GEH-6721_Vol_III

GE Energy

Mark* VIe Control Vol. IIIDiagnostics and TroubleshootingGEH-6721K

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© 2009 General Electric Company, USA. All rights reserved.Issued:090315

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Contents 1-1

Alarms 2-1Mark VIe Controller Alarms .............................................................................................................................................2-1

Controller Specific Alarms.........................................................................................................................................2-1Specific I/O Pack Alarms ................................................................................................................................................2-21

PAIC Specific Alarms...............................................................................................................................................2-21PAMB Specific Alarms ............................................................................................................................................2-26PAMC Specific Alarms ............................................................................................................................................2-27PAOC Specific Alarms .............................................................................................................................................2-31PCAA Specific Alarms.............................................................................................................................................2-33PCLA Specific Alarms .............................................................................................................................................2-42PCNO Specific Alarms.............................................................................................................................................2-48PDIA Specific Alarms..............................................................................................................................................2-50PDII Specific Alarms................................................................................................................................................2-51PDIO Specific Alarms..............................................................................................................................................2-53PDOA Specific Alarms ............................................................................................................................................2-55PEFV Specific Alarms..............................................................................................................................................2-58PGEN Specific Alarms.............................................................................................................................................2-60PHRA Specific Alarms.............................................................................................................................................2-62PPDA Specific Alarms .............................................................................................................................................2-77PPRA Specific Alarms ...........................................................................................................................................2-101PPRF Specific Alarms............................................................................................................................................2-110PPRO Specific Alarms ...........................................................................................................................................2-114PRTD Specific Alarms ...........................................................................................................................................2-121PSCA Specific Alarms ...........................................................................................................................................2-123PSVO Specific Alarms ...........................................................................................................................................2-124PTCC Specific Alarms ...........................................................................................................................................2-134PTUR Specific Alarms ...........................................................................................................................................2-136PVIB Specific Alarms ............................................................................................................................................2-141

Common I/O Pack Alarms ............................................................................................................................................2-144Common Alarms ....................................................................................................................................................2-144

GEH-6721K Diagnostics and Troubleshooting Contents i

Notes

1-1 GEH-6721K Mark* VIe Control Vol. III

Alarms

Mark VIe Controller Alarms

Controller Specific AlarmsThe controller detects certain system errors during startup, download, and normaloperation. These diagnostic alarms can be displayed and reset from the ToolboxSTapplication, and are recorded in historical manner using WorkstationST* Recorder.

The following alarms are specific to the Mark VIe Controller.

20

Description I/O communication failure between [ ] and controller.

Possible Cause

• I/O pack did not complete Start• I/O pack configuration files missing

• I/O pack restarted• I/O pack configured for dual networks, but only one network is connected• Network issue

Solution

• If the Control/Status communication is working correctly, any additional diagnosics should indicate the cause of theproblem.

• Build and download parameters to the I/O pack.

• Download firmware and parameters to the I/O pack.• Verify that the Ethernet cables and network switch are operating correctly.• Manually restart the I/O pack.

21

Description Control/Status communication failure between [ ] and controller.

Possible Cause

• Asynchronous Drive Language (ADL) communication unhealthy

• Terminal board barcode typed incorrectly in the ToolboxST configuration• Wrong terminal board is configured in the ToolboxST application

• Pack is plugged into wrong Jack on terminal board, or wrong jack number is configured in the ToolboxST application

• I/O pack configured in ToolboxST application, but configuration not downloaded to the controller• I/O pack in program mode

Solution

• Verify that the I/O pack configuration (Type, HW Form, Bar Code, position) matches the actual hardware.• Build and download the configuration to the controller, wait for pack communication status to change, then scan and

download to the I/O pack.

• Manually restart the I/O pack.

GEH-6721K Diagnostics and Troubleshooting Alarms 2-1

22

Description Diagnostic status signal (...L3DIAG and/or ...ATTN) is [ ]; therefore, diagnostic status for this I/O pack maybeinaccurate, unknown, or indeterminate.

Possible Cause

• I/O status signal quality in warning state• signal quality unhealthy, forced, or being simulated• Status information inaccurate

Solution Check signal health, remove the force, or simulated condition.

23

Description [ ] controller state is not OK...(i.e. Major Difference).

Possible Cause major difference in controller application/configuration code

Solution Rebuild the system and download.

24

Description Cannot retrieve pack Information. [ ]

Possible Cause

• Cannot get requested information from I/O pack• Communication program failure

• I/O pack unable to retrieve IP address

• Terminal board barcode typed incorrectly in ToolboxST configuration• Wrong terminal board configured in ToolboxST application

• Pack plugged into wrong Jack on terminal board, or wrong jack number in ToolboxST configuration

• I/O pack configured in ToolboxST application, but configuration not downloaded to controller• I/O pack in program mode

Solution



• Manually restart the I/O pack.• Check network cables for proper connection.• Verify that the switch is functioning correctly.

25

Description Control/Status communication Error: [ ]

Possible Cause

• Cannot get diagnostic information from I/O pack

• I/O pack not able to load firmware

Solution

• Verify the I/O pack configuration.

• Rebuild application and download firmware and application to the I/O pack.• Check network cables for proper connection.• Verify that the switch is functioning correctly.

2-2 Alarms GEH-6721K Mark* VIe Control Vol. III

259

Description Application Runtime Error - [ ] Frame overruns occurred

Possible Cause Overloaded controller or controller sequencer malfunction (one or more frame overruns occurred)

Solution Increase frame idle time by:

• Reducing application or by increasing EGD period• Using a faster processor board (UCCC)• Replacing the processor module

260

Description Application Runtime Error - [ ] Frame skips occurred

Possible Cause Overloaded controller or controller malfunction. Frame number skips detected. Frame number should

monotonically increase during Controlling state

Solution

• Reduce controller processor load by increasing EGD period or by reducing application.• Use a faster processor board such as UCCC.

• Replace the processor module.

279

Description Could not determine platform type from hardware

Possible Cause During commissioning/maintenance:

• Incorrect firmware version or hardware malfunction (firmware could not recognize host hardware type)

During normal operation:

• Hardware failure

Solution

• Verify that all connectors are aligned properly and fully seated.• Check the firmware version for compatibility with platform. If correct, replace the processor module.

280

Description Platform hardware does not match configuration


• Platform type identified in the application configuration does not match actual hardware



Solution

• Fix the platform type in the ToolboxST application (General tab, General Properties, Platform).• Rebuild and download the application.

• If problem persists, replace the processor module.


282

Description Firmware Load Error - application independent processes failed to initialize

Possible Cause Runtime malfunction. An application-independent firmware process could not be started successfully.

Solution

• Reload firmware and application and restart.

• Controller: If failure persists, remove the Compact Flash module and reprogram the boot loader using the ToolboxSTconfiguration. Download using the Device | Download | Controller setup | Format Flash selection. After reinstalling theflash module and restarting, reload the firmware and application.

• Replace the module.• I/O pack: Re-download the base load.

283

Description Firmware execution error - Internal process crashed

Possible Cause Runtime or hardware malfunction (runtime process failed)

Solution


• Controller: If failure persists, remove the Compact Flash module and reprogram the boot loader using ToolboxST.Download using the Device | Download | Controller setup | Format Flash pick, then, after reinstalling the flash moduleand restarting, reload firmware and application.

• If this does not work, replace processor module.• IoPack: Redownload the base load.

292

Description Application Error - application overruning the frame

Possible Cause Application cannot start within frame

Solution Check application loading and reduce the amount of application code or frequency of execution. Build application

and download to all processors.

294

Description Controller CPU overtemperature, Temp [ ] degC, Threshold [ ] degC

Possible Cause

• Fan loss• Excessive ambient temperature• Hardware malfunction

Solution Check the fan, including the ambient temperature, and any dust on the processor module. If okay, replace the

processor module.


300

Description Application Code Load Failure


• Invalid application configuration


• Firmware or hardware malfunction

Solution

• Rebuild and download the application to all processors .

• Reload firmware and application.• if problem persists, replace processor module.

320

Description Process Alarm Buffers Full - MarkVIe can miss alarm transitions

Possible Cause

• Multiple alarm variables changing state too quickly to transmit all transitions

• Excessive alarms in queue (Plant-wide system failures)

Solution During commissioning/maintenance:

• Reduce the number of alarms that can change state at the same time (filter alarm variables in the application code).


• Eliminate the conditions causing excessive process alarms.

321

Description Internal Runtime error - Process Alarms not being scanned

Possible Cause Runtime malfunction: alarms not being scanned. Processor may restart on software watchdog timeoutdue to processor overload

Solution

322

Description Configuration Load error - Too many consumed EGD variables for Fault Tolerant EGD

Possible Cause Number of relevant, consumed UDH EGD variables exceeds fault tolerant EGD limitation of 1400 bytes of

data.

Normal UDH EGD operation not affected; however, in the event of UDH EGD failure, some consumed variables may notbe transmitted to redundant controllers over the IONet.


• Reduce the amount of relevant, consumed UDH EGD data by removing the appropriate number of variables fromEGD pages.


323

Description EGD Error - Fault Tolerant EGD activated

Possible Cause EGD exchange timeout occurred on requesting processor. Redundant processor unable to receive UDH

EGD inputs and requested that EGD data be transferred over the IONet.

Solution

• Verify that all redundant processors on the UDH network are receiving all expected EGD exchanges.• that all relevant devices are powered up and producing data on the network.

324

Description EGD Error - Fault Tolerant EGD data requested

Possible Cause An EGD exchange timeout occurred on the requesting processor. Redundant processor unable to receive

UDH EGD inputs and has requested that EGD data be transferred over the IONet.

Solution

• Check UDH network and verify that all redundant processors are receiving all of the expected EGD exchanges.• Verify that all relevant devices are powered on and producing data on the network.

326

Description Communication lost from R processor

Possible Cause

• IONet or hardware malfunction

• S or T processor in redundant system lost communication with R processor

Solution

• Go online with the R processor. Verify that the processor is in the Controlling state. If not communicating or in

Controlling state, restart the processor.• Check for disconnected IONet cables or malfunctioning switches.• Rebuild and download application.

• Check for bad ethernet cable to network switch.• Check for bad network switch: place ethernet cable into empty port. If problem persists, replace network switch.

327

Description Communication lost from S processor

Possible Cause

• IONet or hardware malfunction• R or T processor in redundant system lost communication with S processor

Solution

• Go online with the S processor. Verify that the processor is in the Controlling state. If not communicating or inControlling state, restart the processor.

• Check for disconnected IONet cables or malfunctioning switches.

• Rebuild and download the application.• Check for a faulty ethernet cable-to-network switch.

• Check for bad network switch: place ethernet cable into empty port. If problem persists, replace network switch.


328

Description Communication lost from T processor

Possible Cause


• R or S processor in redundant system lost communication with T processor

Solution

• Go online with the T processor. Verify that processor is in the Controlling state. If not communicating or in Controlling

state, restart the processor.• Check for disconnected IONet cables or malfunctioning switches.• Rebuild and download the application.

• Check for a faulty ethernet cable-to-network switch.• Check for a faulty network switch by placing the ethernet cable into an empty port. If problem persists, replace the

network switch.

329

Description Startup sequence failed - Data initialization timeout R processor

Possible Cause Controller unable to complete startup data initialization

• IONet malfunction

• Controllers have different application revisions• One or more controllers powered down• Controller overloaded by external command messages

Solution

• Check for disconnected IONet cables or malfunctioning network switches.• Rebuild and download the application.

• Verify that all controllers are powered on.

• Disable all other command senders (e.g., Modbus masters) until controller is online.

330

Description Startup sequence failed - Data initialization timeout S processor

Possible Cause Controller is unable to complete startup data initialization.

• IONet malfunction• Controllers have different application revisions

• One or more controllers are powered down• Controller is overloaded by external command messages.

Solution

• Check for disconnected IONet cables or malfunctioning network switches

• Rebuild and download application• Ensure all controllers are powered up• Disable all other command senders (e.g., Modbus masters) until controller is online.


331

Description Startup sequence failed - Data initialization timeout T processor



• Controllers have different application revisions• One or more controllers are powered down• Controller is overloaded by external command messages.

Solution

• Check for disconnected IONet cables or malfunctioning network switches• Rebuild and download application

• Ensure all controllers are powered up• Disable all other command senders (e.g., Modbus masters) until controller is online.

332

Description Overtemperature - Processor rebooted and throttled

Possible Cause

• Fan loss.• Excessive ambient temperature

• Hardware malfunction.

Solution

• Check ambient temperature

• Check for dust buildup on cabinet filters

• Check fans• Check for dust buildup on processor module, power supply

334

Description Application Error - [ ] Frame skips detected

Possible Cause

• Hardware or IONet malfunction.

• Frame number skips detected. Frame number should monotonically increase until rollover; alarm occurs following asingle frame number skips in successive frames.

Solution

• Check IONet (switches, cables);

• Replace processor module.

335

Description Memory Verification failed - Firmware processes

Possible Cause Hardware memory failure. A modification has occurred in the code segment for one of the processes. Thisindicates that a hardware memory failure has occurred.

Solution Replace processor module.


336

Description Controller is unlocked

Possible Cause Mark VIeS: leaving Data Init control state and not locked or the controller is unlocked through theToolboxST application.

Solution Lock the controllers from ToolboxST application before executing safety functions.

337

Description Output exchange disagreement detected

Possible Cause IONet malfunction or hardware problem. For at least one output, a difference was detected between the

controller outputs. This alarm remains active until the controllers agree on all outputs. A difference for non-Boolean datagenerally indicates a deviation of more than 10% from the median value or no IONet EGD configuration is present. Formedian values near zero, the variation exceeds integer 2 or real value 0.2.

Solution

• For the Mark VIe runtime, use the ToolboxST disagreement display (View | Disagreements) to determine which variablesare in disagreement.

• In the application, avoid use of global variable ’ControllerID’ and avoid the use of sequencing block ’USB_HB’.

• Check IONet (switches, cables); rebuild and download application to all processors. If the problem persists, replace theprocessor module.

347

Description Running Application does not match the BRANDed Application

Possible Cause Mark VIeS: Application not branded or different from branded version.Note: The purpose of branding is to label a verified safety application, and to ensure that it is running.

Solution Reload the branded application to the controller and I/O packs, or use the ToolboxST application to brandcurrently running application.

348

Description Intermittent communications on I/O Net 1 - Packet loss exceeded [ ]%

Possible Cause

• Power cycled on I/O producer (controller or I/O pack)• IONet malfunction

• I/O message corruption• Communication errors occurred on more than 5% of data transmissions on IO Net 1

Solution

• Check for evidence of pack restart (diagnostic alarms, error logs).

• Faulty ethernet cable from pack to network switch and/or from switch to controller. Replace cable(s).• Replace the pack.

• Faulty network switch; place the pack’s ethernet cable into an empty port. If problem persists, replace the network switch.


349


Possible Cause Power cycled on I/O producer (controller or I/O pack), IONet malfunction, I/O message corruption.

Communication errors occurred on more than 5% of the data transmissions on IO Net 2.

Solution

• Check for evidence of pack restart (diagnostic alarms, error logs).• Faulty ethernet cable from pack to network switch and/or from switch to controller. Replace cable(s).

• Replace the pack.• Faulty network switch; place the pack’s ethernet cable into an empty port. If problem persists, replace the network switch.

350


Possible Cause Power cycled on I/O producer (controller or I/O pack), IONet malfunction, I/O message corruption.Communication errors occurred on more than 5% of the data transmissions on IO Net 3.

Solution

• Check for evidence of pack restart (diagnostic alarms, error logs).• Faulty ethernet cable from pack to network switch and/or from switch to controller. Replace cable(s).• Replace the pack.


352

Description Memory Validation failed - Blockware data structures

Possible Cause Hardware memory failure (application process data that should not change after the controller goes

online was modified; indicates hardware memory problem)

Solution Replace the processor module.

353

Description Memory Validation failed - Configuration shared memory

Possible Cause Hardware memory failure (system process data that should not change after the controller has goneonline was modified)


354

Description Memory Validation failed - EGD data structures

Possible Cause Hardware memory failure (IONet-EGD process data that should not change after the controller has

gone online has been modified)



355

Description State Exchange Voter disagreement detected

Possible Cause

• State Exchange disagreement found.

• Application sequencing error

• IONet malfunction or hardware problem.

Solution

• Use the ToolboxST disagreement display (View | Disagreements) to determine which variables are in disagreement.

• In the application, avoid use of global variable ’ControllerID’ and avoid the use of ’USB_HB’ block.• Check IONet (switches, cables). If problem persists, replace the processor module.

356

Description NANs in CALC or NAN_BREAKER Block detected

Possible Cause

• NaN (Invalid floating point number) received from I/O interface• Hardware problem

Solution

• Check for external devices that may be sending NaNs to the controller.• If conditions persists, replace the processor module.

357

Description Internal Runtime error - Sequencer out-of-order execution detected

Possible Cause Possible hardware malfunction. Sequencer critical clients scheduled out of order. Alarm occurs followingthree successive frames of sequencer critical client out-of-order execution detections; after five, controller put in FAILURE

control state.


358

Description Internal Runtime error - Sequencer client execution underrun

Possible Cause Possible hardware malfunction. Sequencer critical client underrun detected. Alarm occurs after asequencer critical client has been run slower than its nominal rate three times in a row; after five, controller put in FAILURE

control state.

Solution

• Ignore alarm if it occurs during a restartof the controller.• Replace the processor module, if the alarm occurs during normal operation.

359

Description Internal Runtime error - Sequencer client execution overrun

Possible Cause Possible hardware malfunction. Sequencer critical client overrun detected. Alarm occurs after a sequencer

critical client has been run faster than its nominal rate three times in a row; after five, controller put in FAILURE control state.

Solution

• Ignore alarm if it occurs during a restart of the controller.• Replace the processor module, if the alarm occurs during normal operation.


360

Description Internal Runtime error - Sequencer frame period out-of-bounds (+/- 15%)

Possible Cause Possible hardware malfunction. Frame period greater than ±15% of nominal. Alarm occurs following frame

period out-of-bounds condition occurring three frames in a row; after five, controller put in FAILURE control state.

Solution


361

Description Internal Runtime error - Sequencer frame state timeout out-of-bounds (+/- 15%)

Possible Cause Possible hardware malfunction. Sequencer frame state timeout greater than ±15% of nominal. Alarm

occurs following a sequencer frame state timeout being out-of-bounds three frames in row; after five, controller put

in FAILURE control state.

Solution

• Ignore alarm if it occurs during a restart of the controller.

• Replace the processor module, if the alarm occurs during normal operation.

362

Description Internal Runtime error - Sequencer frame number skip detected

Possible Cause Possible hardware or IONet malfunction. Frame number skips detected. Frame number should

monotonically increase until rollover; alarm occurs following three skips in a row, after five, controller put in FAILUREcontrol state.

Solution



• Check for network switch malfunction

• Check for loose or defective network cables• Replace processor module.

363

Description Memory Validation failed - Sequencer data structures

Possible Cause Hardware memory failure (sequencer process data that should not change after the controller is onlinewas modified)


364

Description Too many state voter disagreements detected

Possible Cause

• State exchange voter disagreement overflow. System exceeded the limit of 128 simultaneous disagreements at once.• Application error• IONet malfunction or hardware problem

Solution

• Use the ToolboxST disagreement display (View | Disagreements) to determine which variables are in disagreement.• In the application, avoid use of global variable ’ControllerID’ and avoid the use of ’USB_HB’ block.

• Check IONet (switches, cables). If problem persists, replace the processor module.


462

Description Hardware Reconfigured: Reboot by removing and reapplying power.

Possible Cause Flash file system corruption.

Solution

• After reapplying power, Rebuild and download baseload, firmware and application.• If the problem persists, replace processor module

463

Description Internal runtime error - Could not create CEL log file

Possible Cause Internal runtime error. Could not create the Command and Event log file.

Solution

• Rebuild and download baseload, firmware and application to the processor.

• If the problem persists, replace processor module

464

Description Ethernet Interface [ ] disabled due to excessive traffic.

Possible Cause The network interface has been disabled to protect itself from excessive activity on the network.

Solution

• Check for network loops• Monitor network activity and remove excessive traffic

465



Solution


466



Solution

• Check for network loops

• Monitor network activity and remove excessive traffic

467



Solution



468



Solution


469

Description EGD fault detected by R processor

Possible Cause

• EGD producer is powered down• Producer is unhealthy

• Ethernet connection(s) failure

Solution

• Ensure all EGD producers are powered up and healthy.

• Bad ethernet cable from producer to network switch. Replace cable(s).• Bad network switch, place producer’s ethernet cable into empty port. If problem persists, replace network switch.• Replace producer processor module.

470

Description EGD fault detected by S processor

Possible Cause

• EGD producer is powered down

• Producer is unhealthy• Ethernet connection(s) failure

Solution

• Ensure all EGD producers are powered up and healthy

• Bad ethernet cable from producer to network switch. Replace cable(s).• Bad network switch, place producer’s ethernet cable into empty port. If problem persists, replace network switch.

• Replace producer processor module.

471

Description EGD fault detected by T processor

Possible Cause

• EGD producer is powered down• Producer is unhealthy• Ethernet connection(s) failure

Solution

• Ensure all EGD producers are powered up and healthy• Bad ethernet cable from producer to network switch. Replace cable(s).• Bad network switch, place producer’s ethernet cable into empty port. If problem persists, replace network switch.



486

Description Auto-Reconfiguration server installation is incomplete

Possible Cause A download from ToolboxST to an I/O pack and/or Auto-Reconfiguration server failed

Solution Perform a scan and download using ToolboxST

487

Description Auto-Reconfiguration server failed scanning or downloading an I/O pack

Possible Cause At least one I/O pack is in an unexpected state that the Auto-Reconfiguration server is unable to handle

Solution *Cycle power on the I/O pack

*Perform a scan and download using ToolboxST*Replace the I/O pack

NoteThe following IONet EGD input validation alarms are numbered starting from a base of 1000and uniquely created based on I/O pack topology. This is done so that input validation alarms can begenerated for each I/O pack in a configuration. Four error messages are associated with each alarmnumber and are utilized based on particular validation types.

Alarm ID convention: R I/O pack in TMR module or Simplex, single-net I/O pack: 1000 + ModuleID; S I/O pack in TMRmodule: 1256 + ModuleID; T I/O pack in TMR module or dual-net or dual I/O pack on IONet 1: 1512 + ModuleID;dual-net or dual I/O pack on IONet 2: 1768+ModuleID.

1000-2024

Description Inputs unhealthy on IO Module [ ], R pack IONet [ ] - Message Timeout

Possible Cause

• Pack restarting or restarted• I/O pack application/configuration is missing.• Application/configuration does not match in the pack and controller.

• Failed ethernet connection between pack and controller.• Ethernet cable inserted into wrong connector on pack

Solution

• Reset all diagnostic alarms.

• Rebuild and download application to all controllers and I/O packs.• Reload firmware and application.

• Verify that Ethernet cable on I/O pack matches the ToolboxST configuration.

• Check for faulty Ethernet cable from pack to network switch and/or from switch to controller. Replace cable(s) ifnecessary.

• Replace the pack.

• Bad network switch, place pack’s ethernet cable into empty port. If problem persists, replace network switch.


1000-2024

Description Inputs unhealthy on IO Module [ ], S pack IONet [ ] - Message Timeout

Possible Cause

• Pack restarting or restarted

• I/O pack application/configuration missing• Application/configuration does not match in pack and controller• Failed ethernet connection between pack and controller

• Ethernet cable inserted into wrong connector on pack

Solution


• Rebuild and download application to all controllers and I/O packs.• Reload firmware and application• Verify that Ethernet cable on I/O pack matches the ToolboxST configuration.




1000-2024

Description Inputs unhealthy on IO Module [ ], T pack IONet [ ] - Message Timeout

Possible Cause

• Pack restarting or restarted• I/O pack application/configuration missing• Application/configuration does not match in pack and controller

• Failed ethernet connection between pack and controller• Ethernet cable inserted into wrong connector on pack

Solution


• Rebuild and download application to all controllers and I/O packs.• Reload firmware and application

• Verify that Ethernet cable on I/O pack matches the ToolboxST configuration.





1000-2024

Description Inputs unhealthy on IO Module [ ] IONet [ ] - Message Timeout

Possible Cause

• Pack restarting or restarted

• I/O pack application/configuration missing• Application/configuration does not match in pack and controller• Failed ethernet connection between pack and controller

• Ethernet cable inserted into wrong connector on pack

Solution


• Rebuild and download application to all controllers and I/O packs.• Reload firmware and application.• Verify that the Ethernet cable on I/O pack matches the ToolboxST configuration.




1000-2024

Description Inputs unhealthy on IO Module [ ], R pack IONet [ ] - Message Length not valid

Possible Cause Application/configuration does not match in the pack and controller.

Solution

• Rebuild and download application/parameters to all controllers and I/O packs.• Reload firmware and parameters to the affected I/O pack.

• Reload firmware and application to all controllers.• If problem persists, replace affected I/O pack, then replace controller.

1000-2024

Description Inputs unhealthy on IO Module [ ], S pack IONet [ ] - Message Length not valid

Possible Cause Application/configuration does not match in pack and controller

Solution

• Rebuild and download application/parameters to all controllers and I/O packs.

• Reload firmware and parameters to the affected I/O pack.• Reload firmware and application to all controllers.• If problem persists, replace affected I/O pack, then replace controller.

1000-2024

Description Inputs unhealthy on IO Module [ ], T pack IONet [ ] - Message Length not valid


Solution

• Rebuild and download application/parameters to all controllers and I/O packs.• Reload firmware and parameters to the affected I/O pack.• Reload firmware and application to all controllers.

• If problem persists, replace affected I/O pack, then replace controller.


1000-2024

Description Inputs unhealthy on IO Module [ ] IONet [ ] - Message Length not valid


Solution



1000-2024

Description Inputs unhealthy on IO Module [ ], R Pack IONet [ ] - Major Signature Mismatch

Possible Cause

• Application/configuration does not match in pack and controller

Solution



1000-2024

Description Inputs unhealthy on IO Module [ ], S Pack IONet [ ] - Major Signature Mismatch


Solution



1000-2024

Description Inputs unhealthy on IO Module [ ], T Pack IONet [ ] - Major Signature Mismatch


Solution



1000-2024

Description Inputs unhealthy on IO Module [ ] IONet [ ] - Major Signature Mismatch


Solution




1000-2024

Description Inputs unhealthy on IO Module [ ], R Pack IONet [ ] - Minor Signature Mismatch


Solution



1000-2024

Description Inputs unhealthy on IO Module [ ], S Pack IONet [ ] - Minor Signature Mismatch


Solution



1000-2024

Description Inputs unhealthy on IO Module [ ], T Pack IONet [ ] - Minor Signature Mismatch


Solution



1000-2024

Description Inputs unhealthy on IO Module [ ] IONet [ ] - Minor Signature Mismatch


Solution



1000-2024

Description Inputs unhealthy on IO Module [ ], R Pack IONet [ ] - Timestamp Mismatch


Solution




1000-2024

Description Inputs unhealthy on IO Module [ ], S Pack IONet [ ] - Timestamp Mismatch


Solution



1000-2024

Description Inputs unhealthy on IO Module [ ], T Pack IONet [ ] - Timestamp Mismatch


Solution



1000-2024

Description Inputs unhealthy on IO Module [ ] IONet [ ] - Timestamp Mismatch


Solution



1000-2024

Description Inputs unhealthy on IO Module [ ] IONet [ ] - Message Length not valid


Solution




Specific I/O Pack Alarms

PAIC Specific AlarmsThe following alarms are specific to the PAIC I/O pack.

