PDMM and PCMM Errors and Alarms
When an Error or Alarm occurs, always check the controller log messages. The log messages will provide more details about the failure and the history of events leading up to the failure. From the log messages, you can determine the specifics about the cause of the failure to correct the underlying problem.
PCMM and PDMM Errors
Code | Description | Cause | Remedy | Clear‡ |
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E01 | Critical temperature exceeded. The controller operation is stopped after 20 seconds, CPU will be put to sleep. | CPU temperature exceeded safe operating temperature limit. | Power-off. Check airflow and operating environment are within hardware specifications. Allow unit to cool before power-on. | HW |
E02 | Out of memory. KAS runtimeIn 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). Within KAS, runtime also 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. | Power-off/on. If problem is recurrent, check release notes for firmware updates or return hardware for repair. | HW |
E03 | Fan failure. | CPU cooling fan was not able to operate properly. | Check temperature and monitor for High temp alarm (see A01). Return hardware for fan replacement. | HW |
E10 | Firmware is corrupted. | Flash memory corrupted during firmware download or flash hardware failure. | Re-download firmware or boot into recovery mode, download firmware, and power-off/on. If problem persists, return hardware for repair. | SW |
E11 | Flash is corrupted, no filesystem is available. | At startup the filesystem could not be mounted on the flash. | Reset to factory defaults. If problem persists, return hardware for repair. | SW |
E12 | 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, recipes, or other data files. | SW |
E13 | Out of NVRAM"Non-volatile random access memory" NVRAM is 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 for retained variables. | NVRAM is full. | Change application to reduce the amount of retained variables. | SW |
E14 | Reset to Factory Defaults failed. | Flash memory could not be formatted during a Reset to Factory Defaults procedure. | Try reset to factory defaults again from power-on. If problem persists, return hardware for repair. | SW |
E15 | Cannot read/write files from/to a SD card | SD card is not plugged in or the file system is corrupt and cannot be mounted. PLC"Programmable Logic Controller" A Programmable Logic Controller, PLC, or Programmable Controller is a digital computer used for automation of industrial processes, such as control of machinery on factory assembly lines. Used to synchronize the flow of inputs from (physical) sensors and events with the flow of outputs to actuators and events function failures will not cause this error. | Insert a valid SD card or reformat the SD card using Settings > SD Card > Format button. | SW |
E16 | Not enough space available on the SD card | SD card is full, unable to write to the SD card. PLC function failures. | Clean-up the SD card space by deleting files or re-format the card using Settings > SD Card > Format button. | SW |
E17 | Cannot connect to a shared directory | Improper shared directory configuration on remote computer or PCMM/PDMM. Improper permissions, access control, or security policy for computer’s share configuration. Computer is not accessible via EthernetEthernet is a large, diverse family of frame-based computer networking technologies that operate at many speeds for local area networks (LANs) network. | Check if the computer's shared directory is accessible. Check and Apply the KAS Application->Shared Directory configuration or power-off/on the controller. | SW |
E20 | RuntimeIn 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). Within KAS, runtime also refers to the virtual machine that manage the program written in a computer language while it is running plug-in, process, thread or application failed to start. | KAS runtime or application code failed to auto-start at boot. Caused by either a high controller temperature at power up, or a system error. |
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HW |
E21 | Runtime process, thread, or driver failed to respond during operation. | KAS runtime code failed during normal operation. | Power-off/on. If problem is recurrent, check release notes for firmware updates. | HW |
E22 | Fatal error in PLC program, application stopped. | Virtual machine failed to execute an instruction. | Check the PLC application code for programming errors that could cause a fatal execution error, e.g. divide by zero, array out of bound, etc.. Check that the IDE"Integrated development environment" An integrated development environment is a type of computer software that assists computer programmers in developing software. IDEs normally consist of a source code editor, a compiler and/or interpreter, build-automation tools, and a debugger and controller Runtime versions are compatible. Re-compile the application, download, and re-start. | SW |
E23 | CPU is overloaded. See CPU Overload (E23). | Either the motion engine did not complete or the PLC program did not complete within the timeout period due to excessive CPU load. | Stop the application or power-off/on. Reduce the sample rate, simplify the application, or reduce the application cycles and restart the application. | SW |
E24 | PLC application cannot be started |
PLC application cannot be started, due to an existing condition. Possible reasons:
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Check the following:
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SW |
E30 | EtherCAT communication failure during operational mode. | Network communication error. This is commonly caused by a loose or bad EtherCAT connection occurring after the network successfully starts up. See IDE Controller log for more information |
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SW |
E31 | EtherCAT communication failure during preop mode. | EtherCAT network operation failed due to a network communication error. | Check the EtherCAT network wiring and devices state. Re-start the application. | SW |
E32 | EtