memory card installed, the controller: detected a non-recoverable fault. wrote diagnostic information to the memory card. cleared the project from memory. For a controller with a Secure Digital (SD) card installed, the controller: detected a nonrecoverable fault. wrote diagnostic information to the memory card. When in this state, the controller will not open any connections or allow a transition to Run mode. A required I/O module connection failed.
62
16
3 3 4 4 4 4 4 4 4
20 21 23 16 20 21 31 34 42 82
Possible fault with the chassis. At least one required connection was not established before going to Run mode. Unknown instruction encountered.
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. Control structure .LEN or .POS < 0. The parameters of the JSR instruction do not match those of the associated SBR or RET instruction. Adjust the value so it is > 0. Pass the appropriate number of parameters. If too many parameters are passed, the extra ones are ignored without any error.
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. JMP to a label that did not exist or was deleted. 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. Correct the JMP target or add the missing label. Remove the jump back to the calling SFC.
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Major Faults
Chapter 1
40
1. Try again to store the project to nonvolatile memory. 2. If the project fails to store to nonvolatile memory, replace the memory card. If you are using a 1756-L7x controller, verify that the SD card is unlocked. Change to a controller of the correct type or download the project and store it on the memory card. Update the controller firmware to the same revision level as the project that is in nonvolatile memory. Contact Rockwell Automation support. See the back of this publication. Contact Rockwell Automation support. See the back of this publication. Wait for the download to complete and clear fault. Move axis in negative direction until position is within overtravel limit and then execute Motion Axis Fault Reset. Move axis in positive direction until position is within overtravel limit and then execute Motion Axis Fault Reset. Move the position within tolerance and then execute Motion Axis Fault Reset. Reconnect the encoder channel then execute Motion Axis Fault Reset. Fix encoder cabling then execute Motion Axis Fault Reset. Clear Drive Fault then execute Motion Axis Fault Reset.
7 7
41 42
Load from nonvolatile memory failed due to controller type mismatch. Load from nonvolatile memory failed because the firmware revision of the project in nonvolatile memory does not match the firmware revision of the controller. Load from nonvolatile memory failed due to bad checksum. Failed to restore processor memory. Attempted to place controller in Run mode with keyswitch during download. Actual position has exceeded positive overtravel limit. Actual position has exceeded negative overtravel limit. Actual position has exceeded position error tolerance. Encoder channel A, B, or Z connection is broken. Encoder noise event detected or the encoder signals are not in quadrature. Drive Fault input was activated.
7 7 8 11 11 11 11 11 11
43 44 1 1 2 3 4 5 6
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11 11 11 11 11 11 11 11 12
10 11 12 13 14 15 16 32 32
12
34
Just after a switchover occurs, the keyswitch positions of the primary and secondary controllers are mismatched. The old primary controller is in Program mode and the new primary controller is in Run mode. Safety Task watchdog expired. User task has not completed in a specified period of time. A program error caused an infinite loop, the program is too complex to execute as quickly as specified, a higher priority task is keeping this task from finishing, or the safety partner has been removed. An error exists in a routine of the safety task. Safety partner is missing. Safety partner is unavailable. Safety partner hardware is incompatible. Safety partner firmware is incompatible. Safety task is inoperable. This fault occurs when the safety logic is invalid, for example a mismatch in logix exists between the primary controller and safety partner, a watchdog timeout occurred, or memory is corrupt.
14
14 14 14 14 14 14
2 3 4 5 6 7
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Chapter 1
18
The CIP Motion drive has not initialized correctly. This fault is indicated when a manufacturer-specific initialization fault has occurred. The Physical Axis Fault bit is set, indicating a fault on the physical axis.
18
18
The Physical Axis Fault bit is set, indicating a fault on the physical axis. This fault is indicated when a manufacturer-specific axis fault has occurred. A motion fault occurred.
18
18
A CIP Motion Drive fault has occurred. Usually the fault affects all the axis associated with the module and all of the associated axes are shutdown. A motion group fault has occurred. Usually the fault affects all of the axes associated with a motion group. A fault has occurred during the configuration of a CIP Motion Drive. Typically, this fault occurs after an attempt to update an axis configuration attribute of a CIP Motion Drive was unsuccessful. An Absolute Position Recovery (APR) fault has occurred and the absolute position of the axis cannot be recovered.