32-41

Description Analog Input [ ] unhealthy.

Possible Cause

• Excitation to transducer is wrong or missing.

• Transducer is defective.

• Analog input current/voltage input is beyond the specified range.• Terminal board jumper settings do not match the ToolboxST configuration.

• Open or short-circuit on input.

Solution

• Check the field wiring and connections to indicated analog input channel.• Check the field device for failure.

• Verify that the configuration matches terminal board jumper settings for the indicated analog input channel.

44-45

Description Output [ ] individual current feedback unhealthy.

Possible Cause

• Commanded output is beyond the range of the output.• Field wiring problem• Field device problem

• Open loop or too much resistance in the loop.• I/O pack failed.• Terminal board failed.

Solution

• Verify that the commanded output is within the range of the output.• Confirm the correct I/O pack 28 V input power.

• Check the field wiring and device.• Replace the I/O pack.

46-47

Description Output [ ] total current feedback unhealthy.

Possible Cause

• Commanded output is beyond the range of the output.• Field wiring problem

• Field device problem• Open loop or too much resistance in the loop.

Solution

• Verify that the commanded output is within the range of the output.

• Confirm the correct I/O pack 28 V input power.• Check the field wiring and the component.• Replace the I/O pack.


48-49

Description Output [ ] Internal reference current unhealthy.

Possible Cause

• I/O pack failure

Solution

• Confirm the correct I/O pack 28 V input power.• Replace the I/O pack.

66-67

Description Output [ ] Individual current too high relative to total current.

Possible Cause In a TMR setup, the individual current feedback is greater than 1/2 the total current feedback +

TMR_SuicLimit.

• TMR_SuicLimit is set too low.• Hardware failure causing one I/O pack to drive too much output current.

Solution

• Verify that the value of TMR_SuicLimit is set correctly.• Replace the I/O pack.

70-71

Description Output [ ] Total current varies from reference current.

Possible Cause The difference between the commanded output current and total feedback is greater than TMR_SuicLimit.

• Field wiring problem• Open-circuit on output or total loop resistance is too high.

• Command is beyond the range of the output.

Solution

• Check field wiring and device.

• Verify that the value of TMR_SuicLimit is set correctly.

• Verify commanded output is within output range.

74-75

Description Output [ ] commanded current fdbk error.

Possible Cause The difference between the commanded output current and current feedback on the terminal boardis greater than D/A_ErrLimit (%).

• Open-circuit on output

• Terminal board output jumper (J0) setting is incorrect (for output 1).• Command is beyond the range of the output.

Solution

• Check the field wiring and device.

• Check the J0 jumper setting on the terminal board.• Verify that the value of D/A_ErrLimit is set correctly.• Verify that the commanded output is within output range.



82-83

Description Output [ ] Suicide relay non-functional.

Possible Cause The analog output suicide relay command doesn’t match the feedback.

• Relay failure on the acquisition board.


Solution Replace the I/O pack.

86

Description Output [ ] 20/200 mA selection non-functional.

Possible Cause The analog output has been configured for 200 mA but the hardware is not responding to the configuration.


90-91

Description Output [ ] 20/200 mA suicide active.

Possible Cause

• Suicide is enabled on analog output.• Review any additional diagnostics for possible causes.

• TMR_SuicLimit is set too low.• Field wiring problem• Command is beyond the range of the output.

• Analog output configuration does not match hardware jumpers.

Solution

• Verify that the value of TMR_SuicLimit is set correctly.• Verify that the value of D/A_ErrLimit is set correctly.

• Verify the field wiring connections.• Verify that the commanded output is within output range.• On PAICH2A, verify that terminal board jumper (JO) settings for analog output match the configuration (20mA/200mA).

92-93

Description Output [ ] Suicide on overcurrent, check terminal board jumper.

Possible Cause

• Incorrect setting of terminal board 20/200 mA jumper

• Hardware failure in I/O pack.

Solution

• Check the terminal board jumper (JO).

• Replace the I/O pack.

97

Description Hardware form (PAICH1A) does not support 200mA on Output 01.

Possible Cause Analog Output 1 is configured for 0-200 mA, but the hardware form of the pack (PAICH1A) does

not support 200 mA.

Solution Configure the analog output 1 to be 0-20 mA or if 200 mA is required, the pack must be replaced with thecorrect hardware form (PAICH2A).


98

Description PAICH2A 200mA driver temperature ([ ] deg F) exceeds the max limit ([ ] deg F).

Possible Cause The internal temperature on a PAICH2A has exceeded the maximum temperature limit of 185 °F (85°C).

Solution Check the environmental controls applied to the cabinet containing the I/O pack. The pack operation will continue

correctly beyond these temperature limits but long-term operation at elevated temperatures may reduce equipment life.

99

Description Pack internal power supply status not OK.

Possible Cause The internal power supply that provides analog circuit control power is not operating correctly.

Solution

• Check the I/O pack ground quality through mounting bolts.• Confirm that 28 V input power is within 26.6 - 29.4 V range.

• Replace I/O pack.

100

Description Dither Time is frozen or out of range - [ ].

Possible Cause The time signal used to generate a dither on the valve output signal does not appear to being changing.This could cause a frozen valve.

Solution

• Cycle the power on I/O pack.


101

Description Pack internal reference voltage out of limits.

Possible Cause The calibration reference voltage for the analog inputs is more than +/-5% from the expected value,indicating a hardware failure.

Solution

• Check the I/O pack ground quality through mounting bolts.

• Cycle power on I/O pack.• Replace the I/O pack.

102

Description Pack internal null voltage out of limits.

Possible Cause The calibration Null voltage for the analog inputs is more than +/-5% from the expected value, indicatinga hardware failure.

Solution

• Check the I/O pack ground quality through mounting bolts.• Cycle power on the I/O pack.• Replace the I/O pack.

128

Description Logic Signal [ ] Voting Mismatch.

Possible Cause N/A

Solution N/A


224-235

Description Input Signal [ ] Voting Mismatch, Local=[ ], Voted=[ ].

Possible Cause

• Voter disagreement between the R, S and T I/O packs

• I/O pack is not seated correctly on the terminal board.

Solution

• Adjust the parameter TMR_DiffLimt or correct the cause of the difference.

• Re-seat the I/O pack to the terminal board.• Replace the I/O pack.


PAMB Specific Alarms

Alarm ID Alarm Description Possible Cause

38 Flashdisk error: Unable to revert to flash

configuration after remote access

Permanent configuration data on card is corrupted.

Download firmware to card or replace UCCA.

41-58 Chan x: Open circuit test failed Open circuit detected for terminal board signal Sig x,where x is the identified point. Check wiring and sensor.

61-78 Chan x: Bias nulling error Dc bias designated for sensor type is outside of rangedetected for sensor. Check sensor type in configurationparameter InputUse or check dc bias voltage on signal.

81-98 Chan x: Input signal saturated Peak input voltage is saturating input. Decreaseconfiguration parameter Gain for designated signal orcheck for sensor problem.

101-118 Chan x: Sensor limit exceeded Peak input voltage exceeds limit for selected sensor type.Check sensor type in configuration parameter InputUse orcheck for sensor problem.

120 BAPA ADC reference input calibration failure BAPA failed calibration test at power up. Replace BAPA.

121-138 BAPA Chan x ADC calibration failure BAPA failed calibration test at power up. Replace BAPA.

139-156 BAPA Chan x DAC calibration failure BAPA failed calibration test at power up. Replace BAPA.

212 Communication failure with remote acquisition Link1 Code x

The PAMB/UCCA cannot communicate with remoteacquisition hardware (terminal board and BAPA) throughthe HSSL cable. Cable may be disconnected or

connected to wrong device, the BAPA may be powereddown or bad, or UCCA interface to the HSSL may bebad. Code indicates specific failure type. Common codes

include:51xxxxxx: Remote acquisition target returning bad id52xxxxxx: Download to BAPA failed

53xxxxxx: Link loss detected54xxxxxx: Receive packet error detected55xxxxxx: Transmit packet error (excessive naks)

57xxxxxx: No data received from BAPA in 5 seconds

213 EPMC H3 missing or bad on link Top mezzanine (EPMC) card on UCCA is missing or bad.

214 Serial Link 1 Configuration failure code x PAMB/UCCA failed to setup HSSL properly. Replace

UCCA.


PAMC Specific AlarmsThe following alarms are specific to the PAMC I/O pack.

38

Description Flash disk error: Unable to revert to flash configuration after remote access.

Possible Cause The permanent configuration data on PAMC is corrupted.

Solution

• Build and download the firmware and configuration to the PAMC.

• Replace the PAMC UCSA.

41-58

Description Sig [ ]: Open Circuit Test Failure.

Possible Cause An open circuit for a specified terminal board signal has been detected.

Solution

• Check the wiring and sensor.• Replace the BAPA.

• Replace the terminal board.

61-78

Description Sig [ ]: Excessive DC Bias.

Possible Cause

• Configuration does not match the sensor type.• DC bias (DC offset) designated for the sensor type is outside the range detected for the sensor.

Solution

• Check the sensor type in the configuration parameter InputUse.

• Check the dc voltage on the signal. Refer to the PAMC documentation.

81-98

Description Sig [ ]: Input Signal exceeds HW limit.

Possible Cause The peak input voltage exceeds the HW limit for the input.

Solution

• Decrease the configuration parameter Gain for the designated signal.

• Check the sensor for issues.

101-118

Description Sig [ ]: Sensor Limit Exceeded.

Possible Cause The peak input voltage exceeds the limit for the selected sensor type.

Solution

• Check the sensor type in the configuration parameter InputUse.• Check the sensor for issues.

120

Description BAPA ADC Reference input calibration failure.

Possible Cause The BAPA failed the calibration test when powered on.

Solution Replace the BAPA.


121-138

Description BAPA Chan [ ]: ADC calibration failure.

Possible Cause The BAPA failed the calibration test when powered on.


139-156

Description BAPA Chan [ ]: DAC calibration failure.

Possible Cause the BAPA failed the calibration test when powered on.


157-174

Description BAPA Chan [ ]: DC test failure.

Possible Cause The BAPA failed the DC test during the manually invoked self-test.


175-192

Description BAPA Chan [ ]: Analog gain test failure.

Possible Cause The BAPA failed the gain test during the manually invoked self-test.


193-210

Description BAPA Chan [ ]: AC FFT test failure.

Possible Cause The BAPA failed the AC FFT test during the manually invoked self-test.


212

Description HSSL Comm link [ ] Communication Failure, Code [ ].

Possible Cause The PAMC/UCSA cannot communicate with the remote acquisition hardware (terminal board and BAPA)

through the High-Speed Serial Link (HSSL) cable. The code indicates a specific failure type.Common codes include:

• 51xxxxxx: Remote acquisition target returning bad id

• 52xxxxxx: Download to BAPA failed• 53xxxxxx: Link loss detected• 54xxxxxx: Receive packet error detected

• 55xxxxxx: Transmit packet error (excessive naks)• 57xxxxxx: No data received from BAPA in 5 seconds

Solution

• Verify that the BAPA is connected to the SL1 connector on the PAMC UCSA.

• Check the HSSL cables. If a problem still exists, replace the PAMC UCSA module.• Check the power on the BAPA.• Replace the BAPA.


213

Description HSSL Comm link [ ] Initialization Failure.

Possible Cause The PAMC UCSA cannot properly initialize the BAPA through the HSSL.

Solution

• Verify that the BAPA is connected to the appropriate HSSL connector on the PAMC UCSA.

• Check the HSSL cables. If a problem still exists, replace the PAMC UCSA module.• Check the power on the BAPA.• Replace the BAPA.

214

Description HSSL Comm link [ ] Configuration Failure, Code [ ].

Possible Cause The PAMC UCSA interface to the HSSL failed to initialize properly.

Solution Replace the PAMC UCSA.

215

Description BAPA plugged into wrong SAMx connector on HSSL [ ].

Possible Cause The SAMB or SAMC connector that the BAPA is plugged into does not agree with HSSL connector

configured in the ToolboxST application.

Solution

• Verify that the HSSL cable is plugged into the PAMC UCSA SL1 connector.

• Verify that the HSSL cable is plugged into the correct BAPA.

• Verify that the SAMC/SAMB configured connections in the ToolboxST application match the BAPA connection tothe terminal board.

216

Description BICA (JA1) On Board power supply failure, expected [ ] V, read [ ] V.

Possible Cause The BICA power supply failed.

Solution Replace the BICA plugged into the JA1 connector.

217

Description BICA (JB1) On Board power supply failure, expected [ ] V, read [ ] V.

Possible Cause The BICA power supply failed.

Solution Replace the BICA plugged into the JB1 connector.

218

Description Bad power supply on connector P28 [ ](1=A,2=B,3=C) in charge amp junction box.

Possible Cause There is no 28 volt power connected to the P28B or the P28C in the junction box.

Solution

• Parameter JuncBox is set for the wrong type.• Verify the power supply connection to the P28B or the P28C in the junction box.• Replace the power supply cable/connector.

• Replace the power supply.


219

Description Bad power supply on connector P28B or P28C in charge amplifier junction box.

Possible Cause The junction box power supply is faulty.

Solution

• Parameter JuncBox is set for the wrong type.• Verify the power supply connections to both the P28B and the P28C in the junction box.• Replace the power supply cable/connector.

• Replace the power supply.

220

Description SAMC terminal board failure in charge amplifier junction box.

Possible Cause The power supply status on the SAMC terminal board indicates an SAMC failure.

Solution Replace the SAMC in the junction box.

221

Description BICA (JA1) to BAPA communications error.

Possible Cause The power supply status in the BICA is not being updated.

Solution

• Replace the BICA on the JA1 connector in the junction box.

• Replace the BAPA in the junction box.

222

Description BICA (JB1) to BAPA communications error.

Possible Cause The power supply status in the BICA is not being updated.

Solution

• Replace the BICA on the JB1 connector in the junction box.• Replace the BAPA in the junction box.

230-247

Description BAPA Chan [ ]: Anti alias rolloff test failure.

Possible Cause The BAPA failed the anti-alias test during the manually invoked self-test.



PAOC Specific AlarmsThe following alarms are specific to the PAOC I/O pack.

32-39

Description Output [ ] feedback unhealthy.

Possible Cause

• Analog output is being driven beyond the valid output range.• Analog output feedback is out of range.

• Possible hardware failure in pack or terminal board

Solution

• Verify that the analog output command is within the range of 0-20mA.

• Verify that the analog output feedback matches the expected command.

• Verify analog output connections and field wiring.• If all active analog output feedbacks are unhealthy with a valid command, a board failure is probable. Replace the I/O

pack, replace the terminal board.

46-53

Description Output [ ] feedback current varies from reference current.

Possible Cause

• D/A_ErrLimit is not configured properly (set too low).• Field wiring problem• Open-circuit on output or total loop resistance is too high.

• Possible hardware failure in pack

Solution

• Verify the D/A_ErrLimit settings.• Check the field wiring and device.


54-61

Description Output [ ] feedback current is excessive.

Possible Cause The analog output current feedback is greater than 30mA. This will typically cause the output to suicide.

• Field wiring problem• Possible hardware failure in pack

Solution

• Verify the analog output connections and field wiring.• Replace the I/O pack.

62-69

Description Output [ ] Suicide relay non-functional.

Possible Cause The analog output suicide relay command doesn’t match the feedback.

• Possible relay failure on the acquisition board• Possible hardware failure in pack



70-77

Description Output [ ] Suicide Active.

Possible Cause

• Suicide is enabled (Suicide_Enab) for analog output.

• Review any additional diagnostics for possible causes.

• Analog output current feedback is too high (30mA).• Field wiring problem

• Command is beyond the range of the output.

Solution

• Verify that the commanded output is within output range.• Verify the analog output connections and field wiring.

78

Description Output Driver Temperature [ ] deg F exceeds the max limit ([ ] deg F).

Possible Cause The output driver temperature on the PAOC has exceeded the maximum temperature limit of 185 °F (85°C).

Solution

• Review pack derating guidelines in help documentation.• Environmental controls applied to the cabinet containing the I/O pack should be checked. Pack operation will continue

correctly beyond these temperature limits but long-term operation at elevated temperatures may reduce equipment life.

79

Description Internal +15V Power Supply status Not OK.


Solution

• Check the I/O pack ground quality through mounting bolts.• Confirm that the 28 V input power is within 26.6 - 29.4 V range.• Replace the I/O pack.

80

Description Internal -15V Power Supply status Not OK.


Solution

• Check the I/O pack ground quality through mounting bolts.• Confirm that the 28 V input power is within 26.6 - 29.4 V range.• Replace the I/O pack.


PCAA Specific AlarmsThe following alarms are specific to the PCAA I/O pack.

32

Description Unallowed VarIOCompatCode Change: Old - [ ]; New - [ ].

Possible Cause A .dll file (ToolboxST support file) has been installed that is incompatible with the firmware loaded onthe I/O processor.

Solution

• Confirm the correct installation of the ToolboxST application.• Rebuild the application and download firmware, and the application code to the affected I/O pack.

33-67

Description Thermocouple [ ] Unhealthy.

Possible Cause

• Thermocouple millivolt input on terminal board has exceeded the thermocouple range or hardware limit. Refer to thePCAA help documentation for specified thermocouple ranges.

• The thermocouple is configured as the wrong type.• The board has detected a thermocouple open, and has applied a bias to the circuit driving it to a large negative number,

or the TC is not connected, or a condition such as stray voltage or noise caused the input to exceed -63 mV.

• Stray voltage or noise has caused the input to exceed -63 mV.

Solution

• Check the field wiring, including shields. Check the installation of the PCAA on terminal board. The problem is usually

not a PCAA or terminal board failure if other thermocouples are working correctly.

• Check the thermocouple for an open circuit.• Measure the incoming millivolt signal to verify that it does not exceed -63 mV.

• Verify that the thermocouple type matches the configuration.

68

Description Cold Junction Unhealthy, Using Backup.

Possible Cause The local cold junction signal from the TCAS terminal board is out of range. The normal range is -30 to

65°C (-22 - 145 °F).

Solution If the hardware is in the normal temperature range, a possible hardware failure of the cold junction sensor on theTCAS board may have occurred. Replace the PCAA module.

69-80

Description Analog Input (TCAS) [ ] unhealthy.

Possible Cause

• The excitation to the transducer is wrong or missing.

• The transducer may be faulty.• The terminal board jumper settings do not match the ToolboxST configuration.• The analog input current/voltage input is beyond the specified range.

• There may be an open or short-circuit on the input.

Solution

• Check the field wiring and connections to the indicated analog input channel.

• Check the field device for failure.

• Check the PCAA ground select jumper for the input.• Verify that the inputs are in the operable range (3.0-21.5 mA,+/-5.25 V,+/-10.5 V).


81-104

Description Analog Input (TCAT) [ ] unhealthy.

Possible Cause

• The excitation to the transducer is wrong or missing.

• The transducer may be faulty.• The terminal board jumper settings do not match the ToolboxST configuration.• The analog input current input is beyond the specified range.

• There may be an open or short-circuit on the input.

Solution

• Check the field wiring and the connections to the indicated analog input channel.

• Check the field device for failure.• Check the PCAA ground select jumper for the input.• Verify that the TCAT - PCAA cables are fully seated in connectors.

• Verify that the inputs are in the operable range (3.0-21.5 mA)

105-116

Description Vibration Input for Seismic (Velocity) Sensor [ ] unhealthy.

Possible Cause

• The transducer may be faulty.• There may be an open circuit.• The configuration for sensor resistance (Ohms) is incorrect.

Solution

• Check the field wiring, including the shields. The problem is usually not a PCAA or terminal board failure if othervibration inputs are working correctly.

• Verify that the sensor resistance matches the configured sensor resistance.

117-122

Description LVDT Excitation [ ] Failed.

Possible Cause

• There may be an excitation ground fault.• There may be a field wiring issue or an LVDT sensor failure.• There may be an internal hardware failure.

Solution

• Check the field wiring, including shields, for LVDT excitation output. The problem is usually not a PCAA or terminalboard failure if other LVDT excitation outputs are working correctly.

• Check the LVDT sensor.

• If the problem is a hardware failure, replace the PCAA.


123-134

Description LVDT [ ] Excitation voltage out of range.

Possible Cause ExcitMonCal is set during servo regulator calibration, and is a nominal excitation value. If actual LVDTexcitation goes out of range (+/- 10% of ExcitMonCal), this alarm is generated.

• There may be a terminal board failure.

Solution

• Measure the excitation voltage, and verify against the configuration parameter.• Check the LVDT sensor.

• Recalibrate the servo.• Replace the PCAA.

135-146

Description LVDT [ ] Position Out of Limit.

Possible Cause

• There may be an issue with excitation to the LVDT, a faulty transducer, or an open or short-circuit.• The LVDT input is out of range.

• The LVDT has not been calibrated.

Solution

• Check the field wiring, including the shields and the LVDT excitation. The problem is usually not a PCAA or terminal

board failure if other LVDT inputs are working correctly.• Check the LVDT sensor.• Calibrate the servo regulator with the proper LVDT.

• Verify the configuration limits: MinVrms and MaxVrms.• Verify that the LVDT excitation terminal board connections match the configured excitation source specified in

ExcitSelect.• Verify that PosMargin is set to the proper value.

147-148

Description Invalid Monitor [ ] Configuration.

Possible Cause

• The configuration for the selected servo and regulator type is invalid.

Solution

• Verify that the monitor regulator type matches the regulator type of the selected servo.

• Rebuild and download the configuration.

149

Description More than One Servo Requested for Calibration.

Possible Cause

• The user has requested more than one servo calibration (only one servo can be calibrated at a given time).

Solution

• Check the variables in the Variables tab to verify that only one CalibEnab# for only one servo is set to True at agiven time.


150

Description Calibration : Selected LVDT Max / Min Pos Limit Out of Range.

Possible Cause Used to ensure that all selected LVDTs are scaled to the same units.

• The parameter MaxPosValue or MinPosValue for the selected LVDT configured in the regulator configuration is

out of range (+/-50%, encountered during calibration).

Solution

• Check the regulator configuration for the parameter PositionInput#1 for the particular servo.

• Check the parameters MaxPosValue and MinPosValue for the LVDT# selected input in PositionInput#1.• The parameter MaxPosValue for LVDT input should be between 50% to 150%.• The parameter MinPosValue for LVDT input should be between -50% to 50%.

151-154

Description FlowRate [ ] Input unhealthy.

Possible Cause

• There may be a broken wire on the flow rate input.

• There may be a faulty sensor.

Solution

• Verify the field wiring, including shields. The problem is usually not a PCAA or terminal board failure if other flow

rate inputs are working correctly.

• Check the gap for the magnetic pickup sensor.• For the TTL sensor, verify the power to the sensor and the gap.

• Replace the hardware.

155-160

Description Servo [ ] Disabled: Configuration error.

Possible Cause

• The servo position input is connected to an unused LVDT.• The configuration for the position input is incorrect.• The servo flow input is connected to an unused PR.

• The configuration for the flow input is incorrect.• The servo pressure input is connected to an unused analog input.• The configuration for the pressure input is incorrect.

Solution

• Check and correct, if necessary, the configuration parameters relating to the list of possible causes.• Verify that the regulator inputs are connected to used the sensor inputs in configuration.• In the ToolboxST configuration, right-click the PCAA, then select the parameter Troubleshooting->Advanced Diagnostics.

Navigate through the PCAA Commands to the parameter Servos->Servo Cfg Error. Send the command to the PCAAfor a list of configuration errors that were detected in the servo regulator settings.


161-166

Description Servo [ ] Output Suicide Active.

Possible Cause

• The servo position input is connected to an unused LVDT.

• The configuration for the position input is incorrect.• The servo flow input is connected to an unused PR.• The configuration for the flow input is incorrect.

• The servo pressure input is connected to an unused analog input.• The configuration for the pressure input is incorrect.• The regulator feedback is out of range.

• The servo current feedback differs from the servo current command.

Solution

• Check and correct, if necessary, the configuration parameters relating to the list of possible causes.

• Verify that the inputs are connected to used sensor inputs in the configuration.• It is a LVDT feedback issue; check the position sensor connections.• Verify the position sensor mechanical integrity to the valve.

• Check the wiring of the servo output loop for an open or short circuit.• Check for a short or open servo coil.

167-173

Description Pack internal reference voltage out of limits ([ ]).

Possible Cause The calibration reference voltage is more than +/-5% from the expected value, which indicates a hardwarefailure.

Solution

• Cycle power on the PCAA.• Replace the PCAA.

174-180

Description Pack internal null voltage out of limits ([ ]).

Possible Cause The null voltage is more than +/- 5% from the expected value which indicates a hardware failure.

Solution

• Cycle power on the PCAA.

• Replace the PCAA.


181-183

Description Analog Output [ ] Individual current fdbk unhealthy.

Possible Cause

• The commanded output is beyond the range of the output.

• There may be a field wiring problem.

• There may be a field device problem.• There is an open loop or too much resistance in the loop.

• There may be an I/O pack failure.


Solution


• Confirm the correct I/O pack 28 V input power.• Check the field wiring and the device. The problem is usually not a PCAA or terminal board failure if other analog

outputs are working correctly.


184-188

Description Analog Output [ ] Total current fdbk unhealthy.

Possible Cause

• The commanded output is beyond the range of the output.• There may be a field wiring problem.• There may be a field device problem.

• There may be an open loop or too much resistance in the loop.

Solution


• Confirm the correct I/O pack 28 V input power.• Check the field wiring and the device.• Check the PCAA- TCAT cables. The problem is usually not a PCAA or terminal board failure if other analog Inputs are

working correctly.• Replace the I/O pack.

189-190

Description Analog Output (TCAS) [ ] 20 mA suicide active.

Possible Cause

• There may be a field wiring problem.• The connected device may have problems that are interfering with the current.

• There may be a hardware failure.

Solution

• Check the field wiring and the status of the connected device.

• If there is a hardware failure, replace the PCAA.


191-193

Description Analog Output (TCAT) [ ] 20 mA suicide active.

Possible Cause


• The TMR_SuicLimit parameter is set too low.

• There may be a field wiring problem.• The command is beyond the range of the output.


Solution

• Check the field wiring and the status of the connected device.• Verify that the TCAT-PCAA cables are fully seated in the connectors.

• Verify that the value of the parameter TMR_SuicLimit is set correctly.• Verify the field wiring connections.• Verify that the commanded output is within output range.

• Replace the PCAA module.• Replace the TCAT terminal board.

194-195

Description Analog Output (TCAS) [ ] Suicide relay non-functional.

Possible Cause The analog output suicide relay command does not match the feedback.

• There may be a relay failure on the acquisition board.• There may be a hardware failure.

Solution If there is a hardware failure, replace the PCAA.

