Maintenance and Troubleshooting
Contents
1. oo OD nD 33 o0 ea 13 4 Maintenance and Troubleshooting Power Indicator In general there are four reasons for the CPU power status LED to be OFF 1 Power to the base is incorrect or is not applied 2 The power supply has a blown fuse 3 Base power supply is faulty 4 Other component s have the power supply shut down This problem could be in the base or in the I O modules 5 Power budget for the base has been exceeded Incorrect Base If the voltage to the power supply is not correct the CPU may not operate properly or Power may not operate at all If this is a new installation first check the terminal strip on the local CPU base to insure the base is wired correctly If it is wired for 110 VAC while using 220 VAC the power supply in the base will be damaged If this has happened you will need to replace your base If the wiring is correctly installed for the AC or DC you are using you should measure the voltage at the terminal strip to insure it is within specification for the base you are using If the voltage is not correct shut down the system and correct the problem so a Screws Ce amp D L Power Supply Cover Removed Power Supply The fuse for base power is located behind the power2. the LED which indicates the on or off status reflects the status of the point in respect to the CPU On a output module the status indicators could be operating normally while the actual output device transistor triac etc could be damaged With an input module if the indicator LED is on the input circuitry should be operating properly To verify proper functionality check to see the LED goes off when the input signal is removed e Leakage current can be a problem when connecting field devices to I O modules False input signals can be generated when the leakage current of an output device is great enough to turn on the connected input device To correct this install a resistor in parallel with the input or output of the circuit The value of this resistor will depend on the amount of leakage current and the voltage applied but usually a 10K to 20K ohm resistor will work Insure the wattage rating of the resistor is correct for your application e The easiest method to determine if a module has failed is to replace it if you have a spare However if you suspect another device to have caused the failure in the module that device may cause the same failure in the replacement module as well As a point of caution you may want to check devices or power supplies connected to the failed module before replacing it with a spare module To iS oO 0b S oO E E oO Troubleshooting DL305 User Manual Rev D Maint
3. the base To isolate which module is causing the problem remove one module at a time till the Power LED operates normally Follow the procedure below e Turn off power to the base e Remove a module from the base e Reapply power to the base Power Budget This normally would not be the problem if the machine had been operating correctly Exceeded for a considerable amount of time prior to the indicator going off Power budgeting problems usually occur during system start up when the PLC is under operation and the inputs outputs are requiring more current than the base power supply can provide e OS oo OD oD 33 o0 ea WARNING The PLC may reset if the power budget is exceeded If there is any doubt about the system power budget please check it at this time Exceeding the power budget can cause unpredictable results which can cause damage and injury Verify the modules in the base operate within the power budget for the chosen base You can find additional information on power budget calculations by reviewing Chapter 4 VA mD TENN CPU Firmware The D3 330 CPU firmware can be updated by replacing the EPROM with the new Update Mode firmware programmed into it The D3 340 CPU firmware can be updated with a firmware update tool When this tool is used the BATT indicator will flash as the CPU is being updated Contact AutomationDirect Technical support team at 770 844 4200 for assistance DL305 User Manual
4. the handheld programmer along with a cassette tape recorder The CPU has a built in capacitor to retain the memory for several minutes while the z 2 battery is being replaced Saving the program prior to replacing the battery is just an aS added precaution os WARNING If the battery connector is not connected to the PC board or the J M battery is left out of the system the indicator light will not notify you of the s A on error Be sure the battery is in place and the connector is firmly seated before you place the CPU back into the base DL330 DL330P To replace the CPU battery DL340 CPU Battery 1 Turn power off to the system Replacement 2 Wait 60 seconds then remove the CPU Do not short any connectors or components on the CPU since it may alter the program memory 3 Unlatch and tilt the clip covering the battery 4 Pull the two wire battery connector from the PC board 5 Remove the battery WARNING Do not attempt to recharge the battery or dispose of it by fire The battery may explode or release hazardous materials wee a TANA To install the CPU battery 1 Plug the keyed two wire battery connector on the battery into the connector on the PC board 2 Push gently till the connector snaps closed 3 Slide the battery under the battery retaining clip till the battery is positioned in the socket 4 Push the retaining clip down over the battery snapping the clip