18
18
18
To determine the corrective action, see the APR Fault attributes to determine the cause of the fault. For more information about the APR Fault attributes, see the CIP Motion Configuration and Startup User Manual, publication MOTION-UM003. To determine the corrective action, see the APR Fault - Mfg attributes to determine the cause of the fault. For more information about the APR Fault - Mfg attributes, see the CIP Motion Configuration and Startup User Manual, publication MOTION-UM003. To determine the corrective action, see the Guard Motion attributes and Guard Status bits to determine the cause of the fault. For more information about the Guard Motion attributes and Guard Status bits, see the CIP Motion Configuration and Startup User Manual, publication MOTION-UM003.
18
10
An Absolute Position Recovery (APR) fault has occurred and the absolute position of the axis cannot be recovered. This fault is indicated when a manufacturer-specific APR fault has occurred. A fault specific to the Guard Motion safety function has occurred. This fault is applicable only when a drive with Guard Safety functionality is used.
18
128
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Chapter
Minor Faults
Topic Identifying Minor Faults Minor Fault Codes Page 35 38
The table explains how to use relay ladder logic to monitor information about common minor faults.
1. Enter a GSV instruction that gets the FAULTLOG object, MinorFaultBits attribute. 2. Monitor bit 6. 1. Enter a GSV instruction that gets the FAULTLOG object, MinorFaultBits attribute. 2. Monitor bit 7. 1. Enter a GSV instruction that gets the FAULTLOG object, MinorFaultBits attribute. 2. Monitor bit 9. 1. Enter a GSV instruction that gets the FAULTLOG object, MinorFaultBits attribute. 2. Monitor bit 10. 1. Create a user-defined data type that stores the fault information. Name the data type FaultRecord and assign these members. Name TimeLow TimeHigh Type Code Info 2. 3. 4. 5. 6. Data Type DINT DINT INT INT DINT[8] Style Decimal Decimal Decimal Decimal Hex
Create a tag that will store the values of the MinorFaultRecord attribute. From the Data Type pull-down menu in step 1 of this instruction, choose the data type. Monitor S:MINOR. Use a GSV instruction to get the values of the MinorFaultRecord attribute if S:MINOR is on. Reset S:MINOR if you want to detect a minor fault that is cause by another instruction. S:MINOR remains set until the end of the scan.
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Minor Faults
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.
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Chapter 2
This example checks for a minor fault that is caused by a specific instruction.
EXAMPLE Check for a minor fault that is caused by an instruction.
Multiply value_a by 1000000 and check for a minor fault, such as a math overflow. 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.
42373
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Chapter 2
Minor Faults
Minor faults are indicated in these locations: Controller Properties dialog box, Minor Faults tab PROGRAM object, MINORFAULTRECORD attribute This tables identifies the type, code, and suggested recovery method when applicable.
4 4 4
4 5 6
4 4 4 4 4
7 30 35 36 51
Fix the destination so it has enough space. Verify the ASCII configuration settings. Adjust the PID delta time so that it is > 0. Adjust the setpoint so that it is within range. 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. 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. Either: reduce the size of the ASCII value. use a larger data type for the destination. 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. Either: change the Control Line setting of the serial port. delete the AHL instruction. Make changes such as simplifying programs, lengthening the period, or raising the relative priority. Make changes such as simplifying programs, lengthening the period, raising the relative priority, or slowing the triggering event. Increase the RPI for the CompactBus.
4 4
52 53
The output string is larger than the destination. The output number is beyond the limits of the destination data type.
56
57
The AHL instruction failed to execute because the serial port is set to no handshaking. Periodic task overlap. Periodic task has not completed before it is time to execute again. Event task overlap. Event task has not completed before it is time to execute again. Virtual adapter task overlap. (CompactLogix 1769-L2x and 1769-L3x controllers only.) Virtual adapter has not completed running at the rate specified by the RPI when it executed again. Project loaded from nonvolatile memory. Unknown error while servicing the serial port.
6 6 6
2 3 4
7 9
49 0
Contact Rockwell Automation Technical Support. See the back of this publication.
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Chapter 2
9 9
3 5
9 10 10 10
10 10 11 12
Slow down the rate at which the initiator is sending data. Install new battery. Install new battery. Install an ESM in the controller.
10 10
13 14
Replace the installed ESM with one that is compatible with the controller. Replace the ESM.
10 17
15 1n
Replace the ESM. Contact Rockwell Automation Technical Support with the fault type and fault code logged. See the back of this publication.
