Rockwell Automation Allen-Bradley Logix5000 Owner's manual

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 Information
Solid 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.
WARNING Identifies 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.

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

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Summary of Changes
Notes:

5Publication 1756-PM014B-EN-P - July 2008 5
Table of Contents
Preface Purpose of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
How to Use this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Chapter 1
Monitor Minor Faults Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Minor Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Chapter 2
Handle a Major Fault Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Choose Where to Place the Fault Routine . . . . . . . . . . . . . . . . . . . 15
Create a Fault Routine for a Program . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Create the Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Assign the Routine as the Fault Routine . . . . . . . . . . . . . . . . . . . . 16
Create a Routine for the Controller Fault Handler. . . . . . . . . . . . . . . . 17
Create a Routine for the Power-Up Handler . . . . . . . . . . . . . . . . . . . . 17
Programmatically Clear a Major Fault. . . . . . . . . . . . . . . . . . . . . . . . . . 18
Create a Data Type to Store Fault Information . . . . . . . . . . . . . . . 18
Get the Fault Type and Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Check for a Specific Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Clear the Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Clear a Major Fault During Prescan . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Identify When the Controller is in Prescan . . . . . . . . . . . . . . . . . . 21
Get the Fault Type and Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Check for a Specific Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Clear the Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Test a Fault Routine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Create a User-Defined Major Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Create a Fault Routine for the Program . . . . . . . . . . . . . . . . . . . . . 25
Configure the Program to Use the Fault Routine . . . . . . . . . . . . . 25
Jump to the Fault Routine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Major Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

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Table of Contents

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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.

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Summary of Changes Preface
Notes:

9Publication 1756-PM014B-EN-P - July 2008 9
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.)

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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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Chapter 1 Monitor Minor Faults
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
44An arithmetic overflow occurred in an instruction. Fix program by examining arithmetic operations (order)
or adjusting values.
45In a GSV/SSV instruction, the specified instance was
not found. Check the instance name.
46In a GSV/SSV instruction, either:
·specified Class name is not supported
·specified Attribute name is not valid
Check the Class name and Attribute name.
47The GSV/SSV destination tag was too small to hold all
of the data. Fix the destination so it has enough space.
435 PID delta time ≤0. Adjust the PID delta time so that it is > 0.
436 PID setpoint out of range Adjust the setpoint so that it is within range.
451 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.
452 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.
453 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.
456 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.
457 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.
62Periodic 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.
749 Project loaded from nonvolatile memory.
90Unknown error while servicing the serial port. Contact Rockwell Automaiton Technical Support.

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Monitor Minor Faults Chapter 1
91The 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
92Poll list error.
A problem was detected with the DF1 master’s 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
95DF1 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.
99Modem 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.
Type Code Cause Recovery Method

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Chapter 1 Monitor Minor Faults
Notes:

15Publication 1756-PM014B-EN-P - July 2008 15
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 4Create a Fault Routine for a Program 16
Communication with an I/O module fails 3Create 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 1Create a Routine for the Power-Up Handler 17

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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.

Publication 1756-PM014B-EN-P - July 2008 17
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.

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Chapter 2 Handle a Major Fault
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.
+
+
+
−

Publication 1756-PM014B-EN-P - July 2008 19
Handle a Major Fault Chapter 2
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.
42372
1. 2.
1 Equal
Source A major_fault_record.Type
0
Source B fault_type
Equal
Source A major_fault_record.Code
0
Source B fault_code
Move
Source 0
Dest major_fault_record.Type
0
MOV Move
Source
Dest major_fault_recor
d
MOV
2Set system value
CIP Object class P
R
CIP Object name
Attribute name MAJORFAULT
R
jfl di
SSV
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3. 4.

20 Publication 1756-PM014B-EN-P - July 2008
Chapter 2 Handle a Major Fault
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
42372
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.