196-198

Description Analog Output (TCAT) [ ] Suicide relay non-functional.

Possible Cause The analog output suicide relay command does not match the feedback.

• There may be a relay failure on the acquisition board.• There may be a hardware failure.

Solution If there is a hardware failure, replace the PCAA.

199-204

Description Servo [ ] Position Feedback out of range.

Possible Cause

• The LVDT position feedback is outside the specified range.

Solution

• Check the LVDT configuration settings.• Calibrate the affected regulator.

• Check the field wiring.• Check for a shorted or open-position sensor coil.• Verify the mechanical integrity of the position sensor.

• Verify that the TCAT-PCAA cables are fully seated.


205-210

Description Servo [ ] Pressure Feedback out of range.

Possible Cause

• The pressure feedback used in a servo regulator is outside the specified range.

Solution

• Check the source of the pressure signal, including the sensor, field wiring, and configuration.• Verify the terminal board jumper settings for the analog inputs.

211-216

Description Servo [ ] Flow Feedback out of range.

Possible Cause

• The flow feedback used in a servo regulator is outside the specified range.

Solution

• If the out-of-range flow input is connected to the parameter FlowRate3 or FlowRate4 (TTL Pulse input), check thepower to device, the field wiring, the sensor, and the configuration.

• If the out-of-range flow input is connected to the parameter FlowRate1 or FlowRate2 (Magnetic pickup), check the

device, the field wiring, the input configuration, and the TCAT-PCAA cables.• Check the gap between the sensor and the flow wheel.

217

Description TCAT Configuration and Hardware Mismatch.

Possible Cause This diagnostic is only generated on power-up.

• The TCAT is configured in the ToolboxST application, but the terminal board is not connected.

• The TCAT is not configured in the ToolboxST application, but the terminal board is connected.

Solution

• Verify that the TCAT selection in the ToolboxST configuration matches the actual hardware.• Verify that the P1 and P2 cable connections are not swapped.

• Verify the the TCAT terminal board P1 and P2 cable connections are screwed down, and all terminal boards areproperly grounded.

• Perform a power-down reset to clear.

218

Description TCAT Connector P1 and P2 Types Mismatch.

Possible Cause The Type ( for example, R/R or S/S or T/T) of P1 and P2 connections between the TCAT and the TCAS

do not match. The Valid combinations are:

• P1(TCAS)-PR1(TCAT) & P2(TCAS)-PR2(TCAT)• P1(TCAS)-PS1(TCAT), P2(TCAS)-PS2(TCAT)

• P1(TCAS)-PT1(TCAT), P2(TCAS)-PT2(TCAT)

Solution

• Check the ToolboxST configuration, as well as the TCAT terminal board P1 and P2 cable connections between theTCAS and the TCAT.

• Verify that there is no Type (R/R,S/S,T/T) mismatch.


221

Description Calibration Mode Enabled.

Possible Cause

• One of the CalibEnab# outputs is set to True.

Solution

• This alarm is active to annunciate that the board is in a special mode (the servo suicide protection has been disabled,and the user needs to take special precautions).

• Set CalibEnab# to False.

1050-1145


Possible Cause N/A

Solution N/A

1146-1238

Description Input Signal [ ] Voting Mismatch, Local [ ], Voted [ ].

Possible Cause

• A voter disagreement was detected between the R, S and T controllers.

Solution Adjust the specified parameter below for each input type:

• If the input variable is AnalogInput[ ], adjust the TMR_DiffLimit.• If the input variable is PulseInput[ ], adjust the TMR_DiffLimit.• If the input signal is LVDT[ ], adjust the LVDT_TMR_DiffLimit on the Parameters tab.• If the input variable is ServoOutput[ ]:

- Adjust the TMR_DiffLimit on the Regulators tab.

- Also check for a mismatch in the coil resistance between the R, S and T servo coils.

- Reg#_Gain is set too high for specified TMR_DiffLimit value.


PCLA Specific AlarmsThe following alarms are specific to the PCLA I/O pack.

33-36

Description Analog Input (Simplex) [ ] unhealthy.

Possible Cause

• Excitation to transducer wrong or missing• Transducer faulty

• Terminal board jumper settings do not match ToolboxST configuration• Analog input current/voltage input beyond specified range• Open or short-circuit on input

Solution

• Check the field wiring and the connections to the indicated analog input channel.• Check the field device for failure.

• Check the ground select jumper for the input.

• Verify that the inputs are in operable range (3.0-21.5mA,+/-5.25 V,+/-10.5 V).• Verify that the configuration matches the terminal board jumper settings for the indicated analog input channel.

37-40

Description Analog Input (SCLT) [ ] unhealthy.

Possible Cause

• Excitation to transducer wrong or missing

• Transducer faulty• Analog input current/voltage input beyond specified range• Terminal board jumper settings do not match ToolboxST configuration

• Open or short-circuit on input

Solution

• Check the field wiring and connections to the indicated analog input channel.• Check the field device for failure.

• Check the ground select jumper for the input.• Verify that the cable between the SCLT - PCLA module is fully seated in the connector.• Verify that the inputs are in operable range (3.0-21.5 mA,+/-5.25 V,+/-10.5 V).

• Verify that the configuration matches the terminal board jumper settings for the indicated analog input channel.• Replace the SCLT - PCLA cable.


41-46

Description Analog Output [ ] Individual current feedback unhealthy.

Possible Cause

• Commanded output beyond range of output

• Field wiring problem

• Field device problem• I/O pack failure

• Terminal board failure

Solution

• Verify that the commanded output is within the range of the output.• Confirm the correct I/O pack 28 V input power.

• Check the field wiring and the device.• Replace the I/O pack.

47-53

Description Analog Output [ ] Total current feedback unhealthy.

Possible Cause

• Commanded output beyond range of output• Field wiring problem

• Field device problem• Open loop or too much resistance in the loop

Solution

• Verify that the commanded output is within the range of the output.• Confirm the correct I/O pack 28 V input power.• Check the field wiring and the device.

• For the analog outputs 2 through 7, check the cable between the PCLA module and the SCLT.• Replace the I/O pack.

54-60

Description Analog Output [ ] Internal reference current unhealthy.

Possible Cause

• I/O pack failure

Solution

• Confirm the correct I/O pack 28 V input power.

• Replace the PCLA module.


61

Description Analog Output (Simplex) [ ] 20 mA suicide active

Possible Cause

• Suicide parameter enabled on analog output


• Analog output current feedback too high (30 mA)• Parameter TMR_SuicLimit set too low

• Field wiring problem

• Command is beyond range of output

Solution

• Verify that the value of the parameter TMR_SuicLimit is set correctly.

• Verify that the value of the parameter D/A_ErrLimit is set correctly.• Verify that the commanded output is within output range.

62-67

Description Analog Output (SCLT) [ ] 20 mA suicide active.

Possible Cause

• Suicide parameter enabled on analog output• Review any additional diagnostics for possible causes.

• Analog output current feedback too high (30 mA)• Parameter TMR_SuicLimit set too low• Field wiring problem

• Command beyond range of output

Solution

• Verify that the value of the parameter TMR_SuicLimit is set correctly.

• Verify that the value of the parameter D/A_ErrLimit is set correctly.• Verify that the commanded output is within output range.

68

Description Analog Output (Simplex) [ ] Suicide relay non-functional.

Possible Cause

• Analog output suicide relay command does not match feedback• Relay failure on acquisition board

• There is a hardware failure.

Solution Replace the PCLA.

69-74

Description Analog Output (SCLT) [ ] Suicide relay non-functional.

Possible Cause

• Analog output suicide relay command does not match feedback• Relay failure on acquisition board


Solution Replace the PCLA.


75

Description Pack internal reference voltage out of limits [ ].

Possible Cause

• Internal calibration of inputs uses internal reference voltage. This reference voltage is more than +/-5% from the

expected value, and indicates a hardware failure.

Solution

• Check the ground quality through the mounting bolts.• Cycle power on the PCLA.

• Replace the PCLA.

104

Description Pack internal null voltage out of limits [ ].

Possible Cause

• Internal calibration of inputs uses internal null voltage. This null voltage is more than +/-5% from the expected value,which indicates a hardware failure.

Solution

• Check the ground quality through the mounting bolts.• Cycle power on the PCLA.• Replace the PCLA module.

133-140

Description Thermocouple (Simplex) [ ] Unhealthy.

Possible Cause

• Thermocouple millivolt input on terminal board exceeded thermocouple range or hardware limit. Refer to the PCLA

module help documentation for specified thermocouple ranges.• Thermocouple configured as wrong type.• Board detected thermocouple open and applied bias to circuit driving it to large negative number, or TC not connected,

or condition such as stray voltage or noise caused input to exceed -63 mV.

Solution

• Check field wiring including shields. Check installation of PCLA module on terminal board. Problem is usually not a

PCLA module or terminal board failure, if other thermocouples are working correctly.

• Check thermocouple for open circuit.• Measure incoming millivolt signal and verify that it doesn’t exceed -63 mV.

• Verify that the thermocouple type matches the configuration.


141-148

Description Thermocouple (SCLT) [ ] Unhealthy.

Possible Cause

• Thermocouple millivolt input on terminal board exceeded thermocouple range or hardware limit. Refer to PCLA module

help documentation for specified thermocouple ranges.• Thermocouple configured as wrong type• Board detected thermocouple open and applied bias to circuit driving it to large negative number, or TC not connected,

or condition such as stray voltage or noise caused input to exceed -63 mV.

Solution

• Ensure cable between SCLT - PCLA module is fully seated in connector.

• Check field wiring including shields. Check installation of PCLA on terminal board. Problem is usually not a PCLA orterminal board failure if other thermocouples are working correctly.

• Check thermocouple for open circuit.

• Measure incoming millivolt signal and verify that it doesn’t exceed -63 mV.• Verify that the thermocouple type matches the configuration.

149

Description Cold Junction (SCLS) Unhealthy, Using Backup.

Possible Cause

• Local cold junction signal from SCLS terminal board out of range. The normal range is -30 to 65 deg C (-22 - 145 deg F).

Solution

• If hardware is in the normal temperature range, then possible hardware failure of cold junction sensor on the SCLS

board. Replace terminal board.• Replace PCLA.

150

Description Cold Junction (SCLT) Unhealthy, Using Backup.

Possible Cause

• Local cold junction signal from SCLT terminal board out of range. The normal range is -30 to 65 deg C (-22 - 145 deg F).

Solution

• Verify that the cable between the SCLT - PCLA module is fully seated in the connector.• If hardware is in the normal temperature range, then a possible hardware failure of cold junction sensor on the SCLT

board. Replace the terminal board.


151-158

Description RTD [ ] Unhealthy.

Possible Cause

• RTD wiring/cabling open or high impedance

• Open on connections to the terminal board

• RTD device failed*PCLA module internal hardware problem

• Current source on PCLA for RTD faulty or measurement device failed

• Wrong type of RTD configured or selected by default• High-resistance values created by high voltage and/or low current

Solution

• Check the field wiring for open circuit or high impedance.• Verify the proper connections to the terminal board.• Check the RTD for proper operation.

• Verify that the RTD type configuration matches the attached device type.• Replace the PCLA.

159

Description SCLT Configuration & Hardware Mismatch.

Possible Cause

• SCLT terminal board connected in hardware but not configured in ToolboxST application.• In ToolboxST application, the PCLA configured with a SCLT terminal board, but SCLT not physically connected.

• Faulty cable between SCLT - PCLA module

Solution

• Verify that the PCLA pack configuration matches the hardware connected.

• Replace the cable.• Replace the SCLT terminal board.• Replace the SCLS terminal board.

• Replace the PCLA.

160-191


Possible Cause N/A

Solution N/A

192-211


Possible Cause Voter disagreement between R, S and T IO Packs.

Solution Adjust the TMR threshold limit for the inputs causing the diagnostic or correct the cause of the difference.


PCNO Specific AlarmsThe following alarms are specific to the PCNO I/O pack.

33

Description CANopen module upgrade failure

Possible Cause A malfunction occurred when a new CANopen module firmware file was being loaded to the CANopenmodule.

Solution

• Rebuild and download firmware to the PCNO.• If issue persists, replace pack.

34

Description CANopen module access failure - Unable to download configuration

Possible Cause A malfunction occurred when a new CANopen configuration was being loaded to the CANopen module

Solution

• Rebuild and download firmware to the PCNO.

• If issue persists, replace pack.

35

Description Bad configuration loaded to CANopen module

Possible Cause Invalid CANopen configuration files were downloaded to the CANopen module. This causes the CANopen

module to not reach the RUN status, which is generally reached when a valid configuration has been processed.

Solution

• Power cycle the pack

• Reload the PCNO firmware with updated CANopen configuration files.

36

Description Unable to communicate with CANopen module

Possible Cause The CANopen host watchdog (a heartbeat between the pack processor and CANopen module) could not

be activated.

Solution

• Rebuild and download the firmware to the PCNO.

• If the issue persists, replace the pack.

37

Description CANopen module failure

Possible Cause From the PCNO firmware perspective, the CANopen watchdog timed out (indicating failure of the

CANopen firmware).

Solution

• Rebuild and download the firmware to the PCNO.

• If the issue persists, replace the pack.


38

Description CANopen module failure - Module shutdown

Possible Cause The CANopen module has shut down, indicated by a loss of READY/RUN. CANopen READY indicatesthat the firmware is running, and RUN indicates that a valid configuration has been processed. Loss of READY/ RUN

implies that the CANopen module has shut down.

Solution

• Power cycle the pack.• If the issue persists, replace the pack.

39

Description Unknown CANopen device identified on CANopen network

Possible Cause An identity check for one of the connected devices has failed. During startup, and when a new device is

detected, the I/O pack confirms the identity of expected devices before starting normal operation.

Solution Verify that the (re)connected device is the same as the ToolboxST configuration.

40

Description Waiting for all CANopen devices to connect

Possible Cause

• Not all required slaves are connected to the CANopen network.• During startup, the IO Pack requires all slaves to be connected to confirm the identity of all required devices before

starting normal operation.• During normal operation, the IO Pack generates this alarm if a disconnected device is reconnected with a duplicate ID.

Solution

• Verify that the number of connected devices matches the number configured in the ToolboxST application.

• Verify that all connected devices have power applied and are operating correctly.• Verify that the connected devices are configured correctly (for example, the device ID and baud rate).• Check to see if any devices are configured with the same CANopen device ID.

41-45

Description CANopen slave device #[ ] communication error

Possible Cause

• Connected device is powered off or rebooting

• Failed CANopen bus connection between pack and controller.• Connected device has not communicated or sent heartbeat message on CAN bus over at least five consecutive

MarkVIe frames.

Solution

• Verify that the connected device has power applied.• Verify that the CANopen cable is properly connected.

• Troubleshoot the connected device for internal errors, refering to its manual. If problem persists, replace the connecteddevice.


PDIA Specific AlarmsThe following alarms are specific to the PDIA I/O pack.

56-79

Description Contact Input [ ] not responding to high self-test mode.

Possible Cause The input hardware internal to the I/O pack has experienced a failure.


80-143


Possible Cause In a TMR application, the values for the specified contact do not agree between the R, S, and T I/O packs.

Solution

• Verify that R, S, and T I/O packs are equal with ToolboxST configuration.

• Check the I/O pack power and networking.• Check the I/O pack mounting on terminal board.• Replace the I/O pack.

240

Description Excitation Voltage not valid, Contact Inputs not valid.

Possible Cause The contact excitation voltage applied to the terminal board is not within the acceptable range for the board.

Solution Check power distribution and wiring to ensure that the correct excitation voltage is applied to the terminal board.


PDII Specific AlarmsThe following alarms are specific to the PDII I/O pack.

34-49

Description Contact Input [ ] Invalid excitation voltage

Possible Cause This diagnostic occurs for contact inputs that are configured as ’Isolated’ inputs, OR if configured with astandalone SDII terminal board.

• Configured excitation voltage for the contact input does not match the applied excitation voltage.

• Applied excitation voltage for the contact is outside its valid range.

Solution

• Verify that the contact input configuration matches the external excitation voltage.

• Verify that the external excitation voltage power supply voltage is within the expected voltage range.

• Refer to the PDII help documentation for more information.

50-65

Description Line to line short on contact [ ]

Possible Cause This alarm is only valid for SDII+WDIIH2 or SDII+WDIIH3.

• ToolboxST configuration does not match the actual hardware.• Parameter, LineMonitoring/FuseDiag (SDII+WDIIH2) or LineMonitoring (SDII+WDIIH3), is set incorrectly.

• Series and/or the parallel resistor have an incorrect resistance.• Shorted wire between the contact and the terminal board screws

Solution

• Verify that the actual hardware matches the ToolboxST configuration.

• Verify the value and location of the connected series and parallel resistors with respect to the contact.• Verify that LineMonitoring configuration is set to SeriesParResistor.• Check and correct the wiring to clear the line fault.


66-81

Description Open field wire for contact [ ]

Possible Cause This alarm is specific to WDIIH3.

• Parallel resistor is not connected across the contact.• Open wire between the contact and the SDII screw connections

Solution

• Verify the parallel resistor values and connection across the contact.• Verify the wiring connections between the SDII and the contact.• Refer to the PDII help documentation for more information.


98

Description Invalid Board excitation voltage connected to the WDII board

Possible Cause

• For WDIIH1: The BoardWettingV parameter does not match the actual excitation voltage applied to the WDII board.

• For WDIIH1/2/3: The board level excitation voltage applied to the WDII board is out of range.

Solution

• For WDIIH1: Verify that the BoardWettingV parameter matches the actual excitation voltage applied to the WDII board.• Verify that the excitation voltage applied to the WDII board is within range.


99

Description GROUND FAULT

Possible Cause A ground fault has occurred in the WDPC.

Solution Replace the WDPC.

100-115

Description Line fault monitoring not possible for contact [ ]

Possible Cause This alarm is specific to WDIIH1.

• Board level excitation voltage is configured for 24 V dc, but the actual excitation voltage connected is ac instead of dc.

Solution

• Verify that the BoardWettingV parameter matches the actual excitation voltage applied to the WDII board.

• Apply 24 V dc to the excitation voltage connector on the WDIIH1 board.• Refer to the PDII help documentation for more information.

116-131

Description Either wire open or fuse blown for contact [ ].

Possible Cause This alarm is specific to WDIIH1 and WDIIH2.

• Parallel resistor is not connected across the contact.• Open wire between the contact and the SDII screw connections.

• Fuse of the associated contact input is blown.• Isolated contact input (fuse pulled so that system excitation voltage is not applied) has been configured as

SystemWetted.

Solution

• Verify the parallel resistor values and connection across the contact.• Verify the wiring connections between the SDII and the contact.

• Replace the blown fuse. Refer to help documentation for the correct part number.• Verify that the isolated contact input has the parameter WettingV configured to the proper external excitation voltage

value (24 V dc, 48 V dc, 125 V dc, 250 V dc, 115 V ac, 230 V ac).



PDIO Specific AlarmsThe following alarms are specific to the PDIO I/O pack.

34-45

Description Fuse [ ] blown.

Possible Cause

• I/O pack fuse status feedback indicates a possible blown fuse.• Consult the relay terminal board help documentation on fuse configuration.

Solution Do the following in order:

• Check the indicated fuse.• Check the power input to the terminal board.

• Check the terminal board configuration.

• Check the I/O pack configuration.• Confirm that all connectors are aligned and fully seated.



46

Description All Fuses Blown or No Terminal Board Excitation.

Possible Cause All fuse sensing indicates an open fuse. This may be due to loss of input power to the terminal board.Without power to the fuses, the sensing may indicate a false open-fuse condition.

Solution

• Confirm the correct input power to terminal board.

• Check the pack connector alignment and seating.• Check the pack configuration.

• Check all fuses.

• Replace the I/O pack.• Replace the terminal board.

47-58

Description Relay Coil [ ] Failure.

Possible Cause Indication that relay feedback does not match commanded state.

Solution

• Clear the voter disagreements (for TMR).

• Check the I/O pack connector alignment and seating.• Check the I/O pack configuration.


59-70

Description Relay Output Driver [ ] Failure.

Possible Cause Relay command signal as seen at the I/O pack output connector to the terminal board does not match the

commanded state.

Solution The command signal feedback requires a properly connected terminal board.

• Check the pack-terminal board connector alignment and seating.




72-95

Description Contact Input [ ] not responding to self-test mode

Possible Cause The input hardware internal to I/O pack has experienced a failure.

Solution

• Replace the I/O pack

120

Description Excitation Voltage not valid, Contact Inputs not valid.

Possible Cause

• The contact excitation may not be connected to the terminal board.

• The contact wetting voltage applied to the terminal board is not within the acceptable range for the board.

Solution

• Check the contact excitation voltage connections to the terminal board.

• Check the power distribution and wiring to ensure that correct wetting power is applied to the terminal board.

1050-1210


Possible Cause In a TMR application, the values for the specified signal do not agree between the R, S, and T I/O packs.

Solution

• Verify that the R, S, and T I/O packs are equal with the ToolboxST configuration.• Check the I/O pack power and networking.

• Check the I/O pack mounting on the terminal board.• Replace the I/O pack.


PDOA Specific AlarmsThe following alarms are specific to the PDOA I/O pack.

33-129


Possible Cause In a TMR application, the values for the specified signal do not agree between R, S, and T I/O packs.

Solution

• Verify that R, S, and T I/O pack configurations are equal to ToolboxST configuration.

• Check the I/O pack power and networking.• Check the I/O pack mounting on terminal board.• Replace the I/O pack.

130-141

Description Fuse [ ] blown.

Possible Cause The I/O pack fuse status feedback indicates a possible blown fuse.

Solution

• Consult the relay terminal board help documentation on fuse configuration.• Check the indicated fuse.• Check the power input to the terminal board.

• Check the terminal board configuration.• Check the I/O pack configuration.• Confirm that all connectors are aligned and fully seated.

• Replace the I/O pack.• Replace the terminal board.

142

Description All fuses blown or no terminal board excitation.

Possible Cause If fuse sensing indicates an open fuse, this may be due to loss of input power to the terminal board.Without power to the fuses, the sensing may indicate a false open-fuse condition.

Solution

• Confirm the correct input power to the terminal board.• Check the pack connector alignment and seating.• Check the pack configuration.

• Check all fuses.• Replace the I/O pack.• Replace the terminal board.

143-154

Description Relay Output Coil [ ] does not match commanded state.

Possible Cause The relay feedback does not match the commanded state for TRLY__B, TRLY__F, or SRLY-specificterminal boards.

Solution

• Clear the voter disagreements.• Check the I/O pack connector alignment and seating.

• Check the I/O pack configuration.• Replace the terminal board.


155-166

Description NO [Normally Open] contact [ ] voltage disagreement with command.

Possible Cause Voltage is not detected across an open TRLY__C or TRLY__E output contact.

Solution

• Clear the voter disagreements.

• Check the application to ensure that voltage should be present when relay is open.• Check that the voltage is within the published detection range. Refer to the terminal board help documentation for

more information.

• Check the I/O pack configuration.• Replace the terminal board.

167-178

Description Relay Driver [ ] does not match commanded state.

Possible Cause The relay command signal, displayed at the I/O pack output connector to the terminal board, doesnot match the commanded state.

Solution The command signal feedback requires a properly connected terminal board.

• Check the pack-terminal board connector alignment and seating.• Replace the I/O pack.• Replace the terminal board.

179-184

Description Relay [ ] connected field device impedance outside of acceptable range.

Possible Cause A connected load does not fall within published impedance limits for TRLY__D-specific terminal boards.

Solution

• Clear the voter disagreements.• Check for field wiring open or short circuits.• Check the attached load to ensure that impedance is within the published limits for TRLY__D. Refer to the terminal

board help documentation for more information.• Check TRLY input power.• Replace TRLY__D.

191

Description Config Mismatch: TRLY__F terminal board is configured for SIMPLEX redundancy.

Possible Cause The TRLY__F board is connected to an I/O pack that is configured as simplex. Due to the redundant

nature of the TRLY__F terminal board, a TMR I/O pack module configuration is required.

Solution

• Configure the I/O pack redundancy as TMR. Build and download a new configuration.


192

Description Peer to Peer Communication Failure Code [ ].

Possible Cause PGEN peer-to-peer communication for the PLU function has been lost. Refer to the PGEN documentation

for a description of peer-to-peer communication.

Solution

• Select None for I/O Module Trip From as the source for a trip if the PLU function is not used. Build and downloadparameters.

• If a PGEN is used as a source for I/O Module Trip From then check the online status of the PGEN and correctif not online.

• If other communication diagnostic alarms are active, check for issues with network cables, switches, and such.

194

Description Peer to Peer Communication Compatibility mismatch: PDOA [ ], Received Message [ ].

Possible Cause The revision of PGEN used for the source of the PLU trip is not compatible with the PDOA revision.

Solution Upgrade PGEN and PDOA to the latest revision in the ControlST release, and download firmware and parameters

to both packs.

195

Description Peer to Peer Communication Initialization failure.

Possible Cause The peer-to-peer link with PGEN for the PLU function could not be initialized.

Solution Build and download parameters to PDOA and PGEN that are used for PLU function.


PEFV Specific AlarmsThe following alarms are specific to the PEFV I/O pack.

32

Description No Ethernet ports could be setup for WGC valve driver.

Possible Cause

• Both Ethernet ports on the PEFV pack have already received an IP address through DHCP so the IP address for theWoodward Governor Controls DVP (WGC) driver network could not be assigned.

• Both ports may be connected to the IONET-EGD network.

Solution

• Verify that network connections are correct.

• Verify that no DHCP server exists on the network connected to the WGC driver.

33

Description Problem with the WGC valve driver Ethernet port.

Possible Cause PEFV could not properly configure the Ethernet port.

Solution

• Re-download the base load and firmware to the I/O pack.• Replace the I/O pack.

34

Description WGC valve driver communication error - packet mismatch.

Possible Cause The received Ethernet Global data is incorrect.

Solution

• Verify that network addresses are configured correctly.

• Verify that the WGC_IP_Addr is set to the IP address of the DVP.• Verify that the Gateway_IP_Addr is set to the IP address of the PEFV gateway port.

35

Description Experiencing delay in reception of data from WGC valve driver.

Possible Cause The PEFV has not received data from the Woodward Governor Controls DVP for five frames (50 ms).

Solution

• Verify that network connections between the PEFV and the Woodward DVP are correct.

• Check for faulty or loose network cables.

38

Description No communication with WGC valve driver.

Possible Cause The PEFV has not received data from the Woodward Governor Controls DVP for three seconds.

Solution

• Verify that network connections between the PEFV and the Woodward DVP are correct.

• Verify that Woodward DVP power is on.

• Verify that Woodward DVP is sending data correctly.


39

Description Config Error - WGC and Gateway IP address subnet mismatch.

Possible Cause The subnet of configured IP addresses WGC_IP_Addr and Gateway_IP_Addr do not match.

Solution

• Verify that the configured IP addresses WGC_IP_Addr and Gateway_IP_Addr are on the same subnet.• Verify that WGC_Subnet is set correctly.


PGEN Specific AlarmsThe following alarms are specific to the PGEN I/O pack.

32

Description Unallowed VarIOCompatCode Change: Old - [ ]; New - [ ].

Possible Cause The .dll for the installed PGEN is incompatible with the firmware loaded on the I/O processor.

Solution

• Confirm the correct installation of the PGEN distributed I/O pack.

• Rebuild the application, then download the firmware and the application code to the affected I/O pack.

33-35

Description Analog Input [ ] Unhealthy.

Possible Cause The analog input 1-3 signal strength is outside the limits for the sensor type.

Solution

• For 4-20 mA analog inputs: Check the configuration parameters MaxMAInput and MinMAInput for proper values.• For voltage analog inputs: the inputs voltage magnitude is greater than 9.24 V.

• Check the analog inputs 1-3 at the terminal points for in-range values.• Replace the PGEN I/O pack or the TGNA terminal board if inputs are in range.

36-39

Description Generator Current Input [ ] Unhealthy.

Possible Cause The CT input current exceeds the configured CT input by 200%.

Solution

• Check the configuration parameter CT_Secondary for the correct setting.

• Check the compatibility of the generator CT secondary output to the TGNA 1 or the 5 A connections.• Check the CT input currents for currents exceeding 200% of the configured (5 or 1 A).• Replace the PGEN I/O pack or the TGNA terminal board if the inputs are in range.

40-46

Description Channel [ ] ADC Conversion Error.

Possible Cause The analog-to-digital conversion for the specified input failed to complete.

Solution Replace the PGEN I/O pack.

47

Description ADC Conversion Not Completed

Possible Cause The analog-to-digital conversion of the terminal board signals failed to complete before the next conversion

cycle was scheduled to start.



51


Possible Cause The calibration reference voltage is more than +/-5% from the expected value, which indicates a hardware

failure.

Solution

• Check the terminal board grounding for noise or poor connections.• Cycle power on the I/O pack.

• Replace the I/O pack if the grounding is okay, and if the condition persists through a power cycle.

52


Possible Cause The null calibration voltage exceeds 150 mV, which indicates a hardware failure.

Solution

• Check terminal board grounding for noise or poor connections.• Cycle power on the I/O pack.

• Replace the I/O pack if grounding OK and condition persists through a power cycle.

53

Description Peer to Peer communication initialization failure.

Possible Cause The peer-to-peer communication link between the PGEN and the PDOA failed to initialize.


54

Description FPGA Interrupt Time Out

Possible Cause Interrupt to read terminal board signals failed to occur at the designated time.


55


Possible Cause N/A

Solution N/A

56-64


Possible Cause

• There is a voter disagreement between the R, S, and T I/O packs.• The I/O pack is not seated on the terminal board correctly.

Solution

• Adjust the parameter TMR_DiffLimt or correct the cause of the difference.• Re-seat the I/O pack to the terminal board.

• Replace the PGEN I/O pack.


PHRA Specific AlarmsThe following alarms are specific to the PHRA I/O pack.

32-41

Description Analog Input [ ] unhealthy.

Possible Cause

• Excitation to the transducer is wrong or missing.• The transducer may be faulty.

• The analog input current/voltage input is beyond the specified range.• The terminal board jumper settings do not match the ToolboxST configuration.• There may be an open or short-circuit on the input.

Solution

• Check the field wiring and connections to the indicated analog input channel.• Check the field device for failure.

• Verify that the configuration matches the terminal board jumper settings for the indicated analog input channel.

46-47

Description Output [ ] total current feedback unhealthy.

Possible Cause

• The commanded output is beyond the range of the output.• There may be a field wiring problem.• There may be a field device problem.

• There may be an open loop or too much resistance in the loop.

Solution

• Verify that the commanded output is within the range of the output.• Confirm that the I/O pack 28 V input power is correct.

• Check the field wiring and the device.• Replace the I/O pack.

48-49

Description Output [ ] Internal reference current unhealthy.

Possible Cause


Solution

• Confirm that the I/O pack 28 V input power is correct.• Replace the I/O pack.


66-67

Description Output [ ] Individual current too high relative to total current.

Possible Cause A disagreement has been detected between the output current sensing inside the I/O pack and the

current sensing on SHRA.

• A hardware failure is causing the I/O pack to drive too much output current.

Solution

• Check the I/O pack mounting on the SHRA.

• Confirm that the field wiring and load are correct.• Check the output configuration.• Replace the SHRA and the I/O pack.

70-71

Description Output [ ] Total current varies from reference current.

Possible Cause


• There may be an open-circuit on the output, or the total loop resistance is too high.• The command is beyond the range of the output.

Solution

• Check the field wiring and the device.• Check the output configuration.• Verify that the commanded output is within output range.

• Check the I/O pack mounting on the SHRA.• Replace the I/O pack.

74-75

Description Output [ ] Reference current error.

Possible Cause The difference between the commanded output current and current feedback on the terminal boardis greater than D/A_ErrLimit (%).

• There may be an open-circuit on the output.

• The command is beyond the range of the output.

Solution

• Check the field wiring and the device.

• Verify that the value of D/A_ErrLimit is set correctly.

• Verify that the commanded output is within the output range.• Replace the I/O pack.


78-79

Description Output [ ] individual current feedback unhealthy.

Possible Cause

• The commanded output is beyond the range of the output.


• There may be a field device problem.• There is an open loop or too much resistance in the loop.



Solution


• Confirm the correct I/O pack 28 V input power.• Check the field wiring and the device.• Replace the I/O pack.

86-87

Description Output [ ] 20/200 mA selection non-functional.

Possible Cause N/A

Solution N/A

92-93

Description Output [ ] Suicide on overcurrent.

Possible Cause

• Hardware failure in I/O pack.

Solution


99

Description Hart Input 1 Channel 1 not initialized.

Possible Cause An enabled Hart input channel does not respond.

Solution

• Verify that the field device is attached to the correct I/O point.

• Using a HART handheld communicator, confirm that the field device is operating correctly and communicating.

100



Solution

• Verify that the field device is attached to the correct I/O point.• Using a HART handheld communicator, confirm that the field device is operating correctly and communicating.


101



Solution


102



Solution



103



Solution


104

Description Hart Output 1 Channel 6 not initialized.

Possible Cause An enabled Hart output channel does not respond.

Solution


105



Solution



106



Solution



107



Solution


108



Solution



109



Solution


110

Description Hart Output 2 Channel 12 not initialized.

Possible Cause An enabled Hart output channel does not respond.

Solution


111

Description Hart Input 1 Channel 1 address mismatch.

Possible Cause The device ID in the ToolboxST configuration does not match the field device.

Solution

• Verify that the correct field device is connected to the I/O point.

• If so, either set the three ID fields to zero, or upload the device ID from the field device.

112



Solution

• Verify that the correct field device is connected to the I/O point.• If so, either set the three ID fields to zero, or upload the device ID from the field device.


113



Solution


114



Solution



115



Solution


116

Description Hart Output 1 Channel 6 address mismatch.


Solution


117



Solution



118



Solution



119



Solution



120



Solution


121



Solution


122

Description Hart Output 2 Channel 12 address mismatch.


Solution



123

Description PHRA Hart Module Modified.

Possible Cause The configuration of the HART multiplexer on the PHRA card was externally modified with either an AMSor a HART handheld communicator.

Solution Determine what change was made and if OK, issue a system diagnostic reset to acknowledge the change

and clear the fault.

124

Description Hart Input 1 Channel 1 Field Device Modified.

Possible Cause The configuration of the HART field device was externally modified with either an AMS or a HART

handheld communicator.

Solution Determine what change was made and if OK, issue a system diagnostic reset to acknowledge the changeand clear the fault.


125





126

Description Hart Input 3 Channel 3 Field Device Modified

Possible Cause The configuration of the HART field device was externally modified with either an AMS or a HARThandheld communicator.



127





128





129

Description Hart Output 1 Channel 6 Field Device Modified




130






131





132





133





134





135

Description Hart Output 2 Channel 12 Field Device Modified.




136

Description Hart Input 1 Chan 1 Control Parm Mismatch - configured: [ ] received: [ ].

Possible Cause The number of dynamic variables returned in Hart Message 3 (Read dynamic variables) does not agreewith the ToolboxST configuration.

Solution Verify that the correct device is attached, and set the ToolboxST configured value to either 0 or the received value.

137


Possible Cause The number of dynamic variables returned in Hart Message 3 (Read dynamic variables) does not agree

with the ToolboxST configuration.



138





139




140




141

Description Hart Output 1 Chan 6 Control Parm Mismatch - configured: [ ] received: [ ].




142




143





144





145





146




147

Description Hart Output 2 Chan 12 Control Parm Mismatch - configured: [ ] received: [ ].



148

Description Hart Input 1 Chan 1 Extended Status Mismatch - configured: [ ] received: [ ].

Possible Cause The number of extended status bytes returned in Hart Message 48 (Read extended status) does not agree



149


Possible Cause The number of extended status bytes returned in Hart Message 48 (Read extended status) does not agreewith the ToolboxST configuration.


150





151





152





153

Description Hart Output 1 Chan 6 Extended Status Mismatch - configured: [ ] received: [ ].



154




155





156




157





158





159

Description Hart Output 2 Chan 12 Extended Status Mismatch - configured: [ ] received: [ ].




160

Description Hart Control Messages disabled. AMS Hart messages only.

Possible Cause The AMS_Msgs_Only parameter is Enabled. No control messages are sent. This parameter overridesthe values in the Hart_Ctrl and Hart_ExStatus for each individual channel.

Solution

• To send AMS messages only, but clear this alarm: Set the AMS_Msgs_Only parameter to Disabled and set each

channel’s Hart_Ctrl and Hart_ExStatus to zero.• To allow control messages and AMS messages, set AMS_Msgs_Only to Disabled.

161

Description Hart Input 1 Chan 1 - Field device not write protected in locked mode.

Possible Cause The field device for this channel is not in a write-protected or secured mode while the controller is inlocked mode.

Solution Refer to the field device manual to determine how to place the device in the write-protected mode. All devices

used in a safety-protected system must be able to be placed in a read-only mode.

162





163


Possible Cause The field device for this channel is not in a write-protected or secured mode while the controller is in

locked mode.

Solution Refer to the field device manual to determine how to place the device in the write-protected mode. All devicesused in a safety-protected system must be able to be placed in a read-only mode.

164



locked mode.



165



locked mode.


166

Description Hart Output 1 Chan 6 - Field device not write protected in locked mode.



167





168



locked mode.


169



locked mode.


170





171



locked mode.


172

Description Hart Output 2 Chan 12 - Field device not write protected in locked mode.




173


Possible Cause The calibration reference voltage for the analog inputs is more than +/-5% from the expected value, whichmay indicate a hardware failure.

Solution

• Check the I/O pack ground quality through the mounting bolts.

• Cycle power on the I/O pack.• Replace the I/O pack.

174


Possible Cause The calibration null voltage for the analog inputs is more than +/-5% from the expected value, whichmay indicate a hardware failure.

Solution

• Check the I/O pack ground quality through the mounting bolts.• Cycle power on the I/O pack.



PPDA Specific AlarmsThe following alarms are specific to the PPDA I/O pack.

32, 35

Description JPDS-[ ] P28v-R volt fdbk (JR/PR connector) out of range.

Possible Cause

• The 28 V Power supply input is out of range. It is expected to be within +/- 5% of 28 V.• The 28 V R power supply has not been connected.

• There could be a power supply problem.

Solution

• The input is not used. Set PS28vEnable to Disable.

• Verify the power supply connections (JR/PR) to the terminal board.

• Verify that the power supply feedback on the JPDS/M Inputs tab in the ToolboxST application is within the expectedtolerance (+/- 5%).

33, 36

Description JPDS-[ ] P28v-S volt fdbk (JS/PS connector) out of range.

Possible Cause

• The 28 V Power supply input is out of range. It is expected to be within +/- 5% of 28 V.

• The 28 V S power supply has not been connected.• There could be a power supply problem.

Solution


• Verify the power supply connections (JS/PS) to the terminal board.• Verify that the power supply feedback on the JPDS/M Inputs tab in ToolboxST is within the expected tolerance (+/- 5%).

34, 37

Description JPDS-[ ] P28v-T volt fdbk (JT/PT connector) out of range.

Possible Cause

• The 28 V Power supply input is out of range. It is expected to be within +/- 5% of 28 V.

• The 28 V T power supply has not been connected.

• There could be a power supply problem.

Solution


• Verify the power supply connections (JT/PT) to the terminal board.• Verify that the power supply feedback on the JPDS/M Inputs tab in the ToolboxST application is within the expected

tolerance (+/- 5%).


38, 41

Description JPDS-[ ] P28v-R contact input (JR connector) indicates PS problem.

Possible Cause

• The power supply contact is open. The power supply is not operating normally.

• The power supply contact feedback is not connected to the terminal board JR connector.• The power supply contact is not used.

Solution

• Verify the status of the power supply contact and that the power supply is operating correctly.• Verify the connections between the power supply and the JR connector on the terminal board.• The JR Input is not used. Set PS28vEnable to Disable.

• The power supply is used, but the JR contact feedback is not connected. Set PS28vEnable to NoDryCnt to disable thisalarm, but continue to monitor the 28 V power supply input.

39, 42

Description JPDS-[ ] P28v-S contact input (JS connector) indicates PS problem.

Possible Cause

• The power supply contact is open. The power supply is not operating normally.• The power supply contact feedback is not connected to the terminal board JS connector.

• The power supply contact is not used.

Solution

• Verify the status of the power supply contact and that the power supply is operating correctly.

• Verify the connections between the power supply and the JS connector on the terminal board.

• The JS Input is not used. Set PS28vEnable to Disable.• The power supply is used, but the JS contact feedback is not connected. Set PS28vEnable to NoDryCnt to disable this

alarm, but continue to monitor the 28 V power supply input.

40, 43

Description JPDS-[ ] P28v-T contact input (JT connector) indicates PS problem.

Possible Cause

• The power supply contact is open. The power supply is not operating normally.• The power supply contact feedback is not connected to the terminal board JT connector.• The power supply contact is not used.

Solution

• Verify the status of the power supply contact and that the power supply is operating correctly.• Verify the connections between the power supply and the JT connector on the terminal board.• The JT Input is not used. Set PS28vEnable to Disable.

• The power supply is used, but the JT contact feedback is not connected. Set PS28vEnable to NoDryCnt to disable thisalarm, but continue to monitor the 28 V power supply input.


44, 47

Description JPDS-[ ] P28v-R aux output fuse (JAR connector) not OK.

Possible Cause

• The auxiliary output JAR fuse has exceeded its current rating (1.6 A at 20°C) and disabled the auxiliary output.

Solution

• Disconnect the auxiliary output connections and troubleshoot the loading of the auxiliary output beyond 1.6 A.• The fuse is self-resetting. Refer to help documentation for more information.

45, 48

Description JPDS-[ ] P28v-S aux output fuse (JAS connector) not OK.

Possible Cause

• The auxiliary output JAS fuse has exceeded its current rating (1.6 A at 20°C) and disabled the auxiliary output.

Solution

• Disconnect the auxiliary output connections and troubleshoot the loading of the auxiliary output beyond 1.6 A.• The fuse is self-resetting. Refer to help documentation for more information.

46, 49

Description JPDS-[ ] P28v-T aux output fuse (JAT connector) not OK.

Possible Cause

• The auxiliary output JAT fuse has exceeded its current rating (1.6 A at 20°C) and disabled the auxiliary output.

Solution

• Disconnect the auxiliary output connections and troubleshoot the loading of the auxiliary output beyond 1.6 A.• Fuse is self resetting. Refer to help documentation for more information.

50, 53

Description JPDM-[ ] P28v-R volt fdbk (JR/PR connector) out of range.

Possible Cause

• The 28 V power supply input is out of range. It is expected to be within +/- 5% of 28 V.

• The 28 V R power supply has not been connected.• There could be a power supply problem.

Solution


• Verify the power supply connections (JR/PR) to the terminal board.• Verify that the power supply feedback on the JPDS/M Inputs tab in the ToolboxST application is within the expected

tolerance (+/- 5%).


51, 54

Description JPDM-[ ] P28v-S volt fdbk (JS/PS connector) out of range.

Possible Cause

• The 28 V power supply input is out of range. It is expected to be within +/- 5% of 28 V.

• The 28 V S power supply has not been connected.• There could be a power supply problem.

Solution

• The input is not used. Set PS28vEnable to Disable.• Verify the power supply connections (JS/PS) to the terminal board.• Verify that the power supply feedback on the JPDS/M Inputs tab in the ToolboxST application is within the expected

tolerance (+/- 5%).

52, 55

Description JPDM-[ ] P28v-T volt fdbk (JT/PT connector) out of range.

Possible Cause

• The 28 V power supply input is out of range. It is expected to be within +/- 5% of 28 V.• The 28 V T power supply has not been connected.• There could be a power supply problem.

Solution

• The input is not used. Set PS28vEnable to Disable.• Verify the power supply connections (JT/PT) to the terminal board.

• Verify that the power supply feedback on the JPDS/M Inputs tab in the ToolboxST application is within the expected

tolerance (+/- 5%).

56, 59

Description JPDM-[ ] P28v-R contact input (JR connector) indicates PS problem.

Possible Cause

• The power supply contact is open. The power supply is not operating normally.• The power supply contact feedback is not connected to the terminal board JR connector.


Solution

• Verify the status of the power supply contact, and that the power supply is operating correctly.• Verify the connections between the power supply and the JR connector on the terminal board.

• The JR input is not used. Set PS28vEnable to Disable.• The power supply is used, but the JR contact feedback is not connected. Set PS28vEnable to NoDryCnt to disable this



57, 60

Description JPDM-[ ] P28v-S contact input (JS connector) indicates PS problem.

Possible Cause


• The power supply contact feedback is not connected to the terminal board JS connector.• The power supply contact is not used.

Solution

• Verify the status of the power supply contact and that the power supply is operating correctly.• Verify the connections between the power supply and the JS connector on the terminal board.• The JS input is not used. Set PS28vEnable to Disable.

• The power supply is used, but the JS contact feedback is not connected. Set PS28vEnable to NoDryCnt to disable thisalarm, but continue to monitor the 28 V power supply input.

58, 61

Description JPDM-[ ] P28v-T contact input (JT connector) indicates PS problem.

Possible Cause

• The power supply contact is open. The power supply is not operating normally.• The power supply contact feedback is not connected to the terminal board JT connector.


Solution

• Verify the status of the power supply contact, and that the power supply is operating correctly.

• Verify the connections between the power supply and the JT connector on the terminal board.

• The JT input is not used. Set PS28vEnable to Disable.• The power supply is used, but the JT contact feedback is not connected. Set PS28vEnable to NoDryCnt to disable this


62, 65

Description JPDM-[ ] P28v-R aux output fuse (JAR connector) not OK.

Possible Cause

• The auxiliary output JAR fuse has exceeded its current rating (3.75 A at 20°C) and disabled the auxiliary output.

Solution

• Disconnect the auxiliary output connections and troubleshoot the loading of the auxiliary output beyond 3.75 A.• The fuse is self-resetting. Refer to the help documentation for more information.

63, 66

Description JPDM-[ ] P28v-S aux output fuse (JAS connector) not OK.

Possible Cause

• The auxiliary output JAS fuse has exceeded its current rating (3.75 A at 20°C) and disabled the auxiliary output.

Solution



64, 67

Description JPDM-[ ] P28v-T aux output fuse (JAT connector) not OK.

Possible Cause

• The auxiliary output JAT fuse has exceeded its current rating (3.75 A at 20°C) and disabled the auxiliary output.

Solution


68, 71

Description JPDM-[ ] fuse FU4 (J1 connector) is blown.

Possible Cause

• The specified fuse is blown.

• The 28 V R power supply input is not connected.

Solution

• Replace the fuse.

• Verify the power supply connections to the terminal board.

69, 72


Possible Cause

• The specified fuse is blown.• The 28 V R power supply input is not connected.

Solution



70, 73


Possible Cause

• The specified fuse is blown.• The 28 V R power supply input is not connected.

Solution

• Replace the fuse.• Verify the power supply connections to the terminal board.

74, 77


Possible Cause

• The specified fuse is blown.• The 28 V S power supply input is not connected.

Solution



75, 78

Description JPDM-[ ] fuse FU8 (J2 connector) is blown

Possible Cause


• The 28 V S power supply input is not connected.

Solution



76,79


Possible Cause


Solution



80,83


Possible Cause

• The specified fuse is blown.• The 28 V T power supply input is not connected.

Solution


81,84


Possible Cause


• The 28 V T power supply input is not connected.

Solution


82,85


Possible Cause


• The 28 V T power supply input is not connected.

Solution




86,89

Description JPDM-[ ] fuse FU1 (JCR connector) is blown.

Possible Cause


• The 28 V R power supply input is not connected.

Solution



87,90

Description JPDM-[ ] fuse FU2 (JCS connector) is blown.

Possible Cause


Solution



88,91

Description JPDM-[ ] fuse FU3 (JCT connector) is blown.

Possible Cause

• The specified fuse is blown.• The 28 V T power supply input is not connected.

Solution


92-95

Description JPDB-[ ] AC In-[ ] [ ]V fdbk (J1 connector) out of range.

Possible Cause

• The specified ac input is configured to the wrong nominal voltage value.

• The ac input voltage is out of tolerance from the nominal voltage value.

• The ac source voltage is out of range.• The ac input is not connected.

Solution

• Verify that the nominal ac input voltage matches the value configured in ACFdbkInVoltage.• The ac tolerance is set too low. Check that ACFdbkInTol is set to the proper value.• Verify that the ac supply is within the specified parameters (Refer to the JPDB help documentation for more information.)

• If the ac input is not used, this diagnostic alarm can be disabled by setting the InputDiagEnab parameter on theassociated input (AC_Fdbk#_Volt) to Disabled.


96-101, 104-109

Description JPDB-[ ] fuse FU[ ] is blown or SW[ ] switched OFF.

Possible Cause

• The specified switch is turned off and FuseDiag is enabled.

• The specified fuse is blown.• The ac input is not connected.

Solution

• If the switch is turned off (the output is not used), disable the diagnostic by setting FuseDiag to Disable.• If the output is used, verify that the switch is turned on.• Replace the fuse.

• Verify the ac input connections to the terminal board.• If the ac input is not used, this diagnostic alarm can be disabled by setting the InputDiagEnab parameter on the

associated input (AC_Fdbk#_Volt) to Disabled.

102-103, 110-111

Description JPDB-[ ] fuse FU[ ] is blown.

Possible Cause


• The ac input is not connected.

Solution



associated input (AC_Fdbk#_Volt) to Disabled.

112, 114

Description JPDF-[ ] DC 125V magnitude (JD1/JZ2/JZ3 connector) out of range.

Possible Cause

• The 125 V dc input is less than DC_125v_Trig_Volt.• DC_125v_Trig_Volt is set too high.• The 125 V dc source voltage is out of range.• The 125 V dc input is not connected.

Solution

• Verify that DC_125v_Trig_Volt is set correctly.• If fed from the dc battery Input, check the connections to JD1 and TB1.

• If fed from DACA, check the connections to JZ2 and/or JZ3.

• Verify the grounding of the dc input signals. Refer to the JPDF help for more info.• If the 125 V dc input is not used, this diagnostic alarm can be disabled by setting the InputDiagEnab parameter on

the associated input (DC_125VFdbkMag) to Disabled.


113, 115

Description JPDF-[ ] DC 125V Ground magnitude (JD1/JZ2/JZ3 connector) out of range.

Possible Cause

• The 125 V ground feedback magnitude is greater than Gnd_Mag_Trig_Volt.• Gnd_Mag_Trig_Volt is set too low.• One side of the dc 125 V source voltage is grounded.

Solution

• Verify that Gnd_Mag_Trig_Volt is set correctly.• Check the connections to the specified connector.• Verify the grounding of the dc input signals. Refer to the JPDF help documentation.

• If DC 125V input is not used, this diagnostic alarm can be disabled by setting the InputDiagEnab parameter onthe associated input (DC_125VFdbkMag) to Disabled.

116, 125

Description JPDF-[ ] fuse FU1R or FU2R (J1R connector) is blown or SW1R switched OFF.

Possible Cause

• The SW1R is turned off and FuseDiag is enabled.• The FU1R or FU2R fuse is blown.

• The 125V dc input is not connected.

Solution

• If the switch is turned off (output is not used), disable the diagnostic by setting FuseDiag to Disable.

• If the output is used, verify that the switch is turned on.

• Replace the fuse.• Verify the 125 V dc input connections to the terminal board.

• If the 125 V dc input is not used, this diagnostic alarm can be disabled by setting the InputDiagEnab parameter on


117, 126

Description JPDF-[ ] fuse FU1S or FU2S (J1S connector) is blown or SW1S switched OFF.

Possible Cause

• The SW1R is turned off and FuseDiag is enabled.• The FU1S or FU2S fuse is blown.

• The 125 V dc input is not connected.

Solution

• If the switch is turned off (output is not used), disable the diagnostic by setting FuseDiag to Disable.• If the output is used, verify that the switch is turned on.



118, 127

Description JPDF-[ ] fuse FU1T or FU2T (J1T connector) is blown or SW1T switched OFF

Possible Cause

• The SW1R is turned off and FuseDiag is enabled.

• The FU1T or FU2T fuse is blown.• The 125 V dc input is not connected.

Solution

• If the switch is turned off (output is not used), disable the diagnostic by setting FuseDiag to Disable.• If the output is used, verify that the switch is turned on.• Replace the fuse.

• Verify the 125 V dc input connections to the terminal board.• If the 125 V dc input is not used, this diagnostic alarm can be disabled by setting the InputDiagEnab parameter on


119, 128

Description JPDF-[ ] fuse FU71 or FU72 (J7X connector) is blown or SW7X switched OFF.

Possible Cause

• The SW7X is turned off and FuseDiag is enabled.

• The FU71 or FU72 fuse is blown.• The 125 V dc input is not connected.

Solution


• Verify the 125 V dc input connections to the terminal board.

• If the 125 V dc input is not used, this diagnostic alarm can be disabled by setting the InputDiagEnab parameter onthe associated input (DC_125VFdbkMag) to Disabled.

120, 129

Description JPDF-[ ] fuse FU73 or FU74 (J7Y connector) is blown or SW7Y switched OFF.

Possible Cause

• The SW7Y is turned off and FuseDiag is enabled.


Solution


• If the output is used, verify that the switch is turned on.• Replace the fuse.• Verify the 125 V dc input connections to the terminal board.



121, 130

Description JPDF-[ ] fuse FU75 or FU76 (J7Z connector) is blown or SW7Z switched OFF.

Possible Cause

• The SW7Z is turned off and FuseDiag is enabled.


Solution




122, 131

Description JPDF-[ ] fuse FU81 or FU82 (J8A connector) is blown.

Possible Cause

• The FU81 or FU82 fuse is blown.


Solution




123, 132

Description JPDF-[ ] fuse FU83 or FU84 (J8B connector) is blown.

Possible Cause



Solution



124, 133

Description JPDF-[ ] fuse FU12 or FU13 (J12 connector) is blown.

Possible Cause



Solution




135

Description PPDA Invalid Combination: More than 2 JPDS boards present.

Possible Cause PPDA allows up to two JPDS boards to be connected as part of the Power Distribution module. The PPDA

has detected more than two JPDS boards connected through ribbon cables to the PDM.

