Rockwell Automation Allen-Bradley Logix 5000 Series Owner's manual

Rockwell Automation Publication 1756-PM014N-EN-P - March 2022
Supersedes Publication 1756-PM014M-EN-P - September 2020
Programming Manual
Original Instructions
Logix 5000 Controllers
Major, Minor, andI\O
Faults
1756 ControlLogix, 1756 GuardLogix, 1769 CompactLogix,
1769 Compact GuardLogix, 1789 SoftLogix, 5069
CompactLogix, 5069 Compact GuardLogix, Studio 5000
Logix Emulate

Logix 5000 Controllers Major, Minor, and I/O Faults
2 Rockwell Automation Publication 1756-PM014N-EN-P - March 2022
Important User Information
Read this document and thedocuments listed in the additional resources section about installation, configuration, and
operation of this equipment before you install, configure, operate, or maintain this product.Usersare required to familiarize
themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws, and standards.
Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required to
be carried out by suitably trained personnel in accordance with applicable code of practice.
If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be
impaired.
In no event will Rockwell Automation, Inc. be responsible orliable 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.
WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, whichmay lead to personal injury
or death, property damage, or economic loss.
ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions
help you identify a hazard, avoid a hazard, and recognizethe consequence.
IMPORTANT
Identifies information that is critical for successful application and understanding of the product.
Labels may also be on or inside the equipment to provide specific precautions.
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.
ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to potential Arc Flash. Arc Flash will cause
severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL Regulatory requirements for safe work practices and for Personal
Protective Equipment (PPE).
Rockwell Automation recognizes that some of the terms that are currently used in our industry and in this
publication are not in alignment with the movement toward inclusive language in technology. We are
proactively collaborating with industry peers to find alternatives to such terms and making changes to our
products and content. Please excuse the use of such terms in our content while we implement these changes.

Rockwell Automation Publication 1756-PM014N-EN-P - March 2022 3
Summary of changes
This manual includes new and updated information. Use these reference
tables to locate changed information.
Grammatical and editorial style changes are not included in this summary.
Global changes
The Legal noticeshave been updated.
New or enhanced features
This table contains a list of topics changed in this version, the reason for the
change, and a link to the topic that contains the changed information.
Topic Name
Reason
Minor fault codes on page 29
Replaced the Minor Fault Codes list with a link to the Logix 5000
Controller Fault Codes spreadsheet, which contains a complete list of
fault codes.
Major fault codes on page 25
Replaced the Major Fault Codes list with a link to the Controller Fault
Codes spreadsheet.
I/O fault codes on page 33
Replaced the I/O Fault Codes list with a link to the Controller Fault
Codes spreadsheet.

Rockwell Automation Publication 1756-PM014N-EN-P - March 2022 5
Table of Contents
Studio 5000 environment ...........................................................................7
Additional resources....................................................................................8
Legal Notices ................................................................................................8
Chapter 1
Major Fault State..........................................................................................9
Recover from a major fault....................................................................9
Fault handling during prescan and postscan .................................... 11
Placement of fault routines.................................................................12
Choose where to place the fault routine.............................................13
Create a fault routine for a program.........................................................13
Change a fault routine assignment of a program .............................14
Create a routine for the controller fault handler .....................................16
Create a routine for the power-up handler ..............................................17
Programmatically clearing a major fault.................................................20
Create a data type to store fault information ...................................20
Write a routine to clear the fault.........................................................21
Clear a major fault during prescan .......................................................... 22
Test a fault routine.................................................................................... 24
Create a user-defined major fault............................................................ 24
Major fault codes....................................................................................... 25
Chapter 2
Identify minor faults .................................................................................27
Minor fault examples...........................................................................28
Minor fault codes....................................................................................... 29
Chapter 3
Indications of I/O faults.............................................................................31
I/O Fault Codes .......................................................................................... 33
Summary of changes
Preface
Major Faults
Minor Faults
I/O Fault Codes
Index

