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Power
application
Initialization Initializatio
Check OK ?
Overseei
ng
processe
Set error flags and
s
activate indicators Preset cycle time
ALARM monitoring time
ERROR (flashing)
OR
ALARM? Execute user program
ERROR
(lit) No
End of program ?
Program
executio Cycle
Check cycle time time
n
Minimum No
cycle time set ?
Cycle
Computer cycle time time
processi
ng
Refresh input bits
and output terminals
Service peripheral
I/O
refreshin
Note Initialization process include cleaning the IR, SR, and ARgareas, pre- setting
system timers, and
checking I/O Units.
9-1
9. MAINTENANCE AND TROUBLESHOOTING
Self-diagnosis Functions
The PLC is equipped with a variety of self-diagnosis functions to help identify
and correct errors that might occur an reduce down time.
PLC errors are divided into 2 categories based on the severity of the errors.
Fatal errors are more serious errors which stop PLC operation. Non-fatal errors
are less serious and don’t stop PLC operation.
Non-fatal Errors
PLC operation and program execution will continue after one or more of these
errors have occurred. Although PLC operation will continue, the cause of the
error should be corrected and the error cleared as soon as possible.
When one of these errors occurs, the POWER and RUN indicators will remain lit
and the ERR/ALM indicator will flash.
You need to refer to the appropriate PLC manuals to check the flags to
determine the cause of the problem and correct the error.
Fatal Errors
PLC operation and program execution will stop and all outputs from the PLC will
be turned OFF when any of these errors have occurred. CPM1A operation can’t
be restarted until the PLC is turned off and then on again or a Peripheral Device
is used to switch the PLC to PROGRAM mode and clear the fatal error.
All CPU indicators will be OFF for the power interruption error. For all other fatal
operating errors, the POWER and ERR/ALM indicators will be lit. The RUN
indicator will be OFF.
• MEMORY ERR
• NO END INST
• I/O BUS ERR
• I/O UNIT OVER
• SYS FAIL FALS**
You need to check the error flag of the appropriate PLC manual to determine
the cause of the problem and correct the error.
9-2
9. MAINTENANCE AND TROUBLESHOOTING
User-defined Errors
There are three instructions that the user can use to define his own errors or
messages. FAL(06) causes a non-fatal error, FAL(07) causes a fatal error, and
MSG(46) sends a message to the Programming Console or host computer
connected to the PC.
FAILURE ALARM-FAL(06)
FAL(06) is an instruction that causes a non-fatal error. The following will occur
when an FAL(06) instruction is executed:
1,2,3… 1. The ERR/ALM indicator on the CPU will flash. PC operation will
continue.
2. The instruction’s 2-digit BCD FAL number (01 to 99) will be written to SR
25300 to
SR 25307.
The FAL numbers can be set arbitrarily to indicate particular conditions. The
same number cannot be used as both an FAL number and an FALS number.
To clear an FAL error, correct the cause of the error and then execute FAL 00 or
clear the error using the Programming Console.
FALS(07) is an instruction that causes a fatal error. The following will occur
when an FALS(07) instruction is executed:
1,2,3… 1. Program execution will be stopped and outputs will be turned
OFF.
2. The ERR/ALM indicator on the CPU will be lit.
3. The instruction’s 2-digit BCD FALS number (01 to 99) will be written to
SR 25300 to
SR 25307.
4. The FALS number and time of occurrence will be recorded in the PC’s
error log area
if a Memory Cassette with a clock (RTC) is used.
MESSAGE-MSG(46)
9-3
9. MAINTENANCE AND TROUBLESHOOTING
Programming Errors
These errors in program syntax will be detected when the program is checked
using the Program Check operation.
Three levels of program checking are available. The desired level must be
designated to indicate the type of errors that are to be detected. The following
table provides the error types, displays, and explanations of all syntax errors.
Check level 0 checks for type A, B, and C errors; check level 1, for type A and B
errors; and check level 2, for type A errors only.
9-4
9. MAINTENANCE AND TROUBLESHOOTING
9-5
9. MAINTENANCE AND TROUBLESHOOTING
Troubleshooting Flowcharts
Use the following flowcharts to troubleshoot errors that occur during operation.
Main Check
Error
N
Power indicator o Check power supply
lit?
Yes
N
RUN indicator o Check for fatal errors
lit?
ERR/ALM N
o
Check for non-fatal
indicator errors
flashing?
Yes
N
Is I/O sequence o Check I/O
normal?
Yes
Operating N
o
Check operating
environment
environment
normal?
Yes
Replace the
CPU
9-6
9. MAINTENANCE AND TROUBLESHOOTING
Preventive Maintenance
Although PLC is designed for reliability. It can fail eventually. Probably the
biggest deterrent to system breakdown is a proper preventive maintenance
program for the PLC and the control system.
Periodically, inspect the tightness of the I/O terminals screws. They can become
loose over a period of time.
Ensure that components are free of dust. Proper cooling of the PLC is
impossible if layer of dust are deposited.
Corrosion may take place in some environment. Check periodically for corrosion
of connecting terminals. Printed circuit board and connector may become
corroded internally.
Maintain a certain amount of commonly used spare parts such as the input and
output modules. It can be very costly if prolonged downtime occurs without
parts.
9-7