Solution

• Verify that only one or two JPDS terminal boards are connected to the PDM through ribbon cables.• Reboot the PPDA after the hardware connections are corrected.

136

Description PPDA Invalid Combination: More than 2 JPDE boards present.

Possible Cause PPDA allows up to two JPDE boards to be connected as part of the Power Distribution module. The PPDA

has detected more than two JPDE boards connected through ribbon cables to the PDM.

Solution

• Verify that only one or two JPDE terminal boards are connected to the PDM through ribbon cables.• Reboot the PPDA after the hardware connections are corrected.

137

Description PPDA Invalid Combination: More than 2 JPDF boards present.

Possible Cause PPDA allows up to two JPDF boards to be connected as part of the Power Distribution module. The PPDA

has detected more than two JPDF boards connected through ribbon cables to the PDM.

Solution

• Verify that only one or two JPDF terminal boards are connected to the PDM through ribbon cables.• Reboot the PPDA after the hardware connections are corrected.

138

Description PPDA Invalid Combination: More than 2 JPDB boards present.

Possible Cause PPDA allows up to two JPDB boards to be connected as part of the Power Distribution module. The PPDA

has detected more than two JPDB boards connected through ribbon cables to the PDM.

Solution

• Verify that only one or two JPDB terminal boards are connected to the PDM through ribbon cables.• Reboot the PPDA after the hardware connections are corrected.

139

Description PPDA Invalid Combination: More than 2 JPDR boards present.

Possible Cause PPDA allows up to two JPDR boards to be connected as part of the Power Distribution module. The PPDA

has detected more than two JPDR boards connected through ribbon cables to the PDM.

Solution

• Verify that only one or two JPDR terminal boards are connected to the PDM through ribbon cables.• Reboot the PPDA after the hardware connections are corrected.


140

Description PPDA Invalid Combination: Terminal board JPDR-[ ] present without JPDB.

Possible Cause PPDA requires that a JPDB board be connected to the PDM for each JPDR connected.

• A JPDR board is connected with out a JPDB present.

• Two JPDR boards are connected with only one JPDB present.

Solution

• Verify that for each JPDR connected through ribbon cable, there is one JPDB present.

• Verify that the ToolboxST configuration matches the hardware configuration.• Reboot the PPDA after the hardware connections are corrected.

141-145

Description Configured TB at Phy Position-[ ] doesn’t match actual H/W.

Possible Cause

• The auxiliary terminal board at the specified physical position does not match the ToolboxST configuration.• The auxiliary terminal boards have been added in the wrong order.

Solution

• Verify that the actual hardware matches the auxiliary terminal board configuration in the ToolboxST configuration.• Verify that the auxiliary board physical position matches the Phy Pos value in the ToolboxST configuration. (Right-click

the PPDA and click Modify....)• NOTE: JPDM and JPDC boards assume two feedback channels, so the first connected auxiliary terminal board is in

Phy Pos 2 rather than Phy Pos 1.

146

Description PPDA Invalid Combination: More than 2 JPDM boards present.

Possible Cause PPDA allows up to two JPDM boards to be connected as part of the Power Distribution module. ThePPDA has detected more than two JPDM boards connected through ribbon cables to the PDM.

Solution

• Verify that only one or two JPDM terminal boards are connected to the PDM through ribbon cables.• Reboot the PPDA after the hardware connections are corrected.

147

Description PPDA Invalid Combination: Both JPDS and JPDM Terminal boards present.

Possible Cause PPDA does not allow JPDS and JPDM terminal boards to be mixed. The PPDA has detected both JPDSand JPDM terminal boards connected through ribbon cables to the PDM.

Solution

• Verify that there are only JPDS or JPDM boards present, but not both.• Verify that the ToolboxST configuration matches the hardware configuration.

• Reboot the PPDA after the hardware connections are corrected.


148, 150

Description JPDE-[ ] 24/48 VDC magnitude (JD1/JPS1/JPS2 connector) out of range.

Possible Cause

• The 24/48 V dc input is less than DC_24v_Trig_Volt.• DC_24v_Trig_Volt is set too high.• The 24/48 V dc source voltage is out of range.• The 24/48 V dc input is not connected.

Solution

• Verify that DC_24v_Trig_Volt is set correctly.• Check the connections to the specified connector.

• Verify the grounding of the dc input signals. Refer to the JPDE help documentation.• If 24/48 VDC input is not used, this diagnostic alarm can be disabled by setting the InputDiagEnab parameter on


149, 151

Description JPDE-[ ] DC Voltage Gnd fdbk mag (JD1/JPS1/JPS2 connector) out of range.

Possible Cause

• The 24/48 V dc ground feedback magnitude is greater than Gnd_Mag_Trig_Volt.• Gnd_Mag_Trig_Volt is set too low.• One side of the 24/48 V dc source voltage is grounded.

Solution

• Verify that Gnd_Mag_Trig_Volt is set correctly.

• Check the connections to the specified connector.• Verify the grounding of the dc input signals. Refer to the JPDE help documentation.

• If 24/48 VDC input is not used, this diagnostic alarm can be disabled by setting the InputDiagEnab parameter on


152, 160

Description JPDE-[ ] fuse FU11/FU12 (JS1 connector) is blown or SWS1 switched OFF.

Possible Cause

• The SWS1 is turned off and FuseDiag is enabled.• The FU11 or FU12 fuse is blown.

• The 24/48 V dc input is not connected.

Solution

• If the switch is turned off (output is not used), disable the diagnostic by setting FuseDiag to Disable.• If the output is used, verify that the switch is turned on.

• Replace the fuse.• Verify the 24/48 V dc input connections to the terminal board.• If the 24/48 V dc input is not used, this diagnostic alarm can be disabled by setting the InputDiagEnab parameter on



153, 161


Possible Cause

• The SWS2 is turned off and FuseDiag is enabled.

• The FU21 or FU22 fuse is blown.• The 24/48 V dc input is not connected.

Solution


• Verify the 24/48 V dc input connections to the terminal board.• If the 24/48 V dc input is not used, this diagnostic alarm can be disabled by setting the InputDiagEnab parameter on


154, 162


Possible Cause

• The SWS3 is turned off and FuseDiag is enabled.

• The FU31 or FU32 fuse is blown.• The 24/48 V dc input is not connected.

Solution


• Verify the 24/48 V dc input connections to the terminal board.

• If the 24/48 V dc input is not used, this diagnostic alarm can be disabled by setting the InputDiagEnab parameter onthe associated input (DC_24VFdbkMag) to Disabled.

155, 163

Description JPDE-[ ] fuse FUA1/FUA2 (JFA connector) is blown.

Possible Cause

• The FUA1 or FUA2 fuse is blown.


Solution

• Replace the fuse.• Verify the 24/48 V dc input connections to the terminal board.



156, 164

Description JPDE-[ ] fuse FUB1/FUB2 (JFB connector) is blown.

Possible Cause

• The FUB1 or FUB2 fuse is blown.


Solution


• Verify 24/48 V dc input connections to the terminal board.• If the 24/48 V dc input is not used, this diagnostic alarm can be disabled by setting the InputDiagEnab parameter on


157, 165

Description JPDE-[ ] fuse FUC1/FUC2 (JFC connector) is blown.

Possible Cause

• The FUC1 or FUC2 fuse is blown.


Solution


• Verify the 24/48 V dc input connections to the terminal board.


158, 166

Description JPDE-[ ] DC Voltage contact input 1 (JPS1 connector) indicates PS problem.

Possible Cause


• The power supply dry contact feedback is not connected to the terminal board JPS1 connector.

Solution

• Verify the status of the power supply contact, and that the power supply is operating correctly.• Verify the connections between the power supply and the JR connector on the JPDE.


159, 167

Description JPDE-[ ] DC Voltage contact input 2 (JPS2 connector) indicates PS problem.

Possible Cause


• The power supply dry contact feedback is not connected to the terminal board JPS2 connector.

Solution

• Verify the status of the power supply contact, and that the power supply is operating correctly.• Verify the connections between the power supply and the JR connector on the JPDE.



169

Description Invalid Terminal board ID at Physical Position [ ].

Possible Cause

• The terminal board ID is not recognized or supported by the current firmware version.

• The electronic terminal board ID is not programmed, or is programmed incorrectly.

Solution

• Upgrade the PPDA firmware to a version that supports the terminal board at the specified physical position. Refer to the

help documentation for a list of supported terminal boards.• Replace the terminal board hardware.

170-171

Description Input Src Mismatch on JPDF-[ ]: AC src detected at input instead DC.

Possible Cause

• The ac voltage has been detected at the 125 V dc input.

Solution

• Verify the 125 V dc input connections. Use a DVM to verify dc voltage on the input connections.

• Verify that the positive and negative inputs to the 125 V dc bus are connected to the proper terminals. Refer to the JPDFhelp documentation for more information.

172

Description JPDC-DC 125V fdbk mag (JD1/JZ2 connector) out of range.

Possible Cause

• The 125 V dc input is less than DC_125v_Trig_Volt.• DC_125v_Trig_Volt is set too high.• The 125 V dc source voltage is out of range.• The 125 V dc input is not connected.

Solution

• Verify that DC_125v_Trig_Volt is set correctly.• If fed from the dc battery input, check the connections to JD1 and TB1.• If fed from DACA, check the connections to JZ2.

• Verify the grounding of dc input signals. Refer to the JPDC help documentation.• If the 125 V dc input is not used, this diagnostic alarm can be disabled by setting the InputDiagEnab parameter on


173

Description JPDC-DC 125V Gnd fdbk mag (JD1/JZ2 connector) out of range.

Possible Cause

• The dc 125 ground feedback magnitude is greater than Gnd_Mag_Trig_Volt.• Gnd_Mag_Trig_Volt is set too low.• One side of the DC 125 V source voltage is grounded.

Solution

• Verify that Gnd_Mag_Trig_Volt is set correctly.• Check the connections to the specified connector.• Verify the grounding of the dc input signals. Refer to the JPDC help documentation.

• If DC 125V input is not used, this diagnostic alarm can be disabled by setting the InputDiagEnab parameter onthe associated input (DC_125VFdbkMag) to Disabled.


174

Description JPDC-Fuse FU71 or FU72 (J7A connector) is blown or SW7A switched OFF.

Possible Cause


• The specified fuse is blown.• The 125 V dc input is not connected.

Solution




175

Description JPDC-Fuse FU73 or FU74 (J7B connector) is blown or SW7B switched OFF.

Possible Cause



Solution


• If the output is used, verify that the switch is turned on.• Replace the fuse.



176

Description JPDC-Fuse FU75 or FU76 (J7C connector) is blown or SW7C switched OFF.

Possible Cause



Solution

• If the switch is turned off (output is not used), disable the diagnostic by setting FuseDiag to Disable.• If the output is used, verify that the switch is turned on.• Replace the fuse.• Verify the 125 V dc input connections to the terminal board.



177

Description JPDC-Fuse FU1R or FU2R (J1R connector) is blown or SW1R switched OFF.

Possible Cause



Solution




178

Description JPDC-Fuse FU1S or FU2S (J1S connector) is blown or SW1S switched OFF.

Possible Cause



Solution


• If the output is used, verify that the switch is turned on.• Replace the fuse.



179

Description JPDC-Fuse FU1T or FU2T (J1T connector) is blown or SW1T switched OFF.

Possible Cause



Solution


• If the output is used, verify that the switch is turned on.• Replace the fuse.• Verify the 125 V dc input connections to the terminal board.



180

Description Input Src Mismatch on JPDC: AC src detected at input instead DC.

Possible Cause

• The ac voltage has been detected at the 125 V dc input.

Solution

• Verify the 125 V dc input connections. Use a DVM to verify the dc voltage on the input connections.• Verify that the positive and negative inputs to the 125 V dc bus are connected to the proper terminals. Refer to the JPDC

help documentation for more information.• If the 125 V dc input is not used, this diagnostic alarm can be disabled by setting the InputDiagEnab parameter on


181

Description JPDC-AC [ ]V fdbk (JAC connector) out of range.

Possible Cause

• The specified ac input is configured to the wrong nominal voltage value.

• The ac input voltage is out of tolerance from the nominal voltage value.• The ac source voltage is out of range.• The ac input is not connected.

Solution

• Verify that the nominal ac input voltage matches the value configured in ACFdbkInVoltage.• The ac tolerance is set too low. Verify that ACFdbkInTol is set to the proper value.

• Verify that the ac supply is within the specified parameters. Refer to the JPDC help documentation for more information.

• If the ac input is not used, this diagnostic alarm can be disabled by setting the InputDiagEnab parameter on theassociated input (AC_VFdbk1_Volt) to Disabled.

182

Description JPDC-Fuse FUAC1 (JAC1 connector) is blown or SWAC1 switched OFF.

Possible Cause


• The specified fuse is blown.• The ac input is not connected.

Solution


• If the output is used, verify that the switch is turned on.• Replace the fuse.• Verify the ac input connections to the terminal board.

• If the ac input is not used, this diagnostic alarm can be disabled by setting the InputDiagEnab parameter on theassociated input (AC_VFdbk1_Volt) to Disabled.


183

Description JPDC-Fuse FUAC2 (JAC2 connector) is blown.

Possible Cause


• The ac input is not connected.

Solution



associated input (AC_VFdbk1_Volt) to Disabled.

184

Description JPDC-P28v-R volt fdbk (JR/PR connector) out of range.

Possible Cause

• The 28 V power supply input is out of range. It should be within +/- 5% of 28 V.

• The 28 V power supply has not been connected.• There may be a power supply problem.

Solution


• Verify the power supply connections (specified connector) to the terminal board.• Verify that the power supply feedback on the JPDC Inputs tab in the ToolboxST configuration is within the expected

tolerance (+/- 5%).

185

Description JPDC-P28v-S volt fdbk (JS/PS connector) out of range.

Possible Cause

• The 28 V power supply input is out of range. It should be within +/- 5% of 28 V.• The 28 V power supply has not been connected.• There may be a power supply problem.

Solution

• The input is not used. Set PS28vEnable to Disable.• Verify the power supply connections (specified connector) to the terminal board.• Verify that the power supply feedback on the JPDC Inputs tab in the ToolboxST configuration is within the expected

tolerance (+/- 5%).

186

Description JPDC-P28v-T volt fdbk (JT/PT connector) out of range.

Possible Cause

• The 28 V power supply input is out of range. It should be within +/- 5% of 28 V.• The 28 V power supply has not been connected.

• There may be a power supply problem.

Solution

• The input is not used. Set PS28vEnable to Disable.• Verify the power supply connections (specified connector) to the terminal board.

• Verify that the power supply feedback on the JPDC Inputs tab in the ToolboxST configuration is within the expectedtolerance (+/- 5%).


187

Description JPDC-P28v-R contact input (JR connector) indicates PS problem.

Possible Cause


• The power supply contact feedback is not connected to the specified terminal board connector.• The power supply dry contact is not used.

Solution

• Verify the status of the power supply contact, and that the power supply is operating correctly.• Verify the connections between the power supply and the specified connector on the JPDC.• The input is not used. Set PS28vEnable to Disable.

• The power supply is used, but the dry contact feedback is not connected. Set PS28vEnable to NoDryCnt to disable thisalarm, but continue to monitor the 28 V power supply input.

188

Description JPDC-P28v-S contact input (JS connector) indicates PS problem.

Possible Cause

• The power supply contact is open. The power supply is not operating normally.• The power supply contact feedback is not connected to the specified terminal board connector.

• The power supply dry contact is not used.

Solution

• Verify the status of the power supply contact, and that the power supply is operating correctly.

• Verify the connections between the power supply and the specified connector on the JPDC.

• The input is not used. Set PS28vEnable to Disable.• The power supply is used, but the dry contact feedback is not connected. Set PS28vEnable to NoDryCnt to disable this


189

Description JPDC-P28v-T contact input (JT connector) indicates PS problem.

Possible Cause

• The power supply contact is open. The power supply is not operating normally.• The power supply contact feedback is not connected to the specified terminal board connector.• The power supply dry contact is not used.

Solution

• Verify the status of the power supply contact, and that the power supply is operating correctly.• Verify the connections between the power supply and the specified connector on the JPDC.• The input is not used. Set PS28vEnable to Disable.

• The power supply is used, but the dry contact feedback is not connected. Set PS28vEnable to NoDryCnt to disable thisalarm, but continue to monitor the 28 V power supply input.


190

Description PPDA Invalid Combination: More than 1 JPDC board present.

Possible Cause The PPDA allows only one JPDC board to be connected as part of the Power Distribution module. The

PPDA has detected more than one JPDC boards connected through the ribbon cables to the PDM.

Solution

• Verify that only one JPDC terminal boards is connected to the PPDA. The PPDA should be plugged into the JPDCterminal board.

• Reboot the PPDA after the hardware connections are corrected.

191

Description PPDA Invalid Combination: JPDC and JPDS boards present Together.

Possible Cause The PPDA does not allow JPDC and JPDS terminal boards to be mixed. The PPDA has detected both

JPDC and JPDS terminal boards connected through ribbon cables to the PDM.

Solution

• Verify that there are only JPDC or JPDS boards present, but not both.

• Verify that the ToolboxST configuration matches the hardware configuration.• Reboot the PPDA after the hardware connections are corrected.

192

Description PPDA Invalid Combination: More than one JPDF Connected to JPDC board.

Possible Cause The PPDA allows only one JPDF board to be connected to a JPDC as part of the Power Distributionmodule. The PPDA has detected more than one JPDF boards connected through ribbon cables to the PDM.

Solution

• Verify that only one JPDF terminal board is connected to the PDM through ribbon cables.• Reboot the PPDA after the hardware connections are corrected.

193

Description PPDA Invalid Combination: More than one JPDB Connected to JPDC board.

Possible Cause The PPDA allows only one JPDB board to be connected to a JPDC as part of the Power Distributionmodule. The PPDA has detected more than one JPDB boards connected through ribbon cables to the PDM.

Solution

• Verify that only one JPDB terminal board is connected to the PDM through ribbon cables.• Reboot the PPDA after the hardware connections are corrected.

194

Description PPDA Invalid Combination: JPDC and JPDM boards present Together.

Possible Cause The PPDA does not allow JPDC and JPDM terminal boards to be mixed. The PPDA has detected bothJPDC and JPDM terminal boards connected through ribbon cables to the PDM.

Solution

• Verify that there are only JPDC or JPDM boards present, but not both.• Verify that the ToolboxST configuration matches the hardware configuration.• Reboot the PPDA once the hardware connections have been corrected.


PPRA Specific AlarmsThe following alarms are specific to the PPRA I/O pack.

40

Description Contact Excitation Voltage Test Failure

Possible Cause Voltage for the contact inputs on the trip board is not within published limits.

Solution Check source of contact excitation voltage applied to trip board.

50

Description Main Terminal Board Mismatch

Possible Cause

• The terminal board that was selected in the ToolboxST configuration does not match the actual board found by the PPRA.• The WREA daughterboard has not been attached to the TREA.

Solution

• Change the ToolboxST configuration to use the correct board.• Replace the terminal board to match the board selected in the ToolboxST configuration.

• Verify that the WREA is seated correctly on the TREA.

51

Description Trip Board Mismatch

Possible Cause The trip board selected in the ToolboxST configuration does not match the actual board found by the PPRA.

Solution Verify that you are using a TREA terminal board. The TREA should not have any auxilliary trip boards.

52

Description Dual speed requires fanned speed inputs berg set

Possible Cause The JP1 and JP2 jumpers are not set to fan the speed signals to all three packs. This is required for

dual speed inputs.

Solution Remove the WREA daughterboard, and set the jumpers to the correct position.

53

Description WREA - Repeater status fault 1/4

Possible Cause The speed repeater output does not match the input speed signal.

• One of the speed sensors is not connected.

• The pins on the cable are shorted.

• The RS-232/RS-485 chip is not functioning.

Solution

• Verify the pins and connections on the cable.

• Verify the connection of both speed sensors.• Replace the WREA daughterboard.


54




• The pins on the cable are shorted.• The RS-232/RS-485 chip is not functioning.

Solution

• Verify the pins and connections on the cable.• Verify the connection of both speed sensors.• Replace the WREA daughterboard.

55




• The pins on the cable are shorted.• The RS-232/RS-485 chip is not functioning.

Solution

• Verify the pins and connections on the cable.

• Verify the connection of both speed sensors.• Replace the WREA daughterboard.

56

Description Dual speed sensors mismatch: PR 1=[ ], PR 4=[ ]

Possible Cause The dual speed sensors are reporting speeds that differ by more than the configured Dual_DiffLimit value.

Solution

• Verify that the Dual_DiffLimit value is set correctly. Note that the value is given in engineering units.

• Verify the connection and correct operation of the speed sensors.

57



Solution

• Verify that the Dual_DiffLimit value is set correctly. Note that the value is given in engineering units.

• Verify the connection and correct operation of the speed sensors.

58



Solution

• Verify that the Dual_DiffLimit value is set correctly. Note that the value is given in engineering units.• Verify the connection and correct operation of the speed sensors.


59

Description Internal power supply failure - P5 power for WREA

Possible Cause The PPRA internal 5 V power supply is unhealthy, causing either a faulty PPRA or TREA+WREA terminal

board.

Solution

• If all three PPRAs are reporting the problem, replace the TREA+WREA terminal board.• If only one pack is reporting the problem, replace the PPRA.

60

Description Internal power supply failure - P15 power for WREA

Possible Cause The PPRA internal 15 V power supply is unhealthy, causing either a faulty PPRA or TREA+WREA

terminal board.

Solution


61

Description Internal power supply failure - N15 power for WREA

Possible Cause The PPRA internal -15 V power supply is unhealthy causing either a faulty PPRA or TREA+WREA

terminal board.

Solution


69-71

Description Trip Relay (ETR) Driver [ ] does not match commanded state

Possible Cause The driver output of the I/O pack for Emergency Trip Relay 1 (K1), ETR2 (K2), or ETR3 (K3) does not

match the commanded state. This indicates that the I/O pack does not see the relay command going out the DC-62

connector into the expected terminating impedance on the trip board.

Solution

• Check the I/O pack connector seating on the terminal board.

• Check the trip board cable seating (if not TREA) and the cable integrity.• Replace the cable, the trip board, the main terminal board, and the I/O pack.

72-74

Description Econ Relay Driver [ ] does not match commanded state

Possible Cause The driver output of the I/O pack for Economizing Relay KE1, KE2, or KE3 does not match thecommanded state. This indicates that the I/O pack does not see the relay command going out the DC-62 connector into

the expected terminating impedance on the trip board.

Solution

• Check the I/O pack connector seating on terminal board.• Check the trip board cable seating and the cable integrity.

• Replace the cable, the trip board, the main terminal board, and the I/O pack.


75

Description Servo Clamp Relay Driver does not match commanded state

Possible Cause The driver output of I/O pack for K4CL does not match the commanded state. This indicates that I/O packdoes not see the relay command going out the DC-62 connector into the expected terminating impedance on the trip board.

Solution

• Check the I/O pack connector seating on terminal board.• Check the trip board cable seating and the cable integrity.• Replace the cable, the trip board, the main terminal board, and the I/O pack.

76

Description K25A Relay (synch check) Driver does not match commanded state

Possible Cause The driver output of I/O pack for K25A does not match the commanded state. This indicates that I/O pack

does not see the relay command going out the DC-62 connector into the expected terminating impedance on the trip board.

Solution


• One at a time, replace the following: the emergency trip board cable, the trip terminal board, the terminal board hostingthe I/O pack, and the I/O pack.

83-85

Description Trip Relay (ETR) Contact [ ] does not match commanded state

Possible Cause Relay feedback from Emergency Trip Relay 1 (K1), ETR2 (K2), or ETR3 (K3) does not match thecommanded state. This indicates that the relay feedback from the trip board does not agree with the commanded state.

Solution Check the trip board relays, as well as the cable from trip board to main terminal board (if not TREA).

86-88

Description Econ Relay Contact [ ] does not match commanded state

Possible Cause The relay feedback from Economizing Relay 1 (KE1), KE2, or KE3 does not match the commanded state.

This indicates that the relay feedback from the trip board does not agree with the commanded state.

Solution Check the trip board relays, as well as the cable from trip board to main terminal board.

89

Description Servo Clamp Relay Contact does not match commanded state

Possible Cause The relay feedback from K4CL does not match the commanded state. This indicates that the relayfeedback from the trip board does not agree with the commanded state.

Solution

• Check the I/O pack connector seating on the terminal board.• Check the trip board cable seating and the cable integrity.• Replace the cable, the trip board, the main terminal board, and the I/O pack.


90

Description K25A Relay Coil Feedback does not match commanded state

Possible Cause The relay feedback from K25A does not match the commanded state. This indicates that the relayfeedback from the trip board does not agree with the commanded state. Relay feedback is taken after hardware command

voting on the trip terminal board has occurred; therefore, a probable cause is that one I/O pack is not commanding the samestate as the other two I/O packs.

Solution

• Confirm that the TMR packs are commanding the same state for K25A.

• Check the I/O pack connector seating on the terminal board.• Check the trip board cable seating and the cable integrity.• One at a time, replace the following: the emergency trip board cable, the trip terminal board, the terminal board hosting

the I/O pack, and the I/O pack.

97

Description Solenoid Power Source is missing

Possible Cause Solenoid power monitoring provided by the trip board indicates the absence of power.

Solution

• Check the source of solenoid power.• Confirm that the wiring between the trip boards is correct.

99-101

Description Solenoid Voltage [ ] does not match commanded state

Possible Cause The solenoid voltage associated with K1-K3 does not match the commanded state. K1-K3 are closed,

but no voltage is detected on the solenoid.

Solution This may be due to removal of solenoid voltage through another means when the I/O pack expects to seeit. Review the system-level trip circuit wiring and confirm the the voltage should be present if the I/O pack energizes

the associated trip relay.

105

Description TREL/S, Solenoid Power, Bus A, Absent

Possible Cause TRES/TREL solenoid power A is absent. Solenoid power does not match the solenoid state for longer

than 40 milliseconds.

Solution

• Check power applied to the trip board.

• Check the field wiring.

• Check the solenoid.• Replace the terminal board.

106

Description TREL/S, Solenoid Power, Bus B, Absent

Possible Cause TRES/TREL solenoid power B is absent. The solenoid power does not match the solenoid state forlonger than 40 milliseconds.

Solution

• Check power applied to the trip board.• Check the field wiring.

• Check the solenoid.



107

Description TREL/S, Solenoid Power, Bus C, Absent

Possible Cause TRES/TREL solenoid power C is absent. The solenoid power does not match The solenoid state forlonger than 40 milliseconds.

Solution

• Check power applied to the trip board.• Check the field wiring.• Check the solenoid.


108

Description Control Watchdog Protection Activated

Possible Cause This alarm only occurs if the parameter ContWdogEn has been enabled. An alarm indicates that thevariable ContWdog has not changed for five consecutive frames. The alarm clears if changes are seen for 60 seconds.

Solution Verify that the ContWdog is set up correctly in the ToolboxST application, and that the source of the signal

is changing the value at least once a frame.