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Minor Faults
Notes:
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Page 41 43
I/O faults are indicated by these means: The I/O indicator of the controller (shown in examples below) flashes green or red.
Figure 2 - 175 Figure 2 - 175
RUN FORCE BATT I/O OK DCH 0
I/O RS232 OK
Status Display
RUN FORCE SD
OK
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The I/O status indicator and message in the controller status area of RSLogix 5000 software.
I/O indicator flashes green or red and the corresponding status message indicates an error.
A yellow warning symbol appears on the module in the I/O Configuration tree of RSLogix 5000 software.
A module fault code and description is indicated in the Connection tab of the Module Properties dialog box.
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Depending on where the fault code is indicated, the code format contains either the full Hexidecimal number (for example, 16#000A) or the last characters of the code (for example, #000A). This table lists commonly-experienced I/O fault codes and a corresponding description and recovery method when applicable. Each code is listed by the last characters of the full Hexidecimal number (that is, #XXXX).
Interpretation A connection to a module failed. Either: there are not enough connections available either for the controller or for the communication module being used to connect through. Check the connection use of the controller or communication module. If all of the connections are used, try to free some of the used connections or add another module to route the errant connection through. the I/O memory limits of the controller are exceeded. Check the I/O memory available and make program or tag changes if needed. the I/O module targeted does not have enough connections available. Check the number of controllers making a connection to this I/O module and verify that the number of connections is within the limits of the I/O module. The controller is attempting to make a connection to the module and has received an error. Either: the configured address for the connection to the module is incorrect. the module in use (that is, the physical module) is different than the module specified in the I/O configuration tree and is therefore causing the connection or service to fail. The fault may occur even when the module passed the electronic keying test. This may result when Disable Keying or Compatible Keying options were used in the module configuration instead of the Exact Match option. Despite passing the electronic keying test, the module being connected to does not have the same features or settings as the module specified in the I/O configuration tree and does not support the connection or service being attempted. Check the module in use and verify that it exactly matches the module specified in the I/O configuration tree of RSLogix 5000 software. For more information about electronic keying, see the user manual for the module you are using. If you are using a 1756-DHRIO module, verify that the Channel type selected in the software (DH+ or remote I/O network) matches the modules rotary switch settings. Either: the response buffer is too small to handle the response data. the module in use (that is, the physical module) is different than the module specified in the I/O configuration tree and is therefore causing the connection or service to fail. The fault may occur even when the module passed the electronic keying test. This may result when Disable Keying or Compatible Keying options were used in the module configuration instead of the Exact Match option. Despite passing the electronic keying test, the module being connected to does not have the same features or settings as the module specified in the I/O configuration tree and does not support the connection or service being attempted. Check the module in use and verify that it exactly matches the module specified in the I/O configuration tree of RSLogix 5000 software. For more information about electronic keying, see the user manual for the module you are using. A service request is unconnected, but should be connected. The controller has requested a service which is not implemented on the target module. The configuration for the module is invalid. The module configuration may have been changed in the Data Monitor or programmatically. Access the Connections tab of the Module Properties dialog box for the additional fault code. The additional fault code indicates the configuration parameter that is causing the fault. You may have to correct multiple parameters before this fault is cleared and connection is properly established. Verify that the configuration is valid by using the module configuration software to validate your configuration. Consult the module documentation for a list of fault codes to determine the configuration parameter that is in error. Either: a connection is being created where the connection type is invalid. an object attribute or tag value is invalid. If an object attribute or tag is invalid, export the RSLogix 5000 file, then re-import it. Reschedule the ControlNet network after re-importing if applicable.
#0005
#0006
#000A
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Code #000C
Interpretation The controller is attempting to request a service from the module and has received an error. First, verify that the module is not faulted. For an I/O module, this may indicate that the module has one of these conditions: Limited communication, but has a Major Fault A firmware update needs to be completed or is currently being completed. Refer to the Module Info tab to determine the exact cause.