5. Maintenance and Troubleshooting In This Chapter Maintenance CPU Indicators Power Indicator RUN Indicator CPU Indicator BATT Indicator Expansion Base Power Testing Output Points O Module Troubleshooting Noise Troubleshooting Machine Startup and Program Troubleshooting 13 2 Maintenance and Troubleshooting Maintenance The DL305 is a low maintenance system requiring only a few periodic checks to ensure your system stays up and running without problems There are two things you should check periodically e Air quality cabinet temperature etc e CPU battery Air Quality The quality of the air your system is exposed to can affect system performance If Maintenance you have placed your system in an enclosure check to se the ambient temperature is not exceeding the operating specifications If there are filters in the enclosure you should clean or replace them as necessary A good guideline is to check your system environment every one to two months and make sure the environment meets the system operating specifications CPU Battery The CPU battery is used to retain the application program data register and Replacement retentive memory types The life expectancy of this battery is five years zaar NOTE Before replacing your CPU battery you should back up your application j program This can be done by saving the program to hard floppy disk on a personal computer or using
6. Rev D 13 6 Maintenance and Troubleshooting RUN Indicator If the CPU will not enter the run mode the RUN indicator is off the problem is usually in the application program unless the CPU has a fatal error in which case the CPU LED should be on Both of the programming devices handheld programmer and PC programming package will return a error message and depending on the error may also recommend an AUX function to run that will aid in further diagnosing the problem A complete list of error codes can be found in Appendix B CPU Indicator If the CPU indicator is on a fatal error has occurred in the CPU Generally this is not a programming problem but an actual hardware failure You can power cycle the system to clear the error If the error clears the system should be closely monitored and every effort should be made to try to determine the cause of the problem You will find this problem is sometimes caused by high frequency electrical noise introduced into the CPU from a outside source Check your system grounding and install electrical noise filters if the grounding is suspected If power cycling the system does not reset the error or if the problem returns replace the CPU The CPU indicator lights when the watchdog timer is not processed within 100 ms The RUN output from the power supply will also turn off BATT Indicator To oO 0b S oO E E oO gt Troubleshooting If the BATT indicator is o
7. dheld LED display shows 16 consecutive programmer use the following keystrokes status points The MON command has SHF 2 0 MON designated this LED to be output number 20 CO wo ce Go Sa 20 To turn on the output point use the following keystrokes 21 SET SHF 2 0 ENT 22 Cm Ge om Go Gy Go 23 To turn off the output point use the following keystrokes RST SHF 2 0 ENT 20 ane co cS Ga 21 ce Ge Ca GO 22 ee CO ca Ge 23 a z gt ED E 5 e oo OD oD 33 oku ea DL305 User Manual Rev D Maintenance and Troubleshooting I O Module Troubleshooting Important Notes When troubleshooting the DL series I O modules there are a few facts you should be About I O Module aware of These facts may assist you in quickly correcting an I O problem Diagnostics e The output modules cannot detect shorted or open output points If you suspect one or more points on a output module to be faulty you should measure the voltage drop from the common to the suspect point Remember when using a Digital Volt Meter leakage current from an output device such as a triac or a transistor must be considered A point which is off may appear to be on if no load is connected the point e If the I O status indicators on the modules are logic side indicators This means