109

Description Speed Difference Protection Activated

Possible Cause This alarm only occurs if the parameter SpeedDifEnable has been enabled. An alarm indicates that the

difference between the output signal Speed1 and the first I/O pack pulse rate speed is larger than the percentage OS_DIFFfor more than three consecutive frames. The alarm clears if the difference is within limits for 60 seconds.

Solution Verify that the Speed1 signal is set up correctly in the ToolboxST and that the source of the signal reflects

the primary (PTUR/YTUR) pulse rate speed.

110

Description Stale Speed Protection Activated

Possible Cause The speed trip protection may be stale. This alarm can only occur if the parameter StaleSpdEn has been

enabled. An alarm indicates that the variable Speed1 has not changed for five consecutive frames. The alarm clears ifthe speed dithers for 60 seconds.

Solution Verify that the Speed1 signal is set up correctly in the ToolboxST configuration, and that the source of the

signal reflects the primary (PTUR/YTUR) pulse rate speed.

111

Description Frame Sync Monitor Protection Activated

Possible Cause This alarm only occurs if the parameter FrameMonEn has been enabled. An alarm indicates that the

communication with the controller was lost for at least five consecutive frames after the I/O pack was online. The alarmclears if the frame synch is established for at least 60 seconds.

Solution Verify that the IONET is healthy. This indicates that the I/O pack is not synchronized with the Mark VIe

start-of-frame signal.

112-114

Description Overspeed [ ] firmware setpoint configuration error

Possible Cause There is a firmware over-speed limit mismatch between IO signal space limit and the configuration. Thecurrent configuration file downloaded from the ToolboxST application has a different over-speed limit than the IO signalOS1_Setpoint.

Solution Change the output signal designated in OS1_Setpoint (Vars-Speed tab) to match the configuration value

OS_Setpoint (Pulse Rate tab).


115-117

Description Overspeed [ ] hardware setpoint configuration error

Possible Cause There is a hardware over-speed limit mismatch between IO signal space limit and the configuration. The

current configuration file downloaded from the ToolboxST application has a different over-speed limit than the IO signal

OSHW_Setpoint1.

Solution Change the output signal designated in OSHW Setpoint [ ] to match the configuration value in HWOS_Setpoint(Pulse Rate tab).

118-120

Description Overspeed [ ] hardware setpoint changed after power up

Possible Cause This alarm always occurs when Pulse Rate [ ] HWOS_Setpoint is changed and downloaded to the I/O

pack after the turbine has started.

Solution Confirm that the limit change is correct. Restart the I/O pack to force the hardware overspeed to re-initializethe limit.

121

Description TREA - K1 solid state relay shorted

Possible Cause The TREA provides voltage-based detection of relays that remain in the energized position in the six votingcontacts used to provide K1. Zero voltage has been detected on one or more contacts of K1 when voltage should be present.

Solution Replace the TREA.

122

Description TREA - K2 solid state relay shorted

Possible Cause TREA provides voltage based detection of relays that remain in the energized position in the six voting

contacts used to provide K2. Zero voltage has been deleted on one or more contacts of K2 when voltage should be present.


123

Description LED - trip fault detected

Possible Cause The TRIP LED is lit on the pack because of a detected Trip condition. The LedDiag parameter mustbe set to True to get this alarm.

Solution

• Verify the configuration of the LedDiag parameter.• The condition leading to a trip condition must be cleared, and a master reset issued.

124

Description LED - Overspeed fault detected

Possible Cause The Overspeed LED is lit on the pack because of a detected Trip condition. The LedDiag parameter mustbe set to True to get this alarm.

Solution



125

Description LED - Estop detected

Possible Cause The Estop LED is lit on the pack because of a detected Estop signal. The LedDiag parameter must

be set to True to get this alarm.

Solution

• Verify the configuration of the LedDiag parameter.• Remove the Estop condition, and issue a master reset.

126

Description LED - Synch fault detected

Possible Cause The Synch LED is lit on the pack because of a failure to synchronize. The LedDiag parameter must


Solution

• Verify the configuration of the LedDiag parameter.• Issue a master reset to clear the alarm until the next failed attempt to synchronize.

127

Description WREA - K3 solid state relay shorted

Possible Cause WREA provides voltage based detection of "stuck-on" relays in the six voting contacts used to provide K3.

Zero voltage has been deleted on one or more contacts of K3 when voltage should be present.

Solution Replace WREA

224-239

Description Input Signal [ ] Voting Mismatch, Local=[ ], Voted=[ ]

Possible Cause A problem exists with a status input between the R, S, and T I/O packs and one of the following:* the device

• the connections to the terminal board

• the terminal board

Solution

• Adjust the TMR threshold limit or correct the cause of the difference.• Verify that the R, S, and T I/O pack configurations are equal to the ToolboxST configuration.

• Check the I/O pack power and the networking.• Check the I/O pack mounting on terminal board.• Verify the operation of the device generating the specified signal.

• Verify the terminal board wiring and connections.• Replace the I/O pack.


1064-1255

Description Logic Signal [ ] Voting Mismatch

Possible Cause A problem exists with a status input between the R, S, and T I/O packs and one of the following:* the device



Solution

• Verify that the R, S, and T I/O pack configurations are equal to the ToolboxST configuration.

• Check the I/O pack power and the networking.• Check the I/O pack mounting on the terminal board.• Verify the operation of the device generating the specified signal.



PPRF Specific AlarmsThe following alarms are specific to the PPRF I/O pack.

32

Description Configuration Incompatible: Old - [ ]; New - [ ].

Possible Cause An online load was attempted on a configuration change that requires a reboot.

Solution Rebuild and download the firmware and configuration to the pack.

35

Description PROFIBUS module upgrade failure.

Possible Cause A malfunction occurred when a new PROFIBUS module firmware file was being loaded to the PROFIBUSmodule.

Solution

• Rebuild and download the firmware to the PPRF.• If the problem persists, replace the pack.

36

Description PROFIBUS module access failure - Unable to download configuration.

Possible Cause A malfunction occurred when a new PROFIBUS configuration was being loaded to the PROFIBUS module.

Solution

• Rebuild and download the firmware to the PPRF.

• If the problem persists, replace the pack.

37

Description Bad configuration loaded to PROFIBUS module.

Possible Cause Invalid PROFIBUS configuration files were downloaded to the PROFIBUS module. This causes the

PROFIBUS module to not reach the RUN status, which is generally reached when a valid configuration has been processed.

Solution



38

Description Unable to communicate with PROFIBUS module.

Possible Cause The PROFIBUS host watchdog (a heartbeat between the pack processor and PROFIBUS module)

could not be activated.

Solution




39

Description PROFIBUS module failure.

Possible Cause From the PPRF firmware perspective, the PROFIBUS watchdog timed out (indicating failure of thePROFIBUS firmware).

Solution


40

Description PROFIBUS module failure - Module shutdown.

Possible Cause The PROFIBUS module has shut down, indicated by a loss of READY/RUN. PROFIBUS READY indicatesthat the firmware is running, and RUN indicates that a valid configuration has been processed. Loss of READY/ RUN

implies that the PROFIBUS module has shut down.

Solution

• Cycle power on the pack.• If the problem persists, replace the pack.

41

Description PROFIBUS module unable to become active master.

Possible Cause This is applicable to redundant configurations only. On startup, a malfunction occurred in making the

PPRF the active PROFIBUS master.

Solution


42

Description PROFIBUS module unable to become backup master.

Possible Cause This is applicable to redundant configurations only. On startup, a malfunction occurred in making the

PPRF the backup PROFIBUS master.

Solution


43

Description Unable to obtain diagnostic indication from PROFIBUS module.

Possible Cause The PROFIBUS module may have failed.

Solution



44

Description PROFIBUS diagnostic present.

Possible Cause A PROFIBUS diagnostic has been received from a slave device.

Solution

• Refer to the Advanced Diagnostics tool within the ToolboxST application to determine the cause of the diagnostic.

• Identify which slave device is generating the diagnostic.• Determine and resolve the issue with the slave device. Refer to the slave device documentation.

45

Description Error obtaining PROFIBUS diagnostic.

Possible Cause A malfunction occurred while obtaining a PROFIBUS diagnostic message from the PROFIBUS module.

Solution

• Rebuild and download firmware to the PPRF.

• If problem persists, replace pack

46

Description Error interpreting PROFIBUS diagnostic message.

Possible Cause A malformed PROFIBUS diagnostic was received from the PROFIBUS module.

Solution


47

Description Firmware mismatch in redundant PPRF packs.

Possible Cause This is applicable to redundant configurations only. The firmware version of one of the redundant PPRF

I/O packs does not match that of the other I/O pack.

Solution

• Verify that both packs are powered and sending data to the controller.• Download the firmware and configuration to the I/O packs.

• Replace the faulty Ethernet cable from the pack to the IONET network switch.• Replace the pack.• If the network switch is faulty, place the pack’s Ethernet cable into an empty switch port. If the problem persists,

replace the network switch.

48

Description Redundant PPRF pack initialization error.

Possible Cause A redundant PPRF I/O pack is not receiving peer-to-peer communications from the other redundant I/Opack. The redundant PPRF I/O packs will not go online unless peer-to-peer communication is healthy.

Solution

• Verify that both packs are powered.

• Download the firmware and configuration to the I/O packs.• Replace the faulty Ethernet cable from the pack to the IONET network switch.• Replace the pack.

• If the network switch is faulty, place the pack’s Ethernet cable into an empty switch port. If the problem persists,replace the network switch.


49

Description Redundant PPRF pack peer-to-peer communication timeout.

Possible Cause A redundant PPRF I/O pack is not receiving peer-to-peer communications from the other redundantI/O pack.

Solution

• Verify that both packs are powered and sending data to the controller.• Download the firmware and configuration to the I/O packs.• Replace the faulty Ethernet cable from the pack to the IONET network switch.

• Replace the pack.• If the network switch is faulty, place the pack’s Ethernet cable into an empty switch port. If the problem persists,

replace the network switch.

50

Description Active master PPRF PROFIBUS communication failure.

Possible Cause This is applicable in redundant configurations only. The master PPRF lost communications with the

PROFIBUS network.

• The PROFIBUS cable(s) may be faulty.• The terminating resistors on the PROFIBUS cable(s) may be configured incorrectly.

• There may be a hardware failure.

Solution

• Verify that the PROFIBUS cables are connected securely.• Verify that the terminator resistor is configured correctly for the PROFIBUS network. The terminating resistors must

be set at the PPRF pack and at the END of the PROFIBUS network only.• Replace the PROFIBUS network cable.• Replace the pack.

51

Description Backup master PPRF PROFIBUS communication failure.

Possible Cause This is applicable in redundant configurations only. The master PPRF lost communications with the

PROFIBUS network.

• The PROFIBUS cable(s) may be faulty.• The terminating resistors on the PROFIBUS cable(s) may be configured incorrectly.• There may be a hardware failure.

Solution

• Verify that the PROFIBUS cables are connected securely.• Verify that the terminator resistor is configured correctly for the PROFIBUS network. The terminating resistors must

be set at the PPRF pack and at the END of the PROFIBUS network only.• Replace the PROFIBUS network cable.• Replace the pack.

52

Description Invalid PROFIBUS module firmware detected.

Possible Cause The PROFIBUS module firmware does not match the hardware.

Solution



PPRO Specific AlarmsThe following alarms are specific to the PPRO I/O pack.

40

Description Contact Excitation Voltage Test Failure.

Possible Cause Voltage for the contact inputs on the trip board is not within published limits.

Solution Check source of contact excitation voltage applied to trip board.

50

Description Main Terminal Board Mismatch.

Possible Cause The terminal board configured in the ToolboxST application does not match the actual hardware.

Solution

• Verify that the ToolboxST configuration matches the actual hardware. Build and download the configuration to the

I/O pack.

51

Description Trip Board Mismatch.

Possible Cause The trip board configured in the ToolboxST application does not match the actual trip board hardware.

Solution

• Verify that the ToolboxST configuration matches the actual hardware. Build and download the configuration to theI/O pack.

69-71

Description Trip Relay (ETR) Driver [ ] does not match commanded state.

Possible Cause The driver output of the I/O pack for Emergency Trip Relay 1 (K1), ETR2 (K2), or ETR3 (K3) does not

match the commanded state. This indicates that the I/O pack does not see the relay command going out the DC-62

connector into the expected terminating impedance on the trip board.

Solution

• Check the I/O pack connector seating on the terminal board.

• Check the trip board cable seating (if not TREA) and the cable integrity.• Replace the cable, the trip board, the main terminal board, and the I/O pack.

72-74

Description Econ Relay Driver [ ] does not match commanded state.

Possible Cause The driver output of the I/O pack for Economizing Relay KE1, KE2, or KE3 does not match thecommanded state. This indicates that the I/O pack does not see the relay command going out the DC-62 connector into

the expected terminating impedance on the trip board.

Solution


• Replace the cable, the trip board, the main terminal board, and the I/O pack.


75

Description Servo Clamp Relay Driver does not match commanded state.

Possible Cause The driver output of I/O pack for K4CL does not match the commanded state. This indicates that I/O packdoes not see the relay command going out the DC-62 connector into the expected terminating impedance on the trip board.

Solution

• Check the I/O pack connector seating on terminal board.• Check the trip board cable seating and the cable integrity.• Replace the cable, the trip board, the main terminal board, and the I/O pack.

76

Description K25A Relay (synch check) Driver does not match commanded state.

Possible Cause The driver output of I/O pack for K25A does not match the commanded state. This indicates that I/O pack

does not see the relay command going out the DC-62 connector into the expected terminating impedance on the trip board.

Solution



83-85

Description Trip Relay (ETR) Contact [ ] does not match commanded state.

Possible Cause Relay feedback from Emergency Trip Relay 1 (K1), ETR2 (K2), or ETR3 (K3) does not match thecommanded state. This indicates that the relay feedback from the trip board does not agree with the commanded state.

Solution Check the trip board relays, as well as the cable from trip board to main terminal board (if not TREA).

86-88

Description Econ Relay Contact [ ] does not match commanded state.

Possible Cause The relay feedback from Economizing Relay 1 (KE1), KE2, or KE3 does not match the commanded state.

This indicates that the relay feedback from the trip board does not agree with the commanded state.

Solution Check the trip board relays, as well as the cable from trip board to main terminal board.

89

Description Servo Clamp Relay Contact does not match commanded state.

Possible Cause The relay feedback from K4CL does not match the commanded state. This indicates that the relayfeedback from the trip board does not agree with the commanded state.

Solution

• Check the I/O pack connector seating on the terminal board.• Check the trip board cable seating and the cable integrity.• Replace the cable, the trip board, the main terminal board, and the I/O pack.


90

Description K25A Relay Coil Feedback does not match commanded state.

Possible Cause The relay feedback from K25A does not match the commanded state. This indicates that the relay

feedback from the trip board does not agree with the commanded state. Relay feedback is taken after hardware commandvoting on the trip terminal board has occurred; therefore, a probable cause is that one I/O pack is not commanding the samestate as the other two I/O packs.

Solution

• Confirm that the TMR packs are commanding the same state for K25A.• Check the I/O pack connector seating on the terminal board.• Check the trip board cable seating and the cable integrity.


97

Description Solenoid Power Source is missing.

Possible Cause Solenoid power monitoring provided by the trip board indicates the absence of power.

Solution

• Check the source of solenoid power.

• Confirm that the wiring between the trip boards is correct.

99-101

Description Solenoid Voltage [ ] does not match commanded state.

Possible Cause The solenoid voltage associated with K1-K3 does not match the commanded state. K1-K3 are closed,but no voltage is detected on the solenoid.

Solution This may be due to removal of solenoid voltage through another means when the I/O pack expects to see

it. Review the system-level trip circuit wiring and confirm the voltage should be present if the I/O pack energizes the

associated trip relay.

105

Description TREL/S, Solenoid Power, Bus A, Absent.

Possible Cause TRES/TREL solenoid power A is absent. Solenoid power does not match the solenoid state for longerthan 40 milliseconds.

Solution


• Check the field wiring.• Check the solenoid.


106

Description TREL/S, Solenoid Power, Bus B, Absent.

Possible Cause TRES/TREL solenoid power B is absent. The solenoid power does not match the solenoid state for

longer than 40 milliseconds.

Solution


• Check the field wiring.

• Check the solenoid.• Replace the terminal board.


107

Description TREL/S, Solenoid Power, Bus C, Absent.

Possible Cause TRES/TREL solenoid power C is absent. The solenoid power does not match The solenoid state forlonger than 40 milliseconds.

Solution

• Check power applied to the trip board.• Check the field wiring.• Check the solenoid.


108

Description Control Watchdog Protection Activated.

Possible Cause This alarm only occurs if the parameter ContWdogEn has been enabled. An alarm indicates that thevariable ContWdog has not changed for five consecutive frames. The alarm clears if changes are seen for 60 seconds.

Solution Verify that the ContWdog is set up correctly in the ToolboxST application, and that the source of the signal

is changing the value at least once a frame.

109

Description Speed Difference Protection Activated.

Possible Cause This alarm only occurs if the parameter SpeedDifEnable has been enabled. An alarm indicates that the

difference between the output signal Speed1 and the first I/O pack pulse rate speed is larger than the percentage OS_DIFFfor more than three consecutive frames. The alarm clears if the difference is within limits for 60 seconds.

Solution Verify that the Speed1 signal is set up correctly in the ToolboxST and that the source of the signal reflects

the primary (PTUR/YTUR) pulse rate speed.

110

Description Stale Speed Protection Activated.

Possible Cause The speed trip protection may be stale. This alarm can only occur if the parameter StaleSpdEn has been

enabled. An alarm indicates that the variable Speed1 has not changed for five consecutive frames. The alarm clears ifthe speed dithers for 60 seconds.

Solution Verify that the Speed1 signal is set up correctly in the ToolboxST configuration, and that the source of the

signal reflects the primary (PTUR/YTUR) pulse rate speed.

111

Description Frame Sync Monitor Protection Activated.

Possible Cause This alarm only occurs if the parameter FrameMonEn has been enabled. An alarm indicates that the

communication with the controller was lost for at least five consecutive frames after the I/O pack was online. The alarmclears if the frame synch is established for at least 60 seconds.

Solution Verify that the IONET is healthy. This indicates that the I/O pack is not synchronized with the Mark VIe

start-of-frame signal.


112-114

Description Overspeed [ ] firmware setpoint configuration error.

Possible Cause There is a firmware over-speed limit mismatch between IO signal space limit and the configuration. The

current configuration file downloaded from the ToolboxST application has a different over-speed limit than the IO signalOS1_Setpoint.

Solution Change the output signal designated in OS1_Setpoint (Vars-Speed tab) to match the configuration value

OS_Setpoint (Pulse Rate tab).

115-117

Description Overspeed [ ] hardware setpoint configuration error.

Possible Cause There is a hardware over-speed limit mismatch between IO signal space limit and the configuration. The

current configuration file downloaded from the ToolboxST application has a different over-speed limit than the IO signalOSHW_Setpoint1.

Solution Change the output signal designated in OSHW Setpoint [ ] to match the configuration value in HWOS_Setpoint(Pulse Rate tab).

118-120

Description Overspeed [ ] hardware setpoint changed after power up.

Possible Cause This alarm always occurs when Pulse Rate [ ] HWOS_Setpoint is changed and downloaded to the I/O

pack after the turbine has started.

Solution Confirm that the limit change is correct. Restart the I/O pack to force the hardware overspeed to re-initializethe limit.

121

Description TREA - K1 solid state relay shorted.

Possible Cause The TREA provides voltage-based detection of relays that remain in the energized position in the six voting

contacts used to provide K1. Zero voltage has been detected on one or more contacts of K1 when voltage should be present.


122

Description TREA - K2 solid state relay shorted.

Possible Cause TREA provides voltage based detection of relays that remain in the energized position in the six votingcontacts used to provide K2. Zero voltage has been deleted on one or more contacts of K2 when voltage should be present.


123

Description LED - trip fault detected.

Possible Cause The TRIP LED is lit on the pack because of a detected Trip condition. The LedDiag parameter mustbe set to True to get this alarm.

Solution



124

Description LED - Overspeed fault detected.

Possible Cause The Overspeed LED is lit on the pack because of a detected Trip condition. The LedDiag parameter must


Solution


125

Description LED - Estop detected.

Possible Cause The Estop LED is lit on the pack because of a detected Estop signal. The LedDiag parameter must


Solution

• Verify the configuration of the LedDiag parameter.• Remove the Estop condition, and issue a master reset.

126

Description LED - Synch fault detected.

Possible Cause The Synch LED is lit on the pack because of a failure to synchronize. The LedDiag parameter must


Solution

• Verify the configuration of the LedDiag parameter.• Issue a master reset to clear the alarm until the next failed attempt to synchronize.

224-239


Possible Cause A problem exists with a status input between the R, S, and T I/O packs and one of the following:

• the device

• the connections to the terminal board• the terminal board

Solution

• Adjust the TMR threshold limit or correct the cause of the difference.• Verify that the R, S, and T I/O pack configurations are equal to the ToolboxST configuration.• Check the I/O pack power and the networking.

• Check the I/O pack mounting on terminal board.• Verify the operation of the device generating the specified signal.• Verify the terminal board wiring and connections.



1064-1255


Possible Cause A problem exists with a status input between the R, S, and T I/O packs and one of the following:

• the device



Solution

• Verify that the R, S, and T I/O pack configurations are equal to the ToolboxST configuration.

• Check the I/O pack power and the networking.• Check the I/O pack mounting on the terminal board.• Verify the operation of the device generating the specified signal.



PRTD Specific AlarmsThe following alarms are specific to the PRTD I/O pack.

32-39

Description RTD [ ] Voltage out of range - Raw Counts [ ].

Possible Cause

• There is a break in the RTD wiring/cabling or high impedance is blocking the signal.• There is a break in the connections to the terminal board.

• The RTD device has failed.• Internal PRTD hardware problem.

Solution

• Check the field wiring for an open circuit or high impedance.

• Verify the proper connections to the terminal board.• Check the RTD for proper operation.


64-71

Description RTD [ ] Current out of range - Raw Counts [ ].

Possible Cause

• There is a break in the RTD wiring/cabling open or high impedance is blocking the signal.• There is a break in the connections to the terminal board.• The current source on the PRTD has failed.

• The measurement device has failed.

Solution

• Check the field wiring for an open circuit or high impedance.• Verify the proper connections to the terminal board.


96-103

Description RTD [ ] Resistance out of range ([ ] Ohms).

Possible Cause

• The wrong type of RTD has been configured or selected by default.• High-resistance values were created by high voltage and/or low current.

Solution

• Verify that the RTD-type configuration matches the attached device type.• Check the field wiring for high impedance.

128

Description Internal reference out of range - Voltage circuit.

Possible Cause The internal PRTD hardware checks have failed.



144

Description Internal reference out of range - Current circuit.

Possible Cause The internal PRTD hardware checks have failed.



PSCA Specific AlarmsThe following alarms are specific to the PSCA I/O pack.

32-67

Description Modbus Port #[ ] Device/Station #[ ] Communication Failure - No Response.

Possible Cause A command was sent to a field device, but no response was received.

Solution

• Verify that the serial or Ethernet cable is connected to the field device.

• Verify that the device is powered-on and configured for the correct station ID.• For serial connections, verify that the baud rate and parity are set correctly.• For Ethernet connections, verify that the IP address is set correctly.

72-107

Description Modbus Port #[ ] Device/Station #[ ] Communication Failure - Bad Data.

Possible Cause The field device responded, but could not provide data for one or more points.

Solution

• Verify that the point mapping in the ToolboxST configuration matches the Modbus slave field device.• Verify that float values request all 32 bits of the value. A float value requires two registers.

108-113

Description Configuration Problem Port #[ ].

Possible Cause The configuration file downloaded from the Toolbox ST application contained an error.

Solution

• Verify that the I/O and configuration compatibility codes agree between the ToolboxST configuration and the PSCA.

• Build and download the firmware and the configuration to the PSCA.• If diagnostic persists, reboot the PSCA.

114-119

Description Electric Drive Port #[ ] Save Command failed.

Possible Cause The last parameter set saved to the Kollmorgan drive was not successful.

Solution The verify step failed after attempting to save parameters to the drive. Retry the Save command to the Kollmorgandrive.


PSVO Specific AlarmsThe following alarms are specific to the PSVO I/O pack.

33-40

Description LVDT #[ ] RMS voltage for Regulator [ ] out of limits.

Possible Cause

• Excitation to LVDT, faulty transducer, or open or short-circuit.• LVDT [ ] input to the analog to digital converter exceeded the converter limits.

• LVDT scaling configuration (MnLVDT[ ]_Vrms, MxLVDT[ ]_Vrms) has not been calibrated.

Solution

• Check the field wiring the between TSVC excitation output and the LVDT including shields.

• Check for approximately 7 Vrms at the TSVC Excitation screws.

• Check the feedback wire between LVDT and TSVC LVDT Input connections (including shields).• Check the LVDT for mechanical integrity.

• Calibrate the regulator with the proper LVDTs.

• Verify the configuration limits, MnLVDT[ ]_Vrms and MxLVDT[ ]_Vrms for the affected regulator.• Problem is usually not a PSVO or terminal board failure if other LVDT inputs are working correctly.

45

Description Calibration Mode Enabled.

Possible Cause

• Variable CalibEnab# set to True and user has selected the Calibration Mode button in the Calibrate Valve dialog.

Solution

• This alarm is active to annunciate that the pack is in a special mode where servo suicide protection has been disabled,the user needs to take special precautions in this mode.

• Exit calibration mode and set CalibEnab# to False.

46

Description PSVO card not online, Servos suicided.

Possible Cause Servo outputs suicided because I/O pack offline

Solution

• Verify that the controller is online.• Verify that network connections to the pack are okay.

47-48

Description Servo current #[ ] disagrees w/ ref, suicided.

Possible Cause

• Possible open circuit in servo current loop.


• Servo current feedback does not match servo current command within specified (Cur_Suicide) percentage and

EnablCurSuic is enabled.• Jumper configuration set incorrectly.• Open circuit to servo coil.

• I/O pack hardware failure.

Solution

• Check the field wiring for an open loop.

• Check for servo open coil.• Verify the proper settings of TSVC hardware jumpers.• Verify the proper setting of configuration parameters and tuning of servo.

• Replace the PSVO and WSVO.

52-53

Description Servo current #[ ] short circuit.

Possible Cause

• Servo short circuit detection enabled (ShrtCoildiag) and low resistance measured.• Possible shorted servo coil.• Shorted coil threshold (RcoilShort) or shorted coil time limit (RShrtTimeLim) set incorrectly.

Solution

• Verify the proper servo ohm value.• Set AV_Selector to the value Coil_OHMS (build/download), and view the measured coil resistance displayed in

Servo#MonitorNV_R,S,T.

• Verify that the measured resistance matches the actual coil resistance, and is above RcoilShort value.• Verify that the RcoilShort is set to the proper value. Re-calibrate to update measured resistance values.

• Verify the proper setting on the Servo_MA_Out parameter.

• Verify that the terminal board jumpers match the configuration.

57-58

Description Servo current #[ ] open circuit.

Possible Cause

• Servo short circuit detection enabled (OpenCoildiag) and low resistance measured.• Possible open servo coil.