Rockwell Automation Publication 1756-PM014N-EN-P - March 2022 7
Preface
This manual shows how to monitor and handle major and minor controller
faults. The manual also provides lists of major, minor, and I/O fault codes to
use to troubleshoot the system.
This manual is one of a set of related manuals that show common procedures
for programming and operating Logix 5000 controllers.
For a complete list of common procedures manuals, refer to the Logix 5000
Controllers Common Procedures Programming Manual, publication
1756-PM001.
The term Logix 5000 controller refers to any controller based on the Logix
5000 operating system.
The Studio 5000 Automation Engineering & Design Environment® combines
engineering and design elements into a common environment. The first
element is the Studio 5000 Logix Designer® application. The Logix Designer
application is the rebranding of RSLogix 5000® software and will continue to
be the product to program Logix 5000™ controllers for discrete, process,
batch, motion, safety, and drive-based solutions.
The Studio 5000® environment is the foundation for the future of
Rockwell Automation® engineering design tools and capabilities. The Studio
5000 environment is the one place for design engineers to develop all
elements of their control system.
Studio 5000 environment

Preface
8 Rockwell Automation Publication 1756-PM014N-EN-P - March 2022
These documents contain additional information concerning related
products from Rockwell Automation.
Resource
Description
Logix5000 Controllers General Instructions Reference
Manual, publication 1756-RM003
Provides programmers with details about each
available instruction for a Logix5000 controller.
Product Certifications website, http://www.ab.com
Providesdeclarations ofconformity, certificates, and
other certification details.
View or download publications at
http://www.rockwellautomation.com/literature/. To order paper copies of
technical documentation, contact your local Allen-Bradley distributor or
Rockwell Automation sales representative.
Rockwell Automation publishes legal notices, such as privacy policies, license
agreements, trademark disclosures, and other terms and conditions on the
Legal Notices page of the Rockwell Automation website.
End User License Agreement (EULA)
You can view the Rockwell Automation End-User License Agreement ("EULA")
by opening the License.rtf file located in your product's install folder on your
hard drive.
Open Source Licenses
The software included in this product contains copyrighted software that is
licensed under one or more open source licenses. Copies of those licenses are
included with the software. Corresponding Source code for open source
packages included in this product are located at their respective web site(s).
Alternately, obtain complete Corresponding Source code by contacting
Rockwell Automation via the Contact form on the Rockwell Automation
website:
http://www.rockwellautomation.com/global/about-us/contact/contact.page
Please include "Open Source" as part of the request text.
A full list of all open source software used in this product and their
corresponding licenses can be found in the OPENSOURCE folder. The default
installed location of these licenses is C:\Program Files (x86)\Common
Files\Rockwell\Help\<Product Name>\Release
Notes\OPENSOURCE\index.htm.
Additional resources
Legal Notices

Rockwell Automation Publication 1756-PM014N-EN-P - March 2022 9
Chapter 1
Major Faults
This chapter explains major fault codes and how to work with them in the
Logix Designer application.
If a fault condition occurs that prevents an instruction from running, the
instruction aborts and the controller reports a major fault. A major fault halts
logic execution and the controller switches to faulted mode (the OK LED
flashes red).
Depending on the application, you may not want all major faults to shut down
the system. If you do not want all major faults to shut down the system, create
a fault routine to clear the fault and let the application continue to run.
The process of resuming execution after the fault clears 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 cleared. It is also a good idea to log
the fault occurrence to analyze it later.
IMPORTANT
When an instruction generates an error due to a fault (for example, a COP with an indirect
addressing programming error), the fault routine skips the instruction and does not run. 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, program a fault routine to
clear type 4, code 20, major faults.
See also
Create a routine for the controller fault handler on page 16
Clear a major fault during prescan on page 22
These examples show fault routines with logic that take specific action after a
major fault. If the fault clears, the faulted instruction does not run and
execution resumes with the next instruction.
Major Fault State
Recover from a major fault

Chapter 1 Major Faults
10 Rockwell Automation Publication 1756-PM014N-EN-P - March 2022
Example 1
In this example, a JSR instruction passes an input parameter containing an
indirect address that is out of bounds. If the fault clears, the JSR instruction
aborts (the subroutine does not run) and execution resumes with the EQU
instruction.
Example 2
In this example, the logic inside 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 an
Add-On Instruction, the remainder of the Add-On Instruction aborts. If the
fault clears, execution resumes with the MOV instruction.
Important points regarding Add-On Instructions
Keep these considerations in mind when using Add-On Instructions and
major faults.