An I/O map instance is created where the instance is already in use. A MSG instruction is configured to change an attribute that cannot be changed. A MSG instruction has been configured to delete a map object that cannot be deleted. The state of the device prevents a service request from being handled. The reply to a message has a data size that is too large for the destination. Change the destination to a tag that can handle the data size and type being returned. The configuration for the module is invalid - not enough configuration data was sent. Verify that the correct module is being targeted. A MSG instruction is configured to change an attribute that does not exist. The configuration for the module is invalid - too much configuration data was sent. Verify that the correct module is being targeted. The connection being accessed is already in use. Either: the controller is attempting to make a specific connection to a module and the module cannot support more than one of these connections. the target of a connection recognizes that the owner is attempting to remake a connection that is already running. Either: the controller is requesting services not supported by the module. the module in use (that is, the physical module) is different than the module specified in the I/O configuration tree and is therefore causing the connection or service to fail. The fault may occur even when the module passed the electronic keying test. This may result when Disable Keying or Compatible Keying options were used in the module configuration instead of the Exact Match option. Despite passing the electronic keying test, the module being connected to does not have the same features or settings as the module specified in the I/O configuration tree and does not support the connection or service being attempted. Check the module in use and verify that it exactly matches the module specified in the I/O configuration tree of RSLogix 5000 software. For more information about electronic keying, see the user manual for the module you are using. An ownership conflict occurred for the connection. One of these conditions exists: The Connection Request to this module has been rejected due to an Ownership conflict with another Owner (for example, another Controller). This may occur with modules, such as output modules, that allow only a single Owner to configure and control its outputs. This fault may also occur if the module is configured as Listen Only and supports only one connection. If the Owner is connected to the module with a Unicast connection over EtherNet/IP network, other connections to the module may fail because the Owner controls the one connection. If the Owner is connected to the module with a Multicast connection over EtherNet/IP network, Unicast connections to the module may fail because the Owner controls the one connection. Configure both the Owner and the Listen Only connection as Multicast. A connection being accessed was not found. An invalid connection type was used. One of these conditions exists: The controller is requesting a connection type not supported by the module. The module in use (that is, the physical module) is different than the module specified in the I/O configuration tree and is therefore causing the connection or service to fail. The fault may occur even when the module passed the electronic keying test. This may result when Disable Keying or Compatible Keying options were used in the module configuration instead of the Exact Match option. Despite passing the electronic keying test, the module being connected to does not have the same features or settings as the module specified in the I/O configuration tree and does not support the connection or service being attempted. Check the module in use and verify that it exactly matches the module specified in the I/O configuration tree of RSLogix 5000 software. For more information about electronic keying, see the user manual for the module you are using. You have configured a consumed tag or module to use a Unicast connection over EtherNet/IP network, but the producer does not support Unicast connections.
#0103
#0106
#0107 #0108
44
Chapter 3
Code #0109
Interpretation The connection size is inconsistent with that expected. Either: the controller is attempting to set up a connection with the module and cannot - the size of the connection is invalid. the controller may be attempting to connect to a tag in a producing controller whose size does not match the tag in this controller. the module in use (that is, the physical module) is different than the module specified in the I/O configuration tree and is therefore causing the connection or service to fail. the fault may occur even when the module passed the electronic keying test. This may result when Disable Keying or Compatible Keying options were used in the module configuration instead of the Exact Match option. Despite passing the electronic keying test, the module being connected to does not have the same features or settings as the module specified in the I/O configuration tree and does not support the connection or service being attempted. Check the module in use and verify that it exactly matches the module specified in the I/O configuration tree of RSLogix 5000 software. For more information about electronic keying, see the user manual for the module you are using. If the module is a 1756 ControlNet module, verify that the chassis size is correct. For remote I/O adapters, verify that the rack size and/or rack density is correct. The controller is attempting to set up a Listen Only connection with the module and cannot - the module has not been configured and connected to by an Owner (for example, another controller). This controller is not an Owner of this module because it is attempting to establish a Listen Only connection, which requires no module configuration. It cannot connect until an Owner configures and connects to the module first. Either: the Requested Packet Interval (RPI) specified is invalid for this module or for a module in the path to this module. the module in use (that is, the physical module) is different than the module specified in the I/O configuration tree and is therefore causing the connection or service to fail. The fault may occur even when the module passed the electronic keying test. This may result when Disable Keying or Compatible Keying options were used in the module configuration instead of the Exact Match option. Despite passing the electronic keying test, the module being connected to does not have the same features or settings as the module specified in the I/O configuration tree and does not support the connection or service being attempted. Check the module in use and verify that it exactly matches the module specified in the I/O configuration tree of RSLogix 5000 software. For more information about electronic keying, see the user manual for the module you are using. for Listen Only connections: the RPI set by the owner of this module is slower than the one requested. Either increase the requested RPI or decrease the RPI the owner controller is using. See the