Dear Experts
Dear Experts
I'm facing a problem on CPU 928A (6ES5928-3UA21), where it is going to stop suddenly several times per
day.to put it back back inot "RUN", we justactivate the switch stop/run, then it works allOK. the problem
isoccuringsometimes every 10 minutes and sometimes it happened once per day.
I have attached the ISTACK and BSTACK, and I would appreciate your help in this matter.
is it a hardware or software problem?
does this CPU has internally a RAM module?
regards,
Attachment
This can be caused by defective hardware. Defective hardware can cause software to
invoke additional error routines.
Remedies
Kind regards,
BV
Regards,
Hi,
It's a bit tricky to diagnose the hardware if you can't change program to add some
diagnostic code.
8/16/2011 8:55 PM Rate (0)
You could start check connections between different racks to see if you see
something abnormal.
Measuring supply voltage on different IO card can help too.
You could also check IO in variable table and compare what you get there with LEDs
on IO cards
If there are profibus IM cards.like IM308C, problem might by lost of DP station too.
Any BF ledlit on those IM's ?
There is no standard way to check cycle time in S5. Usually theprogrammer has to
foresee some code to test cycle time. You'll have to check program code if there is a
special tool available to test cycle time.
Cycle time is available in system data, but monitoring these words is not possible in
variable table. Check manual of 928A to find out which system data words has to be
checked to read cycle time.
Check error OB's , maybe there is some code foreseen to make diagnose easier.
BV
Your single Slot 928A CPU (6ES5928-3UA21) has 64KB of inbuilt RAM (plus 46KB of
dedicated DB RAM).
I suggestyou do the folwloing:
1.) Put the CPU into Stop
2.) Upload the whole program
3.) Power off the PLC
4.) Remove EPROM from CPU (leave slot empty)
5.) Power PLC up
6.) Download theonline backup into it
7.) Test that all still works as before
If so, you are now in a position to add some capture code into your program
NOTE: Make sure you have a backup battery in your S5 power supply, otherwise
you'll loose your program if a power failure happens.
Berno09
most of the time, the CPU fault wasZYK which is the cycle time exceeded, while twice
it gave me QVZ which is related to transfer of data from I/O cards. but how can I know
which card is causing this problem? the ISTACK took me to the OB24 only.
To start with see chapter 5.6.4 of the AG S5-135U CPU 928 Programming Guide to
get the background and error codes reference info.
Thereafter, do the following:
1.)Find an freeDB and create at least DW 0-3 in it (all of type KH is fine).
2.)Findafree FB andadd the following code to it:
C DBxyz // open DB
TDD 0 // accu1--> DD0
TAK // swap accu1 and 2
TDD2 // accu1--> DD2
TAK // restore accu content (in case its used elswehere in OB)
8/16/2011 8:55 PM Rate (0)
BE
3.) Add the call of this FB to OB24as the first call in it
4.) When the next CPU Stop happens, open DB xyz onlineand compare the values in
DW0-3 with the ones listed in the manual to identify the I/O error cause.
I hope this helps and pelase let us know what you find.
fritz
The advice and opinion given in this thread is that of the author and does not
necessarily reflect the views of I S Systems Pty Limited.
To find out how I S Systems can help you with your automation needs please
visit www.issystems.com.au.
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dear Fritz,
many thanks for your help.
I followed your instruction, uploaded the program and when I tried to re-download it,
itgave me a message "memory in CPU not adequate", andI couldn't download the
program!
in addition, all fault happened today were all related to the ZYK, no one was QVZ.
OB23
NETWORK 1
:A DB 5
:UN D 0.1
:S D 0.1
:STP
:BE
-----------------------------------------------------------
OB24
:A DB 5
:UN D 0.2
:S D 0.2
:STP
:BE
-----------------------------------------------------------
DB5
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0: KM=00000000 00000010; DW0, BIT0=1 STOP UEBER OB19
1: KM=00000000 00000000; DW0, BIT1=1 STOP UEBER OB23
2: KM=00000000 00000000; DW0, BIT2=1 STOP UEBER OB24
-----------------------------------------------------------
Regards.