• Open coil threshold (RcoilOpen) or open coil time limit (RopenTimeLim) set incorrectly.

Solution

• Check field wiring for possible open circuit. Verify the proper servo ohm value.• Set AV_Selector to value Coil_OHMS (build/download) and view the measured coil resistance displayed in

Servo#MonitorNV_R,S,T.• Verify that the measured resistance matches actual coil resistance, and is below value.• Verify that the RcoilOpen is set to the proper value. Re-calibrate to update measured resistance values.

• Verify that the terminal board jumpers match the configuration.

62-63

Description Servo posititon #[ ] fdbk out of range, suicided.

Possible Cause

• LVDT position feedback outside specified range.• LVDT inputs not calibrated or Vrms limits incorrect.


Solution

• Check field wiring including shields and LVDT excitation. Problem is usually not a PSVO or terminal board failureif other LVDT inputs are working correctly.


• Calibrate the servo regulator with the proper LVDT.• Verify that LVDT_Margin is set to the proper value.

67-68

Description Regulator #[ ] configuation error.

Possible Cause

• Configuration settings incorrect for specified regulator type.

Solution

• Verify the regulator configuration settings.

• Verify that the LVDT input setup (Max/Min limits) matches the regulator configuration.• Verify that the configured regulators are used by the proper servos.

72

Description Internal calibration reference voltage range fault.

Possible Cause

• Internal voltage reference values out of range.

Solution Replace I/O pack hardware.

73-74

Description Lvdt excitation #[ ] voltage out of range.

Possible Cause

• Possible short in excitation voltage.• Excitation voltage too low.

Solution

• Disconnect LVDT excitation from terminals and check that excitation voltage at TSVC screws is approximately 7 Vrms.

• If proper voltage is verified, check field wiring from terminal board to the LVDT sensor and LVDT electrical integrity forshorted coil.

• If improper voltage at screws, replace PSVO and WSVO, then TSVC.

77

Description Servo Output Assignment Mismatch.

Possible Cause

• Regulator types 2_LVpilotCyl and 4_LVp/cylMAX require two servos assigned to regulator. These servos mustmatch in configured parameters.

Solution


• Verify that both servos specify the configured regulator.• Verify that servo configuration parameters (Servo_MA_Out) are both set to the same value.

90-97

Description Power supply [ ] V is out of range, voltage = [ ].

Possible Cause

• Specified internal power supply voltage incorrect.

Solution

• Replace the WSVO.

• If the problem still exists, replace the PSVO.

108-109

Description LVDT configuration error on Regulator #[ ].

Possible Cause

• For regulators 4_LV_LM and 4_LV_LMX, the configured LVDT V rms limits configured incorrectly for ratiometric LVDTs.

Solution

• Verify that ratiometric LVDT pairs have opposite V rms values in the Min/Max limits.

110-111

Description Servo Coil #[ ] not within resistance limits.

Possible Cause

• During calibration, the measured servo coil resistance was out of range.

Solution

• Verify that Servo_MA_Out setting matches the terminal board jumpers.• Verify servo coil resistance.

• Verify field wiring.

112-119

Description Regulator #[ ] Sensor #[ ] out of range.

Possible Cause

• LVDT position feedback is outside the specified range.• LVDT inputs have not been calibrated or V rms limits are incorrect.

Solution

• Check field wiring including shields and LVDT excitation. Problem is usually not a PSVO or terminal board failureif other LVDT inputs are working correctly.


• Calibrate the servo regulator with the proper LVDT.• Verify that LVDT_Margin is set to the proper value.

120-121

Description Servo #[ ] Suicided.

Possible Cause

• Servo suicided.• Regulator feedback out of range.

• Servo Current feedback differs from Servo Current command.• Open or shorted coil detected.


Solution

• LVDT feedback issue: Check LVDT connections.• Check LVDT mechanical integrity to the valve.• Check for wiring of servo output loop for open or short circuit.

• Check for a short or an open servo coil.

128


Possible Cause N/A

Solution N/A

192-215

Description LVDT #[ ] RMS voltage for Monitor [ ] out of limits.

Possible Cause

• Excitation to LVDT, faulty transducer, or open or short-circuit.• LVDT [ ] input to analog-to-digital converter exceeded converter limits.• LVDT scaling configuration (MnLVDT[ ]_Vrms, MxLVDT[ ]_Vrms) not calibrated.

Solution

• Check field wiring between the TSVC excitation output and LVDT, including shields.• Check for approximately seven Vrms at the TSVC excitation screws.

• Check the feedback wire between the LVDT and TSVC LVDT input connections, including shields.• Check the LVDT for mechanical integrity.• Verify the configuration limits, MnLVDT[ ]_Vrms and MxLVDT[ ]_Vrms for the affected regulator.

• Problem is usually not a PSVO or terminal board failure if other LVDT inputs are working correctly.

224-247


Possible Cause Voter disagreement between R,S and T packs.

Solution Adjust the specified parameter below for each input type:

• If input variable is FlowRate[ ], adjust the TMR_DiffLimt.• If input signal is Reg[ ]_Fdbk, adjust the TMR_DiffLimt on the Regulators tab.

• If input variable is Mon[ ], adjust the TMR_DiffLimt on the Monitors tab.• If input variable is ServoOutput[ ], adjust the TMR_DiffLimt.• Check for a mismatch in the coil resistance.

• Reg[ ]_Gain is set too high for the specified TMR_DiffLimt value.

1050

Description R Detects S ComFailure on channels 1+2.

Possible Cause

• S pack serial communication to R pack failed.• S pack rebooted.

• S pack not connected properly.

Solution


• Verify that the S PSVO is seated correctly on the terminal board.• Check the S pack for other diagnostics to determine the cause of the reboot.• Replace the S pack.


1051 - 1052

Description R Detects S ComError on channel [ ].

Possible Cause

• S pack serial communication to R pack failed.• S pack rebooted.• S pack not connected properly.

Solution

• Verify that the S PSVO is seated correctly on the terminal board.• Check S pack for other diagnostics to determine cause of reboot.

• Replace the S pack.


1053

Description R Detects T ComFailure on channels 1+2.

Possible Cause

• T pack serial communication to R pack failed.• T pack rebooted.

• T pack not connected properly.

Solution

• Verify that the T PSVO is seated correctly on the terminal board.• Check the T pack for other diagnostics to determine the cause of the reboot.

• Replace the T pack.• Replace the terminal board.

1054 - 1055

Description R Detects T ComError on channel [ ].

Possible Cause

• T pack serial communication to R pack failed.• T pack rebooted.

• T pack not connected properly.

Solution

• Verify that the T PSVO is seated correctly on the terminal board.


• Check the T pack for other diagnostics to determine the cause of the reboot.• Replace the T pack.• Replace the terminal board.

1056

Description R Detects R ComFailure on channels 1+2.

Possible Cause R Pack serial communication failure on R feedback (indicates internal hardware failure).

Solution

• Verify that the R PSVO is seated correctly on the terminal board.• Replace the R pack.• Replace the terminal board.

1057 - 1058

Description R Detects R ComError on channel [ ].

Possible Cause R Pack serial communication failure on R feedback. Indicates an internal hardware failure.

Solution

• Verify that the R PSVO is seated correctly on the terminal board.• Check R pack for other diagnostics to determine cause of reboot.• Replace the R pack.


1059

Description S Detects R ComFailure on channels 1+2.

Possible Cause

• R pack serial communication to S pack failed.• R pack rebooted.• R pack not connected properly.

Solution

• Verify that the R PSVO is seated correctly on the terminal board.• Check the R pack for other diagnostics to determine the cause of the reboot.

• Replace the R pack.• Replace the terminal board.

1060 - 1061

Description S Detects R ComError on channel [ ].

Possible Cause

• R pack serial communication to S pack failed.• R pack rebooted.

• R pack not connected properly.

Solution

• Verify that the R PSVO is seated correctly on the terminal board.

• Check the R pack for other diagnostics to determine the cause of the reboot.


• Replace the R pack.• Replace terminal board.

1062

Description S Detects T ComFailure on channels 1+2.

Possible Cause

• T pack serial communication to S pack failed.• T pack has rebooted.

• T pack is not connected properly.

Solution


• Check the T pack for other diagnostics to determine the cause of the reboot.• Replace the T pack.• Replace the terminal board.

1063 - 1064

Description S Detects T ComError on channel [ ].

Possible Cause

• T pack serial communication to S pack failed.

• T pack rebooted.• T pack not connected properly.

Solution


• Replace the T pack.• Replace the terminal board.

1065

Description S Detects S ComFailure on channels 1+2.

Possible Cause S Pack serial communication failure on S feedback (indicates internal hardware failure).

Solution

• Verify that the S PSVO is seated correctly on the terminal board.

• Replace the S pack.• Replace the terminal board.

1066 - 1067

Description S Detects S ComError on channel [ ].

Possible Cause S Pack serial communication failure on S feedback (indicates internal hardware failure).

Solution

• Verify that the S PSVO is seated correctly on the terminal board.• Replace the S pack.


1068

Description T Detects R ComFailure on channels 1+2.


Possible Cause

• R pack serial communication to T pack failed.• R pack rebooted.• R pack not connected properly.

Solution

• Verify that the R PSVO is seated correctly on the terminal board.• Check the R pack for other diagnostics to determine the cause of the reboot.• Replace the R pack.


1069 - 1070

Description T Detects R ComError on channel [ ].

Possible Cause

• R pack serial communication to T pack failed.• R pack rebooted.

• R pack not connected properly.

Solution

• Verify that the R PSVO is seated correctly on the terminal board.• Check the R pack for other diagnostics to determine the cause of the reboot.

• Replace the R pack.• Replace the terminal board.

1071

Description T Detects S ComFailure on channels 1+2.

Possible Cause

• S pack serial communication to T pack failed.• S pack rebooted.

• S pack not connected properly.

Solution


• Check the S pack for other diagnostics to determine the cause of the reboot.• Replace the S pack.• Replace the terminal board.

1072 - 1073

Description T Detects S ComError on channel [ ].

Possible Cause

• S pack serial communication to T pack failed.

• S pack rebooted.• S pack not connected properly.

Solution


• Check the S pack for other diagnostics to determine the cause of the reboot.• Replace the S pack.


• Replace terminal board.

1074

Description T Detects T ComFailure on channels 1+2.

Possible Cause T Pack serial communication failure on T feedback (indicates internal hardware failure).

Solution

• Verify that the T PSVO is seated correctly on the terminal board.• Replace the T pack.• Replace the terminal board.

1075 - 1076

Description T Detects T ComError on channel [ ].

Possible Cause T Pack serial communication failure on T feedback (indicates internal hardware failure).

Solution

• Verify that the T PSVO is seated correctly on the terminal board.• Replace the T pack.• Replace the terminal board.


PTCC Specific AlarmsThe following alarms are specific to the PTCC I/O pack.

32-43

Description Thermocouple[ ] input voltage exceeds HW limit ([ ]).

Possible Cause

• Thermocouple millivolt input to the analog-to-digital converter exceeded the converter limits and will be removedfrom the scan.

Solution

• Check field wiring, including shields.• Check installation of the I/O pack on the terminal board. Problem is usually not a I/O pack or terminal board failure if

other thermocouples are working correctly.

80

Description Cold Junction [ ] input voltage exceeds HW limit ([ ]).

Possible Cause Cold junction input to the analog-to-digital converter exceeded the limits of the converter. If a cold

junctions fails, the CJ_Backup value is used.

Solution

• Check the mounting of the I/O pack on the terminal board.



92-103

Description Thermocouple [ ] value beyond range of configured TC type ([ ] deg).

Possible Cause

• Thermocouple mV input exceeded range of linearization (lookup) table for this TC type. Refer to documentation forspecified thermocouple ranges.

• Thermocouple configured as wrong type.• Board detected a thermocouple open, applied bias to circuit, driving it to a large negative number.• Stray voltage or noise caused the input to exceed its range.

Solution

• Check field wiring, including shields.• Check thermocouple for open circuit.• Verify that the thermocouple type matches the configuration.

• Measure incoming mV signal and verify that it is within the specified thermocouple range.

128


Possible Cause N/A

Solution N/A

160

Description Internal pack power supply not OK.

Possible Cause A power supply internal to the pack is not working properly. All thermocouple readings are suspect.

Solution Replace the pack.


161

Description Reference Voltage out of limits.

Possible Cause The reference voltage for the inputs is more than +/-5% beyond the expected value, indicating hardwarefailure.


163

Description Null Voltage out of limits.

Possible Cause The Null voltage for the inputs is more than +/-5% beyond the expected value, indicating hardware failure.


224-236


Possible Cause

• The specified input signal varies from the voted value of the signal by more than the TMR_DiffLimt.• A problem exists with the input, either from the device, the wire to the terminal board, or the terminal board.

Solution

• Verify that TMR_DiffLimt is set to the proper value.

• Check the grounding of the connected inputs and terminal board.• Reboot the pack.




PTUR Specific AlarmsThe following alarms are specific to the PTUR I/O pack.

32-34

Description Solenoid #[ ] Relay driver Feedback Incorrect.

Possible Cause The I/O pack monitors the relay command for the correct state and termination into the expected trip boardimpedance. The I/O pack internal feedback of relay command output does not match the desired state.

Solution

• Check the mounting of the I/O pack on the terminal board.• Check the cable from the TTUR to the trip board, if used.• Replace the I/O pack.

• Replace the TRPx trip board.

38-40

Description Solenoid #[ ] Contact Feedback Incorrect.

Possible Cause The contact state feedback from the trip board does not match the relay command.

Solution

• Check the mounting of the I/O pack on the terminal board.• Check the cable from the TTUR to the TRPx.

• Check the operation of the relay.

44

Description Trip Board Solenoid Power Absent.

Possible Cause The I/O pack has detected the absence of solenoid power as indicated by the connected TRPx board.

Solution

• Verify the TRPx on the J1 connector is receiving power.• Check the cabling to the TRPx.

• Replace the TRPx board.

46

Description TRPG Flame Detector Volts Lower than 314.9 V.

Possible Cause Nominal 335 V dc power enters the TRPG through the J3, J4, and J5 connectors. If the voltage is

less than 314.9 V dc, this fault is declared.

Solution

• If the voltage is below 314.9 V dc, check the power supply.

• Check the voltage on the TRPG. If the voltage is above 314.9 V dc, the monitoring circuitry on the TRPG or thecabling to the TRPG may be the problem.

47

Description TRPG Flame Detector Volts Higher than 355.1 V.

Possible Cause This power comes into the TRPG through the J3, J4, and J5 connectors. If the voltage is greater than355.1 V dc, this fault is declared.

Solution

• If the voltage is higher than 355.1 V dc, check the power supply.• Check the voltage on the TRPG. If the voltage is above 355 V, the monitoring circuitry on the TRPG or the cabling to

the TRPG may be the problem.


50

Description L3BKRGXS - Sync Check Relay Is Slow.

Possible Cause

• The K25 (auto sync) has picked up but the Sync check relay L3BKRGXS, known as K25A, on the TTUR has not

picked up.• There is no breaker closing voltage source.

Solution

• Attempt to perform a Sync Reset (set Synch_Reset to True).• Check the breaker to verify closure.• Replace the TTUR.

51

Description L3BKRGES - Auto Sync Relay Is Slow.

Possible Cause

• The Auto Sync relay L3BKRGES, also known as K25, on TTUR has not picked up when it should have.

• The K25P is not picked up.• There is no breaker closing voltage source.

Solution

• Attempt to perform a Sync Reset (set Synch_Reset to True).

• Check the breaker to verify closure.• Replace the TTUR.

52-53

Description Breaker #[ ] Slower Than Adjustment Limit Allows.

Possible Cause

• The self-adaptive function adjustment of the Breaker Close Time has reached the allowable limit and cannot make

further adjustments to correct the Breaker Close Time.• The breaker is experiencing a problem, or the operator should consider changing the configuration (both nominal close

time and self-adaptive limit in ms can be configured).

Solution

• Increase CBxCloseTime for the breaker in question.• Review breaker feedback timing to verify that it meets the documented specifications.• Verify that there are no interposing relays causing a delay.


54

Description Synchronization Trouble - K25 Relay Locked Up.

Possible Cause

• The K25 relay is picked up when it should not be.• K25 on TTUR is most likely stuck closed, or the contacts are welded together.

Solution

• Attempt to perform a Sync Reset (set Synch_Reset to True).• Isolate which relay (K25A or K25) is causing a problem by checking the diagnostics and correcting the source of the

issue.

• Replace TTUR.


55

Description Trip Board required by Main Terminal Board.

Possible Cause When the PTUR is used with a TTUR, a STURH3 or a STURH4 terminal board, an auxiliary trip board isrequired. However, the PTUR does not detect that a required trip board has been connected.

Solution

• Verify that the proper terminal board and trip board has been configured in the ToolboxST application. Rebuild theapplication, then download the firmware and application code to the affected I/O pack.

• Verify the trip board cable connections at both ends.

57

Description Hardware and Configuration Incompatibility - Main Terminal Board.

Possible Cause The PTUR configuration does not match the actual terminal board hardware.

Solution

• Verify that the ToolboxST configuration matches the actual hardware.• Rebuild the application, then download the firmware and application code to the affected I/O pack.• Verify that the PTUR is fully seated on the terminal board.

• Verify that the installed ToolboxST version supports the configured hardware.

58

Description Hardware and Configuration Incompatibility - Trip Board.

Possible Cause The PTUR configuration does not match the connected trip board.

Solution

• Review the hardware compatibility information and correct, if necessary.• Rebuild the application, then download the firmware and application code to the affected I/O pack.

• Verify the trip board cable connections at both ends.• Verify that the installed ToolboxST version supports the configured hardware.

61

Description TRPL/S Solenoid Power on Bus A is absent.

Possible Cause No solenoid power is detected on the TRPL/S bus A.

Solution

• Verify that power is applied to the terminal board.

• Verify that the DC37 cable is fully seated.• Replace the terminal board.

62

Description TRPL/S Solenoid Power on Bus B is absent.

Possible Cause No solenoid power is detected on TRPL/S bus B.

Solution




63

Description TRPL/S Solenoid Power on Bus C is absent.

Possible Cause No solenoid power is detected on TRPL/S bus C.

Solution



64-66

Description TRPL/S Solenoid #[ ] Voltage Mismatch.

Possible Cause Power is applied to the solenoid, but the voltage feedback is not detected.

Solution

• Verify that the J2 connector is fully seated between the primary and emergency trip boards.

• Replace the J2 cable.• Replace the TTUR.

67

Description Overspeed Trip.

Possible Cause

• The I/O pack has detected that a speed input has exceeded the overspeed threshold.

• The overspeed configuration is set too low.

• There is a noisy input signal.

Solution

• Verify the proper overspeed configuration.

• Check the speed sensor.• Determine the cause of the overspeed condition; for example, input signal, configuration, or noise.

68

Description TRPA - K1 solid state relay shorted.

Possible Cause TRPA provides voltage-based detection of stuck-on relays in the six voting contacts used to provide K1.Zero voltage has been detected on one or more contacts of K1 when voltage should be present.

Solution Replace the TRPA.

69

Description TRPA - K2 solid state relay shorted.

Possible Cause TRPA provides voltage-based detection of stuck-on relays in the six voting contacts used to provide K2.

Zero voltage has been deleted on one or more contacts of K2 when voltage should be present.

Solution Replace the TRPA.

70


Possible Cause The calibration reference voltage is beyond the expected value, indicating a hardware failure.

Solution

• Cycle power on the pack.



71


Possible Cause The calibration null voltage is beyond the expected value, indicating a hardware failure.

Solution

• Cycle power on the pack.• Replace the pack.

128-145


Possible Cause A problem exists with a status input between the R, S, and T I/O packs. This could be the device, the wireto the terminal board, or the terminal board.

Solution

• Verify that the R, S, and T I/O pack configurations are equal to the ToolboxST configuration.• Check the I/O pack power and networking.• Check the I/O pack mounting on the terminal board.

• Verify the operation of the device generating the specified signal.• Verify the terminal board wiring and connections.• Replace the I/O pack.

224-252


Possible Cause A problem exists with a status input between the R, S, and T I/O packs. This could be the device, the wire

to the terminal board, or the terminal board.

Solution

• Verify that the R, S, and T I/O pack configurations are equal to the ToolboxST configuration.• Check the I/O pack power and networking.

• Check the I/O pack mounting on the terminal board.• Verify the operation of the device generating the specified signal.• Verify the terminal board wiring and connections.



PVIB Specific AlarmsThe following alarms are specific to the PVIB I/O pack.

32

Description Channel [ ] A/D Converter Calibration Failure.

Possible Cause The board failed to auto-calibrate when powered on.

Solution Replace the PVIB I/O pack.

33-45

Description TVBA Analog Input [ ] exceeded limits.

Possible Cause

• The terminal point voltage is outside of limits for the sensor type.• The Bias level (DC offset), Gain, or sensor limits are improperly set for the sensor/channel.

Solution

• Verify that the sensor configuration is correct.• Verify the proper voltage at the terminal board point on the sensor.

• Replace the PVIB I/O pack or terminal board.

46

Description Channel [ ] D/A Converter Calibration Failure.



47

Description PVIB Initialization Error Detected.

Possible Cause The board failed.


48

Description PVIB internal data transfer error - Expected ID [ ] Read ErrCntr/ID [ ].

Possible Cause There is a board failure or software process conflict that may be cleared by a hard reset.

Solution

• Cycle power on the PVIB I/O pack.• Replace the PVIB I/O pack.

49

Description PVIB internal hardware failure - Status [ ].



50

Description Channel [ ] DC Isolation Test Failure.




51

Description PVIB processor failure - Status [ ].



52-64

Description TVBA Analog Input [ ] Open Circuit ([ ] Volts).

Possible Cause An open circuit has been detected on the terminal board based on the sensor type.

Solution

• Check the wiring between the terminal board and the sensor.

• Check the sensor for proper operation.• Replace the terminal board.

65

Description Negative 28 Volt Power Low ([ ] Counts).

Possible Cause The terminal board failed.

Solution


• Replace the PVIB I/O pack.

66

Description Dual Ethernets not supported with 10 ms frame rate.

Possible Cause The second Ethernet port is connected, but not supported for a 10 ms frame rate.

Solution Remove the second Ethernet connection to the I/O pack.

67




68

Description Internal PVIB temperature limit exceeded ([ ] deg F).

Possible Cause

• The cabinet temperature is too high.• The board overheated.

• If the cabinet temperature is within the specified temperature limits, the PVIB temperature sensor may have failed.

Solution

• Check the environmental controls applied to the cabinet containing the I/O pack. Pack operation will continue correctly

beyond these temperature limits but long-term operation at elevated temperatures may reduce equipment life.• If PVIB temperature sensor failure, replace the PVIB I/O pack.

69

Description PVIB Channel 1,5,9,13 ADC Failure. Status [ ].




70

Description PVIB Channel 2,6,10 ADC Failure. Status [ ].



71




72




73

Description 1x2x Phase Calibration Level [ ] Failure on Channel [ ].

Possible Cause the board failed to auto-calibrate when powered on.


128


Possible Cause N/A

Solution N/A

192


Possible Cause

• There is a voter disagreement between the R, S, and T I/O packs.• The I/O pack is not seated on the terminal board correctly.

Solution

• Adjust the parameter TMR_DiffLimt or correct the cause of the difference.

• Re-seat the I/O pack to the terminal board.• Replace the PVIB I/O pack.


Common I/O Pack Alarms

Common AlarmsThe following are common I/O pack alarms.

2

Description Flash memory CRC failure


• A firmware programming error occurred (board will not go online).


• The hardware failed.


• Rebuild the system, then download the application and the configuration to the pack.



3

Description CRC failure override is active


• A firmware programming error occurred (board will not go online).






• Replace pack.


4

Description I/O pack in stand alone mode


• The I/O pack configuration is invalid.

During normal operation:*The hardware failed.





5

Description I/O pack in remote I/O mode









6

Description Special User Mode active. Now: [ ]






• Rebuild system, then download the application and the configuration to the pack.




7

Description The I/O pack has gone to the Offline state


• Ethernet cable disconnected or connected to wrong port


• controller offline or restarted• Faulty Ethernet switch/cable

Solution Verify that the controller is not offline. If other packs are not reporting a problem, there may be an IONet cableor switch problem.

16

Description System limit checking is disabled

Possible Cause System checking disabled by configuration

Solution System checking was disabled by the configuration.

20

Description I/O communication failure between [ ] and controller.

Possible Cause

• I/O pack did not complete Start• I/O pack configuration files missing

• I/O pack restarted• I/O pack configured for dual networks, but only one network is connected• Network issue

Solution

• If the Control/Status communication is working correctly, any additional diagnosics should indicate the cause of theproblem.

• Build and download parameters to the I/O pack.• Download firmware and parameters to the I/O pack.• Verify that the Ethernet cables and network switch are operating correctly.


21

Description Control/Status communication failure between [ ] and controller.

Possible Cause

• Asynchronous Drive Language (ADL) communication unhealthy• Terminal board barcode typed incorrectly in the ToolboxST configuration• Wrong terminal board is configured in the ToolboxST application

• Pack is plugged into wrong Jack on terminal board, or wrong jack number is configured in the ToolboxST application• I/O pack configured in ToolboxST application, but configuration not downloaded to the controller• I/O pack in program mode

Solution





22

Description Diagnostic status signal (...L3DIAG and/or ...ATTN) is [ ]; therefore, diagnostic status for this I/O pack maybeinaccurate, unknown, or indeterminate.

Possible Cause

• I/O status signal quality in warning state• signal quality unhealthy, forced, or being simulated• Status information inaccurate

Solution Check signal health, remove the force, or simulated condition.

23

Description [ ] controller state is not OK...(i.e. Major Difference).

Possible Cause major difference in controller application/configuration code

Solution Rebuild the system and download.

24

Description Cannot retrieve pack Information. [ ]

Possible Cause

• Cannot get requested information from I/O pack• Communication program failure

• I/O pack unable to retrieve IP address

• Terminal board barcode typed incorrectly in ToolboxST configuration• Wrong terminal board configured in ToolboxST application

• Pack plugged into wrong Jack on terminal board, or wrong jack number in ToolboxST configuration

• I/O pack configured in ToolboxST application, but configuration not downloaded to controller• I/O pack in program mode

Solution



• Manually restart the I/O pack.• Check network cables for proper connection.• Verify that the switch is functioning correctly.

25

Description Control/Status communication Error: [ ]

Possible Cause

• Cannot get diagnostic information from I/O pack

• I/O pack not able to load firmware

Solution

• Verify the I/O pack configuration.

• Rebuild application and download firmware and application to the I/O pack.• Check network cables for proper connection.• Verify that the switch is functioning correctly.


30

Description Firmware/Configuration Incompatibility Error;Firmware: [ ] Config: [ ]

Possible Cause I/O pack configuration files incompatible with firmware. Files have wrong revision.

Solution

• Confirm the correct installation of ToolboxST.• Verify that each I/O pack is upgraded to the latest version by right-clicking each pack and selecting Upgrade.• Rebuild application and download firmware and application code to the affected I/O pack.

256

Description [ ]V Pwr supply voltage is low

Possible Cause

• Input voltage dropped below 18 V. I/O pack input power required to be within range 28V +/- 5%. I/O pack operation will

be compromised or may stop completely.

Solution

• If PPDA is available to monitor control cabinet power, check that I/O pack for active alarms.

• Check the I/O pack power within the control cabinet; begin with power supplies and work toward the affected I/O pack.

257

Description [ ]V Pwr supply voltage is low

Possible Cause Input voltage has dropped below 26.5V. I/O pack input power is required to be within the range 28V +/- 5%.

In most cases, normal pack operation continue below this voltage but field devices that require 24 V from the terminal boardmay begin to experience reduced voltage operation with undetermined results.

Solution

• If PPDA is available to monitor control cabinet power check that I/O pack for active alarms.• Check I/O pack power within the control cabinet; begin with power supplies and working toward the affected I/O pack.

258

Description Temperature [ ] degF is out of range ([ ] to [ ] degF)

Possible Cause Temperature went outside -20°C to +85°C (-4 °F to +185 °F)

Solution Verify the environmental controls for the cabinet containing the I/O pack. Pack operation will continue correctlybeyond these temperature limits but long-term operation at elevated temperatures may reduce equipment life.

259

Description Application Runtime Error - [ ] Frame overruns occurred

Possible Cause Overloaded controller or controller sequencer malfunction (one or more frame overruns occurred)

Solution Increase frame idle time by:

• Reducing application or by increasing EGD period• Using a faster processor board (UCCC)• Replacing the processor module


260

Description Application Runtime Error - [ ] Frame skips occurred

Possible Cause Overloaded controller or controller malfunction. Frame number skips detected. Frame number should

monotonically increase during Controlling state

Solution

• Reduce controller processor load by increasing EGD period or by reducing application.• Use a faster processor board such as UCCC.

• Replace the processor module.

261

Description Unable to read configuration file from flash


• I/O pack does not have correct configuration file stored in flash file system• Hardware problem




• Confirm the correct installation of the ToolBoxST application.

• Rebuild system and download application and configuration to pack.



262

Description Bad configuration file detected

Possible Cause During commission/maintenance:

• Configuration file in the pack not compatible with loaded application code




• Rebuild system and download application and configuration to pack.


• Replace pack.


265

Description Configuration file load error - invalid I/O header size


• Build error

• Controller EGD revision code not supported

• Incompatible version of pack firmware downloaded




• Confirm the correct installation of the ToolboxST application.

• Verify that each I/O pack is upgraded to the latest version by right-clicking each pack and selecting Upgrade.

• Rebuild application and download firmware and application code to the affected I/O pack.



266

Description Configuration file load error - invalid file length


• The configuration file in the pack does not have the correct size to match the application code that is loaded.




• Confirm correct installation of ToolboxST. Rebuild application and download firmware and application code to theaffected I/O pack.


• Replace pack


267

Description Firmware Load Error


• Incompatible version of firmware downloaded

During normal operation:*Hardware failure


• Confirm correct installation of ToolboxST.• Ensure each I/O Pack is upgraded to the latest version by right-clicking each pack and selecting upgrade.• Rebuild application and download firmware and application code to the affected I/O pack.


• Replace pack

268

Description Firmware Load Error - Incompatible FPGA Revision: Found [ ] Need [ ]


• Incompatible version of firmware downloaded

During normal operation:*Hardware failure


• Confirm the correct installation of the ToolboxST application.• Verify that each I/O pack is upgraded to the latest version by right-clicking each pack and selecting Upgrade.• Rebuild application and download firmware and application code to the affected I/O pack.



271

Description Internal communication error - Exchange [ ] Export failed

Possible Cause Internal runtime error

Solution

• Restart the pack. If problem persists, replace the pack.


279

Description Could not determine platform type from hardware


• Incorrect firmware version or hardware malfunction (firmware could not recognize host hardware type)



Solution

• Verify that all connectors are aligned properly and fully seated.

• Check the firmware version for compatibility with platform. If correct, replace the processor module.

280

Description Platform hardware does not match configuration


• Platform type identified in the application configuration does not match actual hardware



Solution

• Fix the platform type in the ToolboxST application (General tab, General Properties, Platform).

• Rebuild and download the application.• If problem persists, replace the processor module.

281

Description Firmware Load Error - FPGA not programmed due to platform errors

Possible Cause File downloaded to configure the Field Programmable Gate Array (FPGA not successfully applied)

Solution

• Verify that all connectors are aligned properly and fully seated.

• Check the firmware version for compatibility with platform. If correct, replace the processor module.

282

Description Firmware Load Error - application independent processes failed to initialize

Possible Cause Runtime malfunction. An application-independent firmware process could not be started successfully.

Solution

• Reload firmware and application and restart.• Controller: If failure persists, remove the Compact Flash module and reprogram the boot loader using the ToolboxST

configuration. Download using the Device | Download | Controller setup | Format Flash selection. After reinstalling theflash module and restarting, reload the firmware and application.

• Replace the module.

• I/O pack: Re-download the base load.


283

Description Firmware execution error - Internal process crashed


Solution

• Reload firmware and application and restart.• Controller: If failure persists, remove the Compact Flash module and reprogram the boot loader using ToolboxST.

Download using the Device | Download | Controller setup | Format Flash pick, then, after reinstalling the flash module

and restarting, reload firmware and application.• If this does not work, replace processor module.• IoPack: Redownload the base load.

284

Description Unexpected reboot occurred - firmware fault


Solution Reload firmware and application and restart. Controller: If failure persists, remove the Compact Flash module and

reprogram the boot loader using the ToolboxST application. Download using the Device | Download | Controller setup |Format Flash selection. After reinstalling the flash module and restarting, reload firmware and application. If this does

not work, replace processor module. I/O pack: Re-download the base load.

285

Description Unexpected reboot occurred - hardware fault

Possible Cause

• Runtime or hardware malfunction• Runtime process stalled

Solution



292

Description Application Error - application overruning the frame

Possible Cause Application cannot start within frame

Solution Check application loading and reduce the amount of application code or frequency of execution. Build applicationand download to all processors.

293

Description Waiting on IP addr Ionet [ ] before continuing.

Possible Cause I/O pack waiting to obtain network address from the controller using DHCP.

• network problem

• controller problem• pack not configured correctly, or incorrect ID (barcode)

Solution Verify that the controller is online. Confirm that the correct terminal board ID is present in the ToolboxST

configuration. Check IONet (switches, cables).


294

Description Controller CPU overtemperature, Temp [ ] degC, Threshold [ ] degC

Possible Cause

• Fan loss

• Excessive ambient temperature• Hardware malfunction

Solution Check the fan, including the ambient temperature, and any dust on the processor module. If okay, replace the

processor module.

295

Description IOPACK - The FPGA is not generating an I/O interrupt

Possible Cause There is a FPGA inside the I/O pack that controls I/O hardware. The logic in the FPGA generates an

interrupt to the processor requesting that the I/O be serviced. That interrupt is not occurring as expected.

Solution Rebuild system and download to pack. If problem persists, replace the pack.

300

Description Application Code Load Failure


• Invalid application configuration


• Firmware or hardware malfunction

Solution

• Rebuild and download the application to all processors .

• Reload firmware and application.• if problem persists, replace processor module.

301

Description Configuration Load Failure

Possible Cause

• I/O pack IO configuration files missing

• I/O pack reseated on terminal board (clears configuration from pack)

Solution

• Rebuild and download application to all processors• Reload firmware and application

• if problem persists, replace processor module.


320

Description Process Alarm Buffers Full - MarkVIe can miss alarm transitions

Possible Cause

• Multiple alarm variables changing state too quickly to transmit all transitions

• Excessive alarms in queue (Plant-wide system failures)


• Reduce the number of alarms that can change state at the same time (filter alarm variables in the application code).


• Eliminate the conditions causing excessive process alarms.

321

Description Internal Runtime error - Process Alarms not being scanned

Possible Cause Runtime malfunction: alarms not being scanned. Processor may restart on software watchdog timeoutdue to processor overload

Solution

322

Description Configuration Load error - Too many consumed EGD variables for Fault Tolerant EGD

Possible Cause Number of relevant, consumed UDH EGD variables exceeds fault tolerant EGD limitation of 1400 bytes ofdata.

Normal UDH EGD operation not affected; however, in the event of UDH EGD failure, some consumed variables may notbe transmitted to redundant controllers over the IONet.


• Reduce the amount of relevant, consumed UDH EGD data by removing the appropriate number of variables fromEGD pages.

323

Description EGD Error - Fault Tolerant EGD activated

Possible Cause EGD exchange timeout occurred on requesting processor. Redundant processor unable to receive UDHEGD inputs and requested that EGD data be transferred over the IONet.

Solution

• Verify that all redundant processors on the UDH network are receiving all expected EGD exchanges.• that all relevant devices are powered up and producing data on the network.

324

Description EGD Error - Fault Tolerant EGD data requested

Possible Cause An EGD exchange timeout occurred on the requesting processor. Redundant processor unable to receiveUDH EGD inputs and has requested that EGD data be transferred over the IONet.

Solution

• Check UDH network and verify that all redundant processors are receiving all of the expected EGD exchanges.• Verify that all relevant devices are powered on and producing data on the network.


325

Description MCL Watchdog Timeout Failure

Possible Cause

Solution

326

Description Communication lost from R processor

Possible Cause


• S or T processor in redundant system lost communication with R processor

Solution

• Go online with the R processor. Verify that the processor is in the Controlling state. If not communicating or in

Controlling state, restart the processor.• Check for disconnected IONet cables or malfunctioning switches.• Rebuild and download application.

• Check for bad ethernet cable to network switch.• Check for bad network switch: place ethernet cable into empty port. If problem persists, replace network switch.

327

Description Communication lost from S processor

Possible Cause

• IONet or hardware malfunction• R or T processor in redundant system lost communication with S processor

Solution

• Go online with the S processor. Verify that the processor is in the Controlling state. If not communicating or inControlling state, restart the processor.

• Check for disconnected IONet cables or malfunctioning switches.• Rebuild and download the application.• Check for a faulty ethernet cable-to-network switch.

• Check for bad network switch: place ethernet cable into empty port. If problem persists, replace network switch.

328

Description Communication lost from T processor

Possible Cause

• IONet or hardware malfunction• R or S processor in redundant system lost communication with T processor

Solution

• Go online with the T processor. Verify that processor is in the Controlling state. If not communicating or in Controlling

state, restart the processor.• Check for disconnected IONet cables or malfunctioning switches.

• Rebuild and download the application.

• Check for a faulty ethernet cable-to-network switch.• Check for a faulty network switch by placing the ethernet cable into an empty port. If problem persists, replace the

network switch.


329

Description Startup sequence failed - Data initialization timeout R processor

Possible Cause Controller unable to complete startup data initialization


• Controllers have different application revisions• One or more controllers powered down• Controller overloaded by external command messages

Solution

• Check for disconnected IONet cables or malfunctioning network switches.• Rebuild and download the application.

• Verify that all controllers are powered on.• Disable all other command senders (e.g., Modbus masters) until controller is online.

330

Description Startup sequence failed - Data initialization timeout S processor


• IONet malfunction• Controllers have different application revisions

• One or more controllers are powered down• Controller is overloaded by external command messages.

Solution

• Check for disconnected IONet cables or malfunctioning network switches

• Rebuild and download application• Ensure all controllers are powered up

• Disable all other command senders (e.g., Modbus masters) until controller is online.

331

Description Startup sequence failed - Data initialization timeout T processor


• IONet malfunction• Controllers have different application revisions• One or more controllers are powered down

• Controller is overloaded by external command messages.

Solution

• Check for disconnected IONet cables or malfunctioning network switches• Rebuild and download application

• Ensure all controllers are powered up• Disable all other command senders (e.g., Modbus masters) until controller is online.


332

Description Overtemperature - Processor rebooted and throttled

Possible Cause

• Fan loss.

• Excessive ambient temperature• Hardware malfunction.

Solution

• Check ambient temperature• Check for dust buildup on cabinet filters• Check fans

• Check for dust buildup on processor module, power supply

333

Description MCL-ACL page revision mismatch

Possible Cause

Solution

334

Description Application Error - [ ] Frame skips detected

Possible Cause

• Hardware or IONet malfunction.• Frame number skips detected. Frame number should monotonically increase until rollover; alarm occurs following a

single frame number skips in successive frames.

Solution

• Check IONet (switches, cables);• Replace processor module.

335

Description Memory Verification failed - Firmware processes

Possible Cause Hardware memory failure. A modification has occurred in the code segment for one of the processes. Thisindicates that a hardware memory failure has occurred.

Solution Replace processor module.

336

Description Controller is unlocked

Possible Cause Mark VIeS: leaving Data Init control state and not locked or the controller is unlocked through the

ToolboxST application.

Solution Lock the controllers from ToolboxST application before executing safety functions.


337

Description Output exchange disagreement detected

Possible Cause IONet malfunction or hardware problem. For at least one output, a difference was detected between the

controller outputs. This alarm remains active until the controllers agree on all outputs. A difference for non-Boolean data

generally indicates a deviation of more than 10% from the median value or no IONet EGD configuration is present. Formedian values near zero, the variation exceeds integer 2 or real value 0.2.

Solution

• For the Mark VIe runtime, use the ToolboxST disagreement display (View | Disagreements) to determine which variablesare in disagreement.

• In the application, avoid use of global variable ’ControllerID’ and avoid the use of sequencing block ’USB_HB’.

• Check IONet (switches, cables); rebuild and download application to all processors. If the problem persists, replace theprocessor module.

338

Description Pack Firmware Error - Inputs are not being updated


• The IO pack application process is not providing system signal inputs to EGD every frame.


• Rebuild and download firmware and application.• Verify that the idle time is adequate for the pack and that the frame rate does not exceed defined limits.• If problem persists, replace the pack.

339

Description Outputs are not being received

Possible Cause

• I/O pack not receiving outputs from controller after previously receiving outputs

• Controller is restarting or has restarted• Failed Ethernet connection between pack and controller• Internal firmware failure

Solution

• Check for disconnected IONet cables or malfunctioning network switches.• Verify that the controller is online and operating correctly.

• Rebuild and download the firmware and configuration to the pack.

340

Description Memory Verification failed - Data structures

Possible Cause Hardware memory failure (data that should not change after pack has gone online has been modified)

Solution

• Rebuild and download the application to all processors.• Reload the firmware and application.



341

Description Firmware/IO Configuration Incompatibility

Possible Cause I/O pack configuration files incompatible with firmware (files do not contain necessary revision)

Solution

• Confirm the correct installation of the ToolboxST software.

• Verify that each I/O Pack is upgraded to the latest version by right-clicking each pack and selecting Upgrade.• Rebuild the application and download firmware and application code to the affected I/O pack.

342

Description Firmware/Configuration Incompatibile


Solution

• Confirm the correct installation of the ToolboxST software.


343

Description Memory Verification failed - Firmware Libraries

Possible Cause Hardware memory failure (data that should not change after the pack has gone online was modified)

Solution

• Rebuild and download application to all processors

• Reload firmware and application• If problem persists, Replace processor module.

344

Description Memory Verification failed - Firmware Executables

Possible Cause Hardware memory failure (modification occurred in the code segment for a process)

Solution

• Rebuild and download application to all processors

• Reload firmware and application• If problem persists, Replace processor module.

345

Description Memory Verification failed - Configuration

Possible Cause Hardware memory failure (data that should not change after the pack has gone online was modified)

Solution

• Rebuild and download the application to all processors.

• Reload firmware and application.• If problem persists, replace the processor module.

347

Description Running Application does not match the BRANDed Application

Possible Cause Mark VIeS: Application not branded or different from branded version.Note: The purpose of branding is to label a verified safety application, and to ensure that it is running.

Solution Reload the branded application to the controller and I/O packs, or use the ToolboxST application to brand

currently running application.


348


Possible Cause

• Power cycled on I/O producer (controller or I/O pack)

• IONet malfunction• I/O message corruption• Communication errors occurred on more than 5% of data transmissions on IO Net 1

Solution

• Check for evidence of pack restart (diagnostic alarms, error logs).• Faulty ethernet cable from pack to network switch and/or from switch to controller. Replace cable(s).


349


Possible Cause Power cycled on I/O producer (controller or I/O pack), IONet malfunction, I/O message corruption.Communication errors occurred on more than 5% of the data transmissions on IO Net 2.

Solution

• Check for evidence of pack restart (diagnostic alarms, error logs).• Faulty ethernet cable from pack to network switch and/or from switch to controller. Replace cable(s).• Replace the pack.


350


Possible Cause Power cycled on I/O producer (controller or I/O pack), IONet malfunction, I/O message corruption.

Communication errors occurred on more than 5% of the data transmissions on IO Net 3.

Solution

• Check for evidence of pack restart (diagnostic alarms, error logs).

• Faulty ethernet cable from pack to network switch and/or from switch to controller. Replace cable(s).• Replace the pack.• Faulty network switch; place the pack’s ethernet cable into an empty port. If problem persists, replace the network switch.

351

Description Internal Firmware error - Thread [ ] timing overrun

Possible Cause An application task scheduled with a scan rate either occurred twice as fast as expected or twice asslowly as expected.

Solution

• Check the idle time on the pack, and verify that the frame rate is correct.• Reload firmware and application to all processors.

• Replace processor module.


352

Description Memory Validation failed - Blockware data structures

Possible Cause Hardware memory failure (application process data that should not change after the controller goesonline was modified; indicates hardware memory problem)


353

Description Memory Validation failed - Configuration shared memory

Possible Cause Hardware memory failure (system process data that should not change after the controller has gone

online was modified)


354

Description Memory Validation failed - EGD data structures

Possible Cause Hardware memory failure (IONet-EGD process data that should not change after the controller hasgone online has been modified)


355

Description State Exchange Voter disagreement detected

Possible Cause

• State Exchange disagreement found.

• Application sequencing error• IONet malfunction or hardware problem.

Solution

• Use the ToolboxST disagreement display (View | Disagreements) to determine which variables are in disagreement.• In the application, avoid use of global variable ’ControllerID’ and avoid the use of ’USB_HB’ block.• Check IONet (switches, cables). If problem persists, replace the processor module.

356

Description NANs in CALC or NAN_BREAKER Block detected

Possible Cause

• NaN (Invalid floating point number) received from I/O interface

• Hardware problem

Solution

• Check for external devices that may be sending NaNs to the controller.

• If conditions persists, replace the processor module.

357

Description Internal Runtime error - Sequencer out-of-order execution detected

Possible Cause Possible hardware malfunction. Sequencer critical clients scheduled out of order. Alarm occurs following

three successive frames of sequencer critical client out-of-order execution detections; after five, controller put in FAILUREcontrol state.



358

Description Internal Runtime error - Sequencer client execution underrun

Possible Cause Possible hardware malfunction. Sequencer critical client underrun detected. Alarm occurs after asequencer critical client has been run slower than its nominal rate three times in a row; after five, controller put in FAILURE

control state.

Solution

• Ignore alarm if it occurs during a restartof the controller.• Replace the processor module, if the alarm occurs during normal operation.

359

Description Internal Runtime error - Sequencer client execution overrun

Possible Cause Possible hardware malfunction. Sequencer critical client overrun detected. Alarm occurs after a sequencer

critical client has been run faster than its nominal rate three times in a row; after five, controller put in FAILURE control state.

Solution


360

Description Internal Runtime error - Sequencer frame period out-of-bounds (+/- 15%)

Possible Cause Possible hardware malfunction. Frame period greater than ±15% of nominal. Alarm occurs following frame

period out-of-bounds condition occurring three frames in a row; after five, controller put in FAILURE control state.

Solution


361

Description Internal Runtime error - Sequencer frame state timeout out-of-bounds (+/- 15%)

Possible Cause Possible hardware malfunction. Sequencer frame state timeout greater than ±15% of nominal. Alarm

occurs following a sequencer frame state timeout being out-of-bounds three frames in row; after five, controller putin FAILURE control state.

Solution


• Replace the processor module, if the alarm occurs during normal operation.

362

Description Internal Runtime error - Sequencer frame number skip detected

Possible Cause Possible hardware or IONet malfunction. Frame number skips detected. Frame number shouldmonotonically increase until rollover; alarm occurs following three skips in a row, after five, controller put in FAILUREcontrol state.

Solution



• Check for network switch malfunction• Check for loose or defective network cables• Replace processor module.


363

Description Memory Validation failed - Sequencer data structures

Possible Cause Hardware memory failure (sequencer process data that should not change after the controller is onlinewas modified)


364

Description Too many state voter disagreements detected

Possible Cause

• State exchange voter disagreement overflow. System exceeded the limit of 128 simultaneous disagreements at once.• Application error• IONet malfunction or hardware problem

Solution

• Use the ToolboxST disagreement display (View | Disagreements) to determine which variables are in disagreement.• In the application, avoid use of global variable ’ControllerID’ and avoid the use of ’USB_HB’ block.• Check IONet (switches, cables). If problem persists, replace the processor module.

366

Description Initialization failure - IO firmware

Possible Cause Pack did not initialize correctly

Solution

• Restart the pack.• Re-download the firmware.• Replace the pack.

367

Description Internal communications error - HSSL Comm link down


Solution

• Check High Speed Serial Link (HSSL) cables.• If problem persists, replace the pack.


368

Description Configuration file load error - invalid header size


• Build error

• Controller EGD revision code not supported

• Incompatible version of pack firmware downloaded





• Verify that each I/O Pack is upgraded to the latest version by right-clicking each pack and selecting Upgrade.

• Rebuild application and download firmware and application code to the affected I/O pack.



369

Description Internal communication error - Exchange [ ] Export failed


Solution

• Restart the pack. If problem persists, replace the pack.

371

Description IONET-EGD signal inputs are not being updated


• I/O pack application process not providing system signal inputs to EGD every frame.


• Rebuild and download firmware and application.• Verify that the idle time is adequate for the pack, and that the frame rate does not exceed defined limits.• If problem persists, replace the pack.

372

Description Memory Validation failed - Data structures

Possible Cause Hardware memory failure (process data that should not change after the controller goes online wasmodified)



373

Description Firmware/IO Configuration Incompatibile







445

Description Incorrect or Missing Acquisition Board on HSSL link 1

Possible Cause The acquisition card on High Speed Serial Link 1 is not connected or does not agree with the ToolboxSTconfiguration.

Solution

• Verify that the correct acquisition card is connected to the specified HSSL connector on the UCSA.• Verify that the ToolboxST configuration for the appropriate HSSL connector matches the hardware.

446

Description Incorrect or Missing Acquisition Board on HSSL link 2


Solution


447

Description Incorrect or Missing Acquisition Board om HSSL link 3


Solution


448

Description Acquisition Board barcode mismatch on HSSL link 1

Possible Cause The barcode on the acquisition card connected to High Speed Serial Link 1 does not agree with thoseprovided in ToolboxST

Solution Verify that the correct acquisition card is connected to the link and that the correct barcode has been entered

in ToolboxST


449


Possible Cause The barcode on the acquisition card connected to High Speed Serial Link 2 does not agree with those

provided in ToolboxST

Solution Verify that the correct acquisition card is connected to the link and that the correct barcode has been enteredin ToolboxST

450


Possible Cause The barcode on the acquisition card connected to High Speed Serial Link 3 does not agree with thoseprovided in ToolboxST

Solution Verify that the correct acquisition card is connected to the link and that the correct barcode has been entered

in ToolboxST

451

Description Communication Lost on HSSL Link 1

Possible Cause The UCSA can no longer communicate with the acquisition card on High Speed Serial Link 1

Solution Verify that the ethernet cable is connected and that the acquisition card is healthy.

452




453




462

Description Hardware Reconfigured: Reboot by removing and reapplying power.

Possible Cause Flash file system corruption.

Solution

• After reapplying power, Rebuild and download baseload, firmware and application.

• If the problem persists, replace processor module

463

Description Internal runtime error - Could not create CEL log file

Possible Cause Internal runtime error. Could not create the Command and Event log file.

Solution

• Rebuild and download baseload, firmware and application to the processor.• If the problem persists, replace processor module


464



Solution



465



Solution


466



Solution


467



Solution



468



Solution


469

Description EGD fault detected by R processor

Possible Cause



Solution

• Ensure all EGD producers are powered up and healthy.• Bad ethernet cable from producer to network switch. Replace cable(s).• Bad network switch, place producer’s ethernet cable into empty port. If problem persists, replace network switch.



470

Description EGD fault detected by S processor

Possible Cause



Solution

• Ensure all EGD producers are powered up and healthy• Bad ethernet cable from producer to network switch. Replace cable(s).• Bad network switch, place producer’s ethernet cable into empty port. If problem persists, replace network switch.


471

Description EGD fault detected by T processor

Possible Cause

• EGD producer is powered down• Producer is unhealthy• Ethernet connection(s) failure

Solution

• Ensure all EGD producers are powered up and healthy• Bad ethernet cable from producer to network switch. Replace cable(s).

• Bad network switch, place producer’s ethernet cable into empty port. If problem persists, replace network switch.• Replace producer processor module.

485

Description Configuration mismatch with Auto-Reconfiguration server

Possible Cause Some or all of the I/O pack configuration files do not match those on the Auto-Reconfiguration server


486

Description Auto-Reconfiguration server installation is incomplete

Possible Cause A download from ToolboxST to an I/O pack and/or Auto-Reconfiguration server failed


487

Description Auto-Reconfiguration server failed scanning or downloading an I/O pack

Possible Cause At least one I/O pack is in an unexpected state that the Auto-Reconfiguration server is unable to handle

Solution *Cycle power on the I/O pack

*Perform a scan and download using ToolboxST

*Replace the I/O pack


1008-1010,1264-1266

Description Outputs unhealthy on IONet [ ] - Message Timeout

Possible Cause

• Controller is rebooting or has rebooted

• Application/configuration does not match in pack and controller.• Failed ethernet connection between pack and controller.

Solution

• Reset all diagnostic alarms.• Rebuild and download application to all processors, including I/O packs.• Reload firmware and application

• Verify that the Ethernet cable on the I/O pack matches the ToolboxST configuration.• Check for a faulty ethernet cable from the pack to the network switch and/or from the switch to the controller. Replace

cable(s) if necessary.


1008-1010,1264-1266

Description Outputs unhealthy on IONet [ ] - Message Length not valid


Solution


• If problem persists, replace affected I/O pack, then replace the controller.

1008-1010,1264-1266

Description Outputs unhealthy on IONet [ ] - Major Signature Mismatch


Solution


• Reload firmware and parameters to the affected I/O pack.• Reload firmware and application to all controllers.• If problem persists, replace affected I/O pack, then replace the controller.

1008-1010,1264-1266

Description Outputs unhealthy on IONet [ ] - Minor Signature Mismatch


Solution


• Reload firmware and application to all controllers.• If problem persists, replace affected I/O pack, then replace the controller.


1008-1010,1264-1266

Description Outputs unhealthy on IONet [ ] - Timestamp Mismatch


Solution


• If problem persists, replace affected I/O pack, then replace the controller.


GE Energy

1501 Roanoke Blvd.

Salem, VA 24153-6492 USA

1 540 387 7000

www.geenergy.com

Documents

GEH-6721_Vol_III