Connection tab for valid RPI values. The Product Code of the actual module hardware does not match the Product Code of the module created in the software. Electronic Keying failed for this module. You may have a mismatch between the module created in the software and the actual module hardware. The Product Type of the actual module hardware does not match the Product Type of the module created in the software. Electronic Keying failed for this module. You may have a mismatch between the module created in the software and the actual module hardware. The Major and/or Minor revisions of the module do not match the Major and/or Minor revisions of the module created in the software. Verify that you have specified the correct Major and Minor Revision if you have chosen Compatible Module or Exact Match keying Electronic Keying failed for this module. You may have a mismatch between the module created in the software and the actual module hardware. The connection is to an invalid port or port that is already in use. One of these conditions exists: Another controller owns this module and has connected with a Communications Format different than the one chosen by this controller. Verify that the Communications Format chosen is identical to that chosen by the first owner controller of the module. The module in use (that is, the physical module) is different than the module specified in the I/O configuration tree and is therefore causing the connection or service to fail. The fault may occur even when the module passed the electronic keying test. This may result when Disable Keying or Compatible Keying options were used in the module configuration instead of the Exact Match option. Despite passing the electronic keying test, the module being connected to does not have the same features or settings as the module specified in the I/O configuration tree and does not support the connection or service being attempted. Check the module in use and verify that it exactly matches the module specified in the I/O configuration tree of RSLogix 5000 software. For more information about electronic keying, see the user manual for the module you are using. The controller may be attempting to connect to a nonexistent tag in a producing controller.
#0110
#0111
#0117
45
Chapter 3
Code #0118
Interpretation An invalid configuration format is used. One of these conditions exists: The configuration class specified does not match the class supported by the module. The connection instance is not recognized by the module. The path specified for the connection is inconsistent. The module in use (that is, the physical module) is different than the module specified in the I/O configuration tree and is therefore causing the connection or service to fail. The fault may occur even when the module passed the electronic keying test. This may result when Disable Keying or Compatible Keying options were used in the module configuration instead of the Exact Match option. Despite passing the electronic keying test, the module being connected to does not have the same features or settings as the module specified in the I/O configuration tree and does not support the connection or service being attempted. Check the module in use and verify that it exactly matches the module specified in the I/O configuration tree of RSLogix 5000 software. For more information about electronic keying, see the user manual for the module you are using. The controlling connection is not open. Where a Listen Only connection is requested, the controlling connection is not open. The controller is attempting to set up a connection with the module and cannot - resources required are unavailable. If the module is a 1756 ControlNet module, up to five controllers can make Rack Optimization connections to the module. Verify that this number has not been exceeded. If the module is a 1794-ACN15, 1794-ACNR15, or 1797-ACNR15 adapter, only one controller can make a Rack Optimization connection to the module. Verify that this number has not been exceeded. The owner or originator recognizes that the target device is on the network or backplane, however, I/O data and messages are not being responded to. In other words, the target can be reached, but its response is not as expected. For example, this fault may be indicated where multicast Ethernet packets are not returned. When this fault occurs, the controller usually attempts to continuously remove and remake the connection. Also, if you are using FLEX I/O modules, verify that you are using the correct terminal device. The controller is attempting to make a connection, however, the target module is not responding. The device also appears to be missing from the backplane or network. To recover, take these actions: Verify that the module has not been removed and is still functioning and receiving power. Verify that the correct slot number has been specified. Verify that the module is properly connected to the network. If you are using FLEX I/O modules, verify that the correct terminal block is in use.
#0119 #011A
#0203
#0204
#0205
Either: the controller is attempting to set up a connection with the module and has received an error - a parameter is in error. the module in use (that is, the physical module) is different than the module specified in the I/O configuration tree and is therefore causing the connection or service to fail. The fault may occur even when the module passed the electronic keying test. This may result when Disable Keying or Compatible Keying options were used in the module configuration instead of the Exact Match option. Despite passing the electronic keying test, the module being connected to does not have the same features or settings as the module specified in the I/O configuration tree and does not support the connection or service being attempted. Check the module in use and verify that it exactly matches the module specified in the I/O configuration tree of RSLogix 5000 software. For more information about electronic keying, see the user manual for the module you are using. Either: the controller is attempting to set up a connection with the module and has received an error - the request size is too large. Verify that the path to this module is sufficiently close to the controller. the module in use (that is, the physical module) is different than the module specified in the I/O configuration tree and is therefore causing the connection or service to fail. The fault may occur even when the module passed the electronic keying test. This may result when Disable Keying or Compatible Keying options were used in the module configuration instead of the Exact Match option. Despite passing the electronic keying test, the module being connected to does not have the same features or settings as the module specified in the I/O configuration tree and does not support the connection or service being attempted. Check the module in use and verify that it exactly matches the module specified in the I/O configuration tree of RSLogix 5000 software. For more information about electronic keying, see the user manual for the module you are using.
