Controller Error and Alarm Descriptions
When either Errors or Alarms occur, always check the controller log messages.
- The controller continuously displays any error or alarm codes after booting and not in recovery mode.
- Errors have a priority over Alarms.
- Only one error or alarm code is displayed at a time.
- The code with the highest priority is displayed until it is cleared.
- The log messages provide more details about the failure and the history of events leading up to the failure.
- Use the log messages to determine the specifics about the cause of the failure and correct the underlying problem.
Errors |
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Alarms |
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Error Code Example
Alarm Code Example
Errors
** In the How to Clear column:
An HW Hardware requires a reboot to clear the error or alarm.
An SW error or alarm can be cleared from the web server.
Code |
Description |
Cause |
Remedy |
How to Clear** |
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AKD PDMM and PCMM:
PCMM2G:
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Controller temperature exceeds the safe operating temperature limit. |
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Out of memory. KAS Kollmorgen Automation Suite Runtime In computer science, runtime (or run-time) describes the operation of a computer program, the duration of its execution, from beginning to termination (compare compile time). In KAS, runtime refers to the virtual machine that manage the program written in a computer language while it is running. is stopping. |
Memory leak, memory corrupted, or hardware memory failure. |
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HW |
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Fan failure. |
CPU cooling fan is not able to operate properly. |
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Firmware is corrupted. |
Flash memory corrupted during firmware download or flash hardware failure. |
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SW |
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AKD PDMM and PCMM only. Flash is corrupted, no file system is available. |
AKD PDMM and PCMM only. At startup, the file system could not be mounted on the flash. |
AKD PDMM and PCMM only.
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SW: AKD PDMM and PCMM only. |
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Not enough flash memory available. |
Flash memory is full, unable to write to flash. |
Clean-up the flash memory by removing log files, application programs The act of performing a sequence of instructions or commands., recipes, or other data files. |
SW |
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Out of NVRAM Non-volatile random access memory - The general name used to describe any type of random access memory which does not lose its information when power is turned off. This is in contrast to the most common forms of random access memory today, which both require continual power in order to maintain their data. NVRAM is a subgroup of the more general class of non-volatile memory types, the difference being that NVRAM devices offer random access, like hard disks. The best-known form of NVRAM memory today is flash memory. space to Retain Variables. |
NVRAM is full. |
Change application to reduce the amount of retained variables. |
SW |
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AKD PDMM and PCMM only. Reset to factory defaults failed. |
AKD PDMM and PCMM only. Flash memory could not be formatted during a Reset to Factory Defaults procedure. |
AKD PDMM and PCMM only.
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SW: AKD PDMM and PCMM only. |
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Cannot read/write files from/to an SD card / USB Universal Serial Bus - A serial bus standard to interface devices. flash drive In electrical engineering, a drive is an electronic device to provide power to a motor or servo. Control device for regulating the speed, torque and position of a motor. A unit controlling a motor using the current and timing in its coils.. |
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AKD PDMM and PCMM
PCMM2G
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SW |
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Not enough space available on the SD card / USB flash drive. |
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AKD PDMM and PCMM
PCMM2G
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SW |
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Cannot connect to a shared directory. |
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SW |
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Runtime plug-in, process, thread or application failed to start. |
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HW |
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Runtime process, thread, or driver In computing and electronics, a driver is a software component allowing higher-level computer programs to interact with a computer hardware device. A driver typically communicates with the device through the computer bus or communications subsystem to which the hardware is connected. failed to respond during operation. |
KAS Runtime code failed during normal operation. In extreme cases, the display may indicate that the controller failed at an early stage of the Boot Sequence. |
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HW |
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Fatal error in PLC program, application stopped. |
Virtual machine The complete assembly of all connected parts or devices, of which at least one is movable. failed to execute an instruction. |
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SW |
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CPU is overloaded. |
Either:
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SW |
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PLC application cannot be started |
PLC application cannot be started because of an existing condition. Possible reasons:
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SW |
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EtherCAT communication failure during operational mode. |
Network communication error.
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SW |
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EtherCAT communication failure during pre-op mode. |
EtherCAT network operation failed due to a network communication error. |
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SW |
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EtherCAT communication failure during bootstrap mode. |
EtherCAT network operation failed due to a network communication error. |
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SW |
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EtherCAT failed to initialize into operational mode. |
EtherCAT network initialization failed.