8. dified Both programming devices offer a way to check the program syntax For example you can use check the program syntax from a Handheld Programmer or you can use the PLC Diagnostics menu option within DirectSOFT This check will find a wide variety of programming errors The following example shows how to use the syntax check with a Handheld Programmer 1 CTR 601 K50 Counter Reset Leg is missing To oO o S oO 09 E E oO Troubleshooting Execute the syntax check CLR SCH w a a a 07 4 1 5 6 ADDRESS DATA ON OFF RUN BATT i 3 7 PWR CPU NoD GR st GEG Press CLR to display the address where the error occurred i o _4 o a Q003 1 5 ADDRESS DATA TNR ON OFF RUN BATT gt 3 7 7 PWR CPU NoD GR ST GEG Correct the problem and continue running the Syntax check until the E07 message no longer appears DL305 User Manual Rev D Using the Pause Relay wee TEN l END Instruction Placement Maintenance and Troubleshooting Special Relay 376 provides a quick way to allow the inputs or other logic to operate while disabling any output points used with an OUT instruction The output image register is still updated but the output status is not written to the modules For example you could make this conditional by adding an input contact or CR to control the instruction with a swi
9. en all connections in your system Loose ground wires are more susceptible to noise than the other wires in your system Review Chapter 2 Installation and Safety Guidelines if you have questions regarding how to ground your system e Electrical noise can enter the system through the power source for the CPU and I O Installing a isolation transformer for all AC sources can correct this problem DC sources should be well grounded good quality supplies Switching DC power supplies commonly generates more noise than linear supplies do e Separate input wiring from output wiring Never run I O wiring close to high voltage wiring 5 e ca exo 0 gt no 33 eku Oa DL305 User Manual Rev D 13 12 Maintenance and Troubleshooting Machine Startup and Program Troubleshooting Even after our your best attempts at creating application programs there are still times when you need some assistance This is especially true during machine startup and program troubleshooting With the DL305 CPUs there are a few things that help make this task easier e Program Syntax Check find problems before startup e Pause Relay monitor output status without enabling the actual output points or field devices e End Statement move the End statement to disable parts of the program Syntax Check Even though the Handheld Programmer and DirectSOFT provide error checking during program entry you may want to check a program that has been mo
10. enance and Troubleshooting Noise Troubleshooting Electrical Noise Noise is one of the most difficult problems to diagnose Electrical noise can enter a Problems system in many different ways and they fall into two categories conducted or radiated It may be difficult to determine how the noise is entering the system but the corrective actions for either of the types of noise problems are similar e Conducted noise is when the electrical interference is introduced into the system by way of a attached wire panel connection etc It may enter through an I O module a power supply connection the communication ground connection or the chassis ground connection e Radiated noise is when the electrical interference is introduced into the system without a direct electrical connection much in the same manner as radio waves Reducing While electrical noise cannot be eliminated it can be reduced to a level that will not Electrical Noise affect the system e Most noise problems result from improper grounding of the system A good earth ground can be the single most effective way to correct noise problems If a ground is not available install a ground rod as close to the system as possible Insure all ground wires are single point grounds and are not daisy chained from one device to another Ground metal enclosures around the system A loose wire is no more than a large antenna waiting to introduce noise into the system therefore you should tight
11. ge the keyswitch to PRG if you are using DirectSOFT select program mode 2 Go to address 0 handheld SHF NXT keys Insert a END handheld CLR SHF INS NXT keys statement at ad 3 dress 0 This will cause program execution to occur only at address 0 and prevent the application program from turning the I O points on or off 4 Change to Run mode using the handheld programmer or DirectSOFT 5 Use the programming device to set turn on or reset turn off the points you wish to test 6 When you finish testing I O points go to address 0 handheld SHF NXT NXT keys and delete the END statement handheld keys DEL PRV The following diagram shows the Handheld Programmer keystrokes used to test an output point To oO o S oO 09 E E oO Troubleshooting unpredictable machine operation that can result in a risk of personal injury or equipment damage Make sure you have taken all appropriate safety WARNING Depending on your application forcing I O points may cause yy Pa O precautions prior to testing any I O points DL305 User Manual Rev D Maintenance and Troubleshooting Insert a END statement ra at the beginning of the END Program This disables 30 the remainder of the 0 2 3 g A program I u Ie od XN 1 3 4 1 1 When the MON command is used the To monitor the output point on the han