#0206
46
Chapter 3
Code #0301
Interpretation One of these conditions may exist: The controller is attempting to set up a connection with the module and has received an error - a module in the path is out of memory. The controller may be attempting to connect to a tag in a producing controller that is not marked as being produced. The controller may be attempting to connect to a tag in a producing controller. That tag may not be configured to allow enough consumers. Reduce the size or number of connections through this module. One of the network modules between the module and the controller may be out of memory. Check network configuration of the system. The module may be out of memory. Check system configuration and capabilities of module. The module in use (that is, the physical module) is different than the module specified in the I/O configuration tree and is therefore causing the connection or service to fail. The fault may occur even when the module passed the electronic keying test. This may result when Disable Keying or Compatible Keying options were used in the module configuration instead of the Exact Match option. Despite passing the electronic keying test, the module being connected to does not have the same features or settings as the module specified in the I/O configuration tree and does not support the connection or service being attempted. Check the module in use and verify that it exactly matches the module specified in the I/O configuration tree of RSLogix 5000 software. For more information about electronic keying, see the user manual for the module you are using. The controller is attempting to set up a connection with the module and has received an error - a module in the path has exceeded its communication bandwidth capacity. Increase the Requested Packet Interval (RPI) and reconfigure your network with RSNetWorx software. Distribute the load on another bridge module. The controller is attempting to set up a connection with the module and has received an error - a module in the path has exceeded its communication bandwidth capacity. Distribute the load on another bridge module. The ControlNet module is not scheduled to send data. Use RSNetWorx for ControlNet software to schedule or reschedule the ControlNet network. The ControlNet configuration in the controller does not match the configuration in the bridge module. This may occur because a ControlNet module was changed after the network was scheduled, or because a new control program has been loaded into the controller. Use RSNetWorx for ControlNet software to reschedule the connections. The ControlNet Configuration Master (CCM) cannot be found. The 1756-CNB module and PLC-5 ControlNet processor are the only devices capable of being a CCM and the CCM must be node number 1. Verify that a 1756-CNB modules or PLC-5 ControlNet processor is at node number 1 and is functioning properly. This fault may temporarily occur when the system is powered up and will be cleared when the CCM is located. The controller is attempting to set up a connection with the module and has received an error. Verify that all modules in the I/O Configuration tree are the correct modules. The controller is attempting to set up a connection with the module and has received an error - an invalid link address has been specified. A link address can be a slot number, a network address, or the remote I/O chassis number and starting group. Verify that the chosen slot number for this module is not greater than the size of the rack. Verify that the ControlNet node number is not greater than the maximum node number configured for the network in RSNetWorx for ControlNet software. The segment type or route is invalid. Either: the controller is attempting to set up a connection with the module and has received an error - the connection request is invalid the module in use (that is, the physical module) is different than the module specified in the I/O configuration tree and is therefore causing the connection or service to fail. The fault may occur even when the module passed the electronic keying test. This may result when Disable Keying or Compatible Keying options were used in the module configuration instead of the Exact Match option. Despite passing the electronic keying test, the module being connected to does not have the same features or settings as the module specified in the I/O configuration tree and does not support the connection or service being attempted. Check the module in use and verify that it exactly matches the module specified in the I/O configuration tree of RSLogix 5000 software. For more information about electronic keying, see the user manual for the module you are using. The controller is attempting to set up a ControlNet connection with the module and has received an error. Use RSNetWorx for ControlNet software to schedule or reschedule the connection to this module. The controller is attempting to set up a connection with the module and has received an error - the link address is invalid. Verify that the associated ControlNet module has the correct slot and/or node number selected. The controller is attempting to set up a connection with the module and has received an error - the redundant module does not have the necessary resources to support the connection. Reduce the size or number of connections through this module or add another controller or ControlNet module to the system.