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SW |
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EtherCAT failed to initialize into pre-op mode. |
EtherCAT network initialization failed due to a network communication error. |
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SW |
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EtherCAT failed to initialize into bootstrap mode. |
EtherCAT network initialization failed due to a network communication error. |
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SW |
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EtherCAT failed to discover the expected devices. |
EtherCAT network discovery failed due to a mismatch between the discovered and expected devices. |
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SW |
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EtherCAT failed to return to init state. |
EtherCAT network initialization failed due to a network communication error. |
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SW |
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Backup to SD card / USB flash drive failed. |
An unrecoverable error occurred during the backup operation. |
AKD PDMM and PCMM
PCMM2G
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SW |
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Restore from SD card / USB flash drive failed. |
An unrecoverable error occurred during the restore operation. |
Do not reboot the Controller!
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SW |
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SD card / USB flash drive Backup files are missing or corrupt. |
The restore operation failed due to missing, incomplete, or corrupt files on the SD card / USB flash drive. |
AKD PDMM and PCMM
PCMM2G
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SW |
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AKD PDMM and PCMM only. SD card Backup files are not compatible. |
AKD PDMM and PCMM only. Backup files on the SD card are not compatible. |
AKD PDMM and PCMM only.
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SW: AKD PDMM and PCMM only. |
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PCMM2G only. Inactive partition is corrupted. |
PCMM2G only. An unrecoverable error occurred when starting KAS Runtime on the inactive partition. |
PCMM2G only. These are the recovery steps. If Step 1 is not successful, go to Step 2 and continue to Step 3 if needed.
See Booting the PCMM2G Controller for more information about partitions. |
SW: PCMM2G only. |
Alarms
** In the How to Clear column:
An HW requires a reboot to clear the error or alarm.
An SW error or alarm can be cleared from the web server.
Code |
Description |
Cause |
Remedy |
How to Clear** |
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High temperature exceeded. |
CPU temperature near the safe operating temperature limit for:
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Check airflow and operating environment are within hardware specifications. |
SW |
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Low on memory. |
Memory leak or corruption. |
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SW |
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Low input voltage. |
+24 volt input power is +19 volts or less. |
Check power supply voltage and connection to the controller. |
SW |
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PCMM2G only. The system time was not set on startup. |
PCMM2G only.
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PCMM2G only. Either:
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SW: PCMM2G only. |
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Flash memory is low on free space. |
Flash memory is almost full. |
Clean-up the flash memory by removing log files, application programs, recipes, or other data files. Reset to factory defaults. |
SW |
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Recoverable process or thread failed to respond during operation. |
KAS non-runtime code failed during normal operation and was automatically restarted. |
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SW |
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CPU is heavily loaded. |
CPU usage is too high for 5 (or more) seconds. |
Reduce the sample rate, simplify the application, or reduce the application cycles. |
SW |
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EtherCAT missed a send frame In networking dialect, a message is called a frame. during operation mode. |
The EtherCAT master was unable to send a frame for one or more cycles. |
Reduce the controller CPU load so it has enough Real-Time margin The measured available execution time in each cycle period. Formula = Cycle Time Period – EtherCAT network execution time – MotionExecTime – PLCProgExecTime. Unit is in microseconds. to send EtherCAT frames every cycle. |
SW |
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EtherCAT received a frame with a wrong Working Counter value. |
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EtherCAT missed a receive frame during operation mode. |
The EtherCAT master did not receive, or received too late, a frame for one or more cycles. |
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Local digital IO missed a cyclic update. |
Local digital IO was not updated during a cycle or the updates are no longer synchronous Combines an axis or axes group (as slave) with an axis as master. The slave executes its path with synchronization to the progress of the master. This is linked to a one dimension source for synchronization.. |
Reduce the sample rate, simplify the application, or reduce the application cycles. |
SW |
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AKD PDMM and PCMM only. The controller was replaced with a higher performance model. |
AKD PDMM and PCMM only. The 1.2GHz model was restored using backup files from an 800MHz model. |
AKD PDMM and PCMM only. Either:
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SW: AKD PDMM and PCMM only. |