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Hi Berno
Since you already made an upload of the program, you can safely give PLC overall
reset either by PG or with switches on PLC.
Download all PB,FB,FX,SB and OB's (all blocks except data blocks)
Once this is done start downloading DB's and DX
This forces the datablocks to be stored in memory dedicated for datablocks if
normally memory is not adequate.
Hello,
As long as BASP is ON, none of the outputs will be ON. Because BASP is a signal issued by the CPU that
disables all outputs. This signal is issued when the PLC goes to stop. Some programs may also use an
instruction BASP to inhibit outputs.
As I told you before, you must read the ISTACK and BSTACK and try to find from that information at what
place the program fails to access a given periphery (L PWxxx or TPWxxx instruction).
Regards
ISteak
I have faced this kind of problem many times. Common practice that I did as following.
1. Delete /clear PLC./Power off for at least 10 min.Put CPU in STOP mode
2. Download all DB , take note if any DB not downloading,
2A.Put the CPU inRUN Check & put again in STOP
3. Download PB/FB/OB step by step, not all together. OBs are always at the last step.
Repeat 2A again
4.Check if any Block not downloading.
5.If you found problem in 2A not going to RUN mode, check ISTAK/BSTAK as
recommended by previous posts.
6.Download & check one by one to find out which block has problem with hardware or
software or any configuration parameters.
Regards,
VViTechs
when i enter block OB13 & OB20 then cpu in stop mode......
without these two blockcpu's run led is on....but output led is off basp led is on.
9/18/2010 5:11 PM Rate (0)
I fear your current "delete this, download that" trial and error troubleshooting
approach is not the most effective one and suggest you go backbasics.
What I suggest you do is essentailly what jklm's already advised you to do, but to
begin with, here are a few observations:
OB23 is NOT the root cause of the CPU Stop, but simply a reaction to theproblem
and being called by the S5 OS when a Timeout (QVZ) in the user program takes
place (e.g. during direct access to I/O modules, see the 928B manual for more on it
and search for "OB 23" related entries).
Someone will have deliberately programmed a STOP command into your OB23 to put
the CPU into a Safe State when a QVZ error occurs in the user program.
Deleting OB23 will as such prevent the CPU Stop, but not eliminate the real problem
nor help you in determining what the root causeis.
To find out what the real problemis I suggest you do the following:
1.) Have the completeprogram in your CPUand give it a Cold restart
9/19/2010 8:58 AM 2.) Go back into the BSTACK (presuming it still crashes) which gets you into the first
Block stack level where OB23 is listed (ref. your screendump in atttachment)
3.) Use <F7> "Continue" to go down one level in block stack.
This will show what block was active before OB23 was called (Take a screendump of
it).
Place your cursor in the bottom half of the screen and press <F2> "Edit".
This will now open the Block in questionandplace the cursoron the
command underneath the one that caused the OB23 call (i.e. the command above
the cursor was last executed, caused a QVZ and triggered a call of OB23).
You may for example see a command that reads directly from an Analogue Input
address (e.g. L PW 156) in which case your root problem would have to do with the
Analogue input card at that address (e.g. missing supply voltage, broken card etc.).
Alternatively to the above, add some code to the start of OB23 to load and store the
contents of ACCU 2-L (Low word of ACCU 2), as it will contain the address that
caused the QVZ (see the "Error identifiers" in the Appendix of the 928B manual for
more on this).
9/19/2010 4:23 AM Rate (1)
I hope this helps, but if you still have problems please make sure to take
screendumps of it all (zip them all up and upload here), upload your S5 program here
too and provide us with an overview of your system configuration (e.g. what type of
cards are in what rack).
Attachment
k53eja.jpg (197 Downloads)
fritz
The advice and opinion given in this thread is that of the author and does not
necessarily reflect the views of I S Systems Pty Limited.
To find out how I S Systems can help you with your automation needs please
visit www.issystems.com.au.
isteak
Rate (0)
Dear Fritz,
part number
6ES565-4UA12
6ES565-4UA11
6ES5470-4UA13
i/o cards-
(see attachment 20v0nll.jpg)