12. n the CPU battery is low and needs to be replaced The battery voltage is continuously monitored while the system voltage is being supplied The detection circuit will be activated when the voltage drops to 2 5 volts and CPU operation will still continue as normal Internal relay 377 energizes when the BATT indicator is on Procedures for how to replace the battery can be found earlier in this chapter DL305 User Manual Rev D Maintenance and Troubleshooting 13 7 Expansion Base Power Because a expansion base contains no CPU the only method of determining if the base power supply if functioning correctly is the run relay provided for that base This relay can be connected to an input point on the local CPU base or an external warning indicator to monitor the expansion base power supply If the power supply fails the run relay will open The procedures for troubleshooting the expansion bases are the same as a local CPU base Refer to the Power Indicator section for procedures e OS oo OD nD 33 o0 eoa DL305 User Manual Rev D 13 8 Maintenance and Troubleshooting Testing Output Points Testing Output Output points can be set on or off in the DL305 series CPUs but they cannot be Points forced in such a way which overrides ladder logic If you want to do an I O check out independent of the application program follow the procedure below Step Action 1 If you are using the handheld programmer chan
13. over the edge of the PC board 5 Note the date the battery was changed DL305 User Manual Rev D Maintenance and Troubleshooting 13 3 Battery Removal 2 Unplug 1 Push back connector FAN retaining clip ms A 1 Push back l retaining clip 2 Unplug connector DL330 DL340 ie TN ID Da o co Ww 0 S HHEBREEAE M Cc o lt 3 D o O 3 Remove batter 3 Remove battery Part D3 04 BATT Part D3 04 BATT CPU Indicators The DL305 CPUs have indicators on the front to help you diagnose problems with the system The table below gives a quick reference of potential problems with each status indicator Following the table will be a detailed analysis of each of these indicator problems Indicator Status Power off Potential Problems 1 Improper wiring 2 Power supply fuse is blown 3 Power supply CPU is faulty 4 Other component such as an I O module has power supply shorted 5 Power budget exceeded for the base power supply RUN will not come on 1 CPU programming error 2 Key switch on handheld not in RUN mode CPU on BATT on BATT flashing 1 CPU defective 2 Severe electrical noise interference CPU battery low CPU in update mode DL305 User Manual Rev D e o
14. supply cover at the right side of 5 Blown Fuse the base co S 9o 1 Remove power from the base Sg 2 Remove the two slotted insert screws from the front cover 2s 3 Remove and replace the 2A 250V fuse 4A 250V for the DC models he 4 Place the front cover back on the power supply and insert the screws 5 Reapply power to the system Fuse 2A m m 4A for DC models e a A AJ oo O o oo lt a ened oo oo oo El oo oo o o El o o oo oo El A z NY Retaining Vid Li l ai DL305 User Manual Rev D Maintenance and Troubleshooting 13 5 Faulty Base Power There is not a good check to test for a faulty power supply other than substituting a Supply known good base to see if this corrects the problem If you have experienced major power surges it is possible the base and power supply have been damaged If you suspect this is the cause of the power supply damage a line conditioner which removes damaging voltage spikes should be used in the future Device or Module It is possible a faulty module or external device using the system power can shut Causing the Power down the power supply Supply to Shutdown To test for a device causing this problem e Turn off power to the base e Disconnect all external devices example Data Communication Unit Prom Writer Unit from the CPU e Reapply power to the base If the Power LED does not operate normally the problem is most likely in one of the modules in
15. tch or a programming device Or you could just add the instruction without any conditions so the outputs would be disabled at all times Normal Program PAUSE disables 020 and 021 000 002 020 376 D j Pause 001 003 004 000 002 020 1 1 C Ng 010 021 001 003 004 D 010 021 Eno C eD By using this relay you can still monitor the output status with a programming device The programming device will show that the output should be on even though the CPU does not actually update the I O point WARNING This special relay only inhibits those outputs referenced by the OUT instruction Output points referenced by the SET OUT instruction are not disabled If you need a way to quickly disable part of the program just insert an END statement prior to the portion that should be disabled When the CPU encounters the END statement it assumes that is the end of the program The following diagram shows an example Normal Program New END disables X10 and Y1 000 002 Ned 000 002 020 C C 001 003 004 001 003 004 007 021 CO eD 007 021 Eno Eno DL305 User Manual Rev D e OS oo OD oD 33 Oo 32 ea
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