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siemens plc

The document outlines troubleshooting steps for a PLC system, emphasizing the importance of downloading specific error OBs to prevent the CPU from entering STOP mode. It provides guidance on identifying and resolving internal errors, particularly related to high nesting depth of synchronous errors and block calls. Additionally, it discusses the need to verify system logic and communication issues that may lead to operational failures.

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Mansoor Ali Khan
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36 views

siemens plc

The document outlines troubleshooting steps for a PLC system, emphasizing the importance of downloading specific error OBs to prevent the CPU from entering STOP mode. It provides guidance on identifying and resolving internal errors, particularly related to high nesting depth of synchronous errors and block calls. Additionally, it discusses the need to verify system logic and communication issues that may lead to operational failures.

Uploaded by

Mansoor Ali Khan
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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SOP, You first need to download HW configuration, then the Logic and finally the

network configuration.
Required OBs
Always download these error OBs to the S7-400H CPU: OB 80, OB 82, OB 83, OB 85,
OB 86, OB 88, OB 121 and OB 122. If you do not download these OBs, the fault-
tolerant system goes into STOP when an error occurs.
So there is a severe error in the software when OB88 is called or it have not the
possibility to manage all the asynchronous errors.
I am facing the same problem in my H-System (CPU 417-4H), where I have OB88 in
the program, so CPU does not Stop, but I am facing internal error every now and
then. My question is, how to identify part of the program where the problem exists
which is nothing but high nesting depth of synchronous errors or block calls?? The
event generated is as below:

Event 1 of 3000: Event ID 16# 3576


Error when allocating local data
Caused by OB: Cyclic interrupt OB (OB 31), Priority class: 8
FC number: 14
Module address: 726
Requested OB: Processing abort OB (OB88)
Priority class: 28
Internal error, Incoming event
10:04:29.922 AM 04/10/2014
go to your Hardware Configuration, select CPU properties, select Memory tab.
Increase the size of local data for Priority class: 8
Rectify all internal and external faults on the plc
You can create OB88 (read it's help) but you must think about the consequences in
process of your decision if the CPU doesn't stop.
Diagnostic Buffer Window in Simatic Manager

PLC:
1. To accurately identify the type of error, capture the event generated in the Diagnostic
Buffer Window in Simatic Manager.
2. As shown in the table below, the activation of OB88 indicates that the operating system is
preventing the CPU from switching to STOP mode. The root issue, 'Execution canceled,'
remains unresolved. While the CPU does not stop, internal errors may occur, and it’s
essential to identify which part of the program is problematic, such as high nesting depth
of synchronous errors or block calls. Automation engineers should re-examine the
program for errors. Key points to consider include:
a. Limit function nesting to a depth of 3 to 4 levels.
b. Break down large blocks into smaller, more manageable modules or functions.
c. Write the application program in a logical manner to ease maintenance and
troubleshooting, and ensure it is annotated.
d. Eliminate any unused or disabled logic.

3. Download the following error OBs to the S7-400H CPU: OB 80, OB 82, OB 83, OB 85,
OB 86, OB 88, OB 121, and OB 122.
4. Address and correct all internal and external faults on the PLC.
5. PLC-2 consists of two sets of PLCs, each including redundant components (CPUs, racks,
power supplies, and communication processors). Prove both PLCs entered stop mode,
through alarms/events that a switchover occurred when the Master PLC went into stop
mode, allowing the Standby PLC to take over as Master PLC, which then also entered
stop mode. The PLC redundancy was tested by simulating a power supply failure or by
turning off the Master PLC. However, it is important to verify whether the switchover
occurred during the real error event.

Process:
1. Did the Emergency recipe for the Nerada reactors activate? If it did not, why? If it was
active, the overflow from the sludge tank would not have occurred, as the system logic
requires that both the holding tank level transmitter (49LT1001 Nerada tag) and the
discharge valve (AV41102) be available to proceed with the sludge discharge phase, as
per Nerada control philosophy. Additionally, the valves on the sludge discharge line are
designed for fail-safe operation as per the P&ID. If there was a loss of signal, the valves
should have automatically closed.
1. The document highlights that there was a failure in communication of differential
pressure (should be level) reading to SCADA. Was this issue caused by a faulty
sensor, and how was it resolved? Alternatively, if the problem was related to the
signal sent to the PLC, it might lead to further inquiries about the transmission of 4-
20mA signals from the field to the PLC and the potential impact of signal due to
noise.
2. It appears there were two issues: one with the differential level transmitter and
another with the fine screen PLC.
3. According to the statements, the analysis report suggests that the PLC's STOP
condition was due to a battery fault. However, this is incorrect because non-volatile
memory does not impact a running application, and such memory loss only occurs if
there is both a power failure and a CPU battery failure, the first condition is unlikely
to happen since the PLC is powered by UPS.
4. Identify the specific error that caused the PLC to enter STOP mode.
5. Attach alarm list from SCADA for instrument fault notifications received.
6. Please refer to the PLC manual for the recommended type of battery.

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