#0302
#0303
#0304 #0305
#0306
#0311 #0312
#0315
47
Chapter 3
Code #0322
Interpretation A connection point mismatch has occurred. Either: a new connection requested does not match the existing connection. Check the controllers that are using the connection and verify that all the configurations are identical. the connection requested is not a listener or a controlling connection type. The controller is attempting to connect to a tag in a producing controller and has received an error. The controller is attempting to connect to a tag in a producing controller and that tag has already been used by too many consumers. Increase the maximum number of consumers on the tag. No SC (servicing controller) connection object was found that corresponds to a symbol instance. No interpretation available. No interpretation available. Invalid connection status information was found. I/O map object attributes were found to be invalid. A fault has occurred while clearing memory. No error code is supplied by an I/O module to describe an I/O fault. The controller is attempting to set up a connection with the module and has received an error - this module requires a particular set of connections and connection types, and one of those connection types is missing. The module requires a CST master in the chassis. Configure a module (typically a controller) in this chassis to be the CST master. The module requires an axis or group table assigned. Assign a Group or Axis. The controller command to transition the SERCOS ring to a new phase returned an error from the module. Check for duplicate Drive Nodes. An attempt to configure the SERCOS ring failed. The baud rate for all devices must be the same and supported by the drives and the SERCOS module. Mainly two sets of faults may cause this fault, physical and interface faults. Possible sources of physical faults include these conditions: Broken ring Loose connector Fiber optics not clean Electrical noise due to improper drive grounding Too many nodes on the ring Interface errors are encountered when you are configuring third party drives. Potential interface errors include the following: No SERCOS MST (Protocol Error). Missed AT (drive did not send data when expected). SERCOS timing error in phase 3. Error in drive data returned to SERCOS module. An attempt by the controller to configure the node for cyclic operation returned an error. A bad response was received from a motion module. An error occurred adding the safety network segment to a route. No safety task appears to be running. Verify the number of physical expansion I/O modules configured for the controller and then update the number of modules selected from the Expansion I/O list on the General page in the Controller Properties dialog. To verify the number of physical expansion I/O the controller supports, open the Controller Properties dialog and expand the Expansion I/O list on the General page. Configure the number of physical expansion I/O modules to match the selection in the Expansion I/O list.
#031E
#031F #0800 #0801 #0814 #FD01 #FD02 #FD03 #FD04 #FD05 #FD06 #FD07 #FD08
An invalid configuration format was encountered. The Requested Packet Interval (RPI) specified is invalid for this module. See the Connection tab for valid RPI values. The input connection point has not been set. The controller is attempting to set up a connection with the module and has received an error.
48
Chapter 3
Code #FE05
Interpretation Either: the controller is attempting to set up a connection with the module and has received an error. the module in use (that is, the physical module) is different than the module specified in the I/O configuration tree and is therefore causing the connection or service to fail. The fault may occur even when the module passed the electronic keying test. This may result when Disable Keying or Compatible Keying options were used in the module configuration instead of the Exact Match option. Despite passing the electronic keying test, the module being connected to does not have the same features or settings as the module specified in the I/O configuration tree and does not support the connection or service being attempted. Check the module in use and verify that it exactly matches the module specified in the I/O configuration tree of RSLogix 5000 software. For more information about electronic keying, see the user manual for the module you are using. The input force pointer has not been set. The output connection point has not been set. The controller is attempting to set up a connection with the module and has received an error. Either: the controller is attempting to set up a connection with the module and has received an error. the module in use (that is, the physical module) is different than the module specified in the I/O configuration tree and is therefore causing the connection or service to fail. The fault may occur even when the module passed the electronic keying test. This may result when Disable Keying or Compatible Keying options were used in the module configuration instead of the Exact Match option. Despite passing the electronic keying test, the module being connected to does not have the same features or settings as the module specified in the I/O configuration tree and does not support the connection or service being attempted. Check the module in use and verify that it exactly matches the module specified in the I/O configuration tree of RSLogix 5000 software. For more information about electronic keying, see the user manual for the module you are using. A connection has been opened without the output force pointer being set. Either: the tag to be consumed on this module is invalid. Verify that the tag is marked as being produced. the module in use (that is, the physical module) is different than the module specified in the I/O configuration tree and is therefore causing the connection or service to fail. The fault may occur even when the module passed the electronic keying test. This may result when Disable Keying or Compatible Keying options were used in the module configuration instead of the Exact Match option. Despite passing the electronic keying test, the module being connected to does not have the same features or settings as the module specified in the I/O configuration tree and does not support the connection or service being attempted. Check the module in use and verify that it exactly matches the module specified in the I/O configuration tree of RSLogix 5000 software. For more information about electronic keying, see the user manual for the module you are using. The controller is attempting to set up a connection with the PLC-5 controller and has received an error. Verify that the instance number specified has been properly specified in the PLC-5 controller. The symbol instance number was found to not be set. The module is currently being updated. Firmware supervisor has attempted to update an unsupported module. The firmware file to update the module cannot be found. The firmware file is corrupted. An error has occurred while updating the module. An active connection could not be made to the target module. The firmware file is currently being read. The target-to-originator netparams connection type is invalid. The target-to-originator netparams connection does not specify whether unicast is allowed.
