ControlLogix PLC Major Fault Codes Causes and Solutions
ControlLogix PLC Fault Codes
You can find ControlLogix PLC Major Fault Codes Type – Code – Cause And Recovery Method
| Type | Code | Cause | Recovery Method |
| 7 | 40 | Store to nonvolatile memory failed. | · Try again to store the project to nonvolatile memory. · If the project fails to store to nonvolatile memory, replace the memory board. · If you are using a 1756-L7x controller, verify that the SD card is unlocked. |
| 7 | 41 | Load from nonvolatile memory failed due to controller type mismatch. | Change to a controller of the correct type or download the project and store it on the memory card. |
| 7 | 42 | Load from nonvolatile memory failed because the firmware revision of the project in nonvolatile memory does not match the firmware revision of the controller. | Update the controller firmware to the same revision level as the project that is in nonvolatile memory. |
| 7 | 43 | Load from nonvolatile memory failed due to bad checksum. | Contact Rockwell Automation support. |
| 7 | 44 | Failed to restore processor memory. | Contact Rockwell Automation support. |
| 7 | 50 | The log file certificate can not be verified. When the controller starts up it attempts to verify the log file key/certificate combination. Depending on the verification, the controller takes one of the following actions: · If the controller verifies the existing log file certificate, the controller continues with existing log directory. · If the existing certificate cannot be verified, the controller logs a major fault and attempts to create a new certificate. · If the controller successfully creates a new certificate, it creates a backup log subdirectory, moves the existing files to that directory, and continues logging and signing with the new verification key and log file certificate. · If the controller cannot create a new certificate, the controller writes log entries to the existing log directory, but does not update signature files in that directory. | Clear the fault and power cycle the controller. If the problem persists, contact Rockwell Automation support. |
| 8 | 1 | Attempted to place controller in Run mode with keyswitch during download. | Wait for the download to complete and clear the fault. |
| 11 | 1 | Actual position has exceeded positive overtravel limit. | Move axis in negative direction until position is within overtravel limit, and then execute Motion Axis Fault Reset. |
| 11 | 2 | Actual position has exceeded negative overtravel limit. | Move axis in positive direction until position is within overtravel limit, and then execute Motion Axis Fault Reset. |
| 11 | 3 | Actual position has exceeded position error tolerance. | Move the position within tolerance and then execute Motion Axis Fault Reset. |
| 11 | 4 | Encoder channel A, B, or Z connection is broken. | Reconnect the encoder channel, and then execute Motion Axis Fault Reset. |
| 11 | 5 | Encoder noise event detected or the encoder signals are not in quadrature. | Fix encoder cabling, and then execute Motion Axis Fault Reset. |
| 11 | 6 | Drive Fault input was activated. | Clear Drive Fault, and then execute Motion Axis Fault Reset. |
| 11 | 7 | Synchronous connection incurred a failure. | First execute Motion Axis Fault Reset. If that does not work, pull servo module out and plug back in. If all else fails, replace servo module. |
| 11 | 8 | Servo module has detected a serious hardware fault. | Replace the module. |
| 11 | 9 | Asynchronous Connection has incurred a failure. | First execute Motion Axis Fault Reset. If that does not work, pull servo module out and plug back in. If all else fails, replace servo module. |
| 11 | 10 | Motor fault has occurred. | See the DriveFaults axis tag for more information. |
| 11 | 11 | Motor thermal fault has occurred. | See the DriveFaults axis tag for more information. |
| 11 | 12 | Motor thermal fault has occurred. | See the DriveFaults axis tag for more information. |
| 11 | 13 | SERCOS ring fault has occurred. | Verify the integrity of the SERCOS fiber-optic ring network and the devices on it. |
| 11 | 14 | Drive enable input fault has occurred. | Re-enable the drive enable input and clear the fault. |
| 11 | 15 | Drive phase loss fault has occurred. | Restore full power connection to the drive and clear the fault. |
| 11 | 16 | Drive guard fault has occurred. | See the GuardFaults axis tag for more information. |
| 11 | 32 | The motion task has experienced an overlap. | The group’s coarse rate is too high to maintain correct operation. Clear the group fault tag, raise the group’s update rate, and then clear the major fault. |
| 12 | 32 | Power to a disqualified secondary controller has been cycled and no partner chassis or controller was found upon power up. | Verify that: · A partner chassis is connected. · Power is applied to both redundant chassis. · Partnered controllers have the same: · catalog number. · slot number. · firmware revision. |
| 12 | 33 | An unpartnered controller has been identified in the new primary chassis after a switchover. | Either: · Remove the unpartnered controller and troubleshoot the cause of the switchover. · Add a partner controller to the secondary chassis. · Troubleshoot the cause of the switchover, and synchronize the system. |
| 12 | 34 | Just after a switchover occurs, the keyswitch positions of the primary and secondary controllers are mismatched. The old primary controller is in Program mode and the new primary controller is in Run mode. | Either: · Change the keyswitches from Run to Program to Run mode twice to clear the fault. · Use the Logix Designer application to go online with the controllers. Then, clear the faults and change both the controllers’ modes to Run. |