#FE0A #FE0B
#FE0C #FE0D #FE0E #FE0F #FE10 #FE11 #FE12 #FE13 #FE14 #FE22 #FE23
49
Chapter 3
Code #FF00
Interpretation The controller is attempting to set up a connection with the module and has received an error. Verify that the physical module is the same module type (or is a compatible module) as created in the software. If the module is a 1756-DHRIO module in a remote chassis (connected via a ControlNet network), verify that the network has been scheduled with RSNetWorx software. Even after the network has been scheduled with RSNetWorx for ControlNet software, if you are online and if the 1756-DHRIO module is configured for DH+ network only, a #ff00 Module Fault (no connection instance) may occur. The module is properly communicating even though Faulted is displayed as its Status on the Module Properties dialog box. Disregard the error message and fault status and continue. The controller is attempting to set up a connection with the module and has received an error. Verify that the path to this module is a valid length. The controllers map instance attempted to access a connection while being in an invalid state. The controller is attempting to set up a connection with the module and has received an error. Verify that the path to this module is a valid length. Either: the configuration for the module is invalid. the module in use (that is, the physical module) is different than the module specified in the I/O configuration tree and is therefore causing the connection or service to fail. The fault may occur even when the module passed the electronic keying test. This may result when Disable Keying or Compatible Keying options were used in the module configuration instead of the Exact Match option. Despite passing the electronic keying test, the module being connected to does not have the same features or settings as the module specified in the I/O configuration tree and does not support the connection or service being attempted. Check the module in use and verify that it exactly matches the module specified in the I/O configuration tree of RSLogix 5000 software. For more information about electronic keying, see the user manual for the module you are using. The controller is attempting to set up a connection with the module and has received an error.
#FF0E
50
Index
Numerics
1756-L2x I/O fault indicator 41 1756-L6x I/O fault indicator 41 1756-L7x codes on status display 41 indicator I/O fault 41 indirect address 25 instruction causing minor fault 37
L
low battery warning 36
C
check specific fault 24 CIP Motion major fault codes 33 clear major fault 9, 22 codes I/O faults 41, 43 major fault 30 minor fault 38 controller shut down 28 status in RSLogix 5000 42 suspend 28 when in prescan 25 create data type store fault information 22 fault routine 14 routine for Fault Handler 17 routine for Power-Up Handler 19
M
major fault codes 30 create user-defined 28 develop fault routine 9 how to cleare 22 major faults CIP Motion 33 minor fault codes 38 logic 35 Module Properties fault in 42 motion major faults 33
P
Power-Up Handler create a routine 19 prescan clear a major fault 25 program create fault routine 14
F
fault clear 9 codes, I/O 43 codes, major 30 codes, minor 38 create user-defined 28 develop routine to clear fault 9 during prescan 25 I/O 43 indirect address 25 monitor minor 35 routine, create 14 shown in Module Properties 42 test a fault routine 27 Fault Handler create routine 17 fault handling during prescan and postscan 12
R
recovering from a major fault 10 important points regarding Add-On Instructions 11 routine 14 create fault 14 Fault Handler 17 Power-Up Handler, create 19
S
shut down the controller 28 status controller in RSLogix 5000 42 store faults create data type 22 suspend controller 28
I
I/O 43 configuration warning 42 I/O faults indication of 41
T
test a fault routine 27
51
Index
W
warning low battery 36
52
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