| 14 | 1 | Safety Task watchdog expired. User task has not completed in a specified period of time. A program error caused an infinite loop, the program is too complex to execute as quickly as specified, a higher priority task is keeping this task from finishing, or the safety partner has been removed. | Clear the fault. If a safety task signature exists, safety memory is re-initialized and the safety task begins executing. If a safety task signature does not exist, you must re-download the program to allow the safety task to run. Reinsert the safety partner, if it was removed. |
| 14 | 2 | An error exists in a routine of the safety task. | Correct the error in the routine in the user-program logic. |
| 14 | 3 | Safety Partner is missing. | Install a compatible safety partner. |
| 14 | 4 | Safety Partner is unavailable. | Install a compatible safety partner. |
| 14 | 5 | Safety Partner hardware is incompatible. | Install a compatible safety partner. |
| 14 | 6 | Safety Partner firmware is incompatible. | Install a compatible safety partner. |
| 14 | 7 | Safety task is inoperable. This fault occurs when the safety logic is invalid, for example a mismatch in logic exists between the primary controller and safety partner, a watchdog timeout occurred, or memory is corrupt. | Clear the fault. If a safety task signature exists, safety memory is re-initialized using the safety task signature and the safety task begins executing. If a safety task signature does not exist, you must download the program again to allow the safety task to run. |
| 14 | 8 | Coordinated System Time Master (CST) not found. | Clear the fault. Configure a device to be the CST master. |
| 14 | 9 | Safety partner nonrecoverable controller fault. | Clear the fault and download the program. If the fault persists, replace the safety partner. |
| 17 | 34 | Controller internal temperature has exceeded operating limit. | Measures should be taken to reduce the ambient temperature of the module. Follow the recommended limits for the ambient (inlet) temperature and apply the required clearance around the chassis. |
| 17 | 37 | Controller has recovered from an internal temperature fault. | Generated when the controller recovers from automatic shutdown. Shutdown occurs when the modules’s temperature exceeds the temperature threshold of the preservation fault. When the temperature decreases to a suitable level, this re-enables the controller voltages and generates the Type 17, Code 37 fault. |
| 18 | 1 | The CIP Motion drive has not initialized correctly. | To determine corrective action, see Initialization Faults Attributes for details about the type of fault that occurred. |
| 18 | 2 | The CIP Motion drive has not initialized correctly. This fault is indicated when a manufacturer-specific initialization fault has occurred. | To determine the corrective action, see CIP Initialization Fault – Mfg attributes for details about the fault that occurred. |
| 18 | 3 | The Physical Axis Fault bit is set, indicating a fault on the physical axis. | To determine corrective action, see CIP Axis Fault attributes for details about the fault that occurred. |
| 18 | 4 | The Physical Axis Fault bit is set, indicating fault on the physical axis. This fault is indicated when a manufacturer-specific axis fault has occurred. | To determine corrective action, see CIP Initialization Fault – Mfg attributes attributes for details about the fault that occurred. |
| 18 | 5 | A motion fault occurred. | To determine corrective action, see the Motion Fault attribute and Motion Fault bits for details about the fault that occurred. |
| 18 | 6 | A CIP Motion Drive fault has occurred. Usually the fault affects all the axis associated with the module and all of the associated axes are shutdown. | Reconfigure the faulted motion module to correct the fault. |
| 18 | 7 | A motion group fault has occurred. Usually the fault affects all of the axes associated with a motion group. | Reconfigure the entire motion subsystem to correct the fault. |
| 18 | 8 | A fault has occurred during the configuration of a CIP Motion Drive. Typically, this fault occurs after an attempt to update an axis configuration attribute of a CIP Motion Drive was unsuccessful. | To determine the corrective action, see the Configuration Fault in the Attribute Error Code and Attribute Error ID attributes associated with the motion or 1756-ENxT module. |
| 18 | 9 | An Absolute Position Recovery (APR) fault has occurred and the absolute position of the axis cannot be recovered. | To determine the corrective action, see the APR Fault to determine the cause of the fault. |
| 18 | 10 | An Absolute Position Recovery (APR) fault has occurred and the absolute position of the axis cannot be recovered. This fault is indicated when a manufacturer-specific APR fault has occurred. | To determine the corrective action, see the APR Fault – Mfg attributes to determine the cause of the fault.attributes |
| 18 | 128 | A fault specific to the Guard Motion safety function has occurred. This fault is applicable only when a drive with Guard Safety functionality is used. | To determine the corrective action, see the Guard Motion attributes and Guard Status bits to determine the cause of the fault. |
| 20 | 1 | A required license is missing or expired during the transition to run or test mode. | Insert a CmCard containing all licenses required by the project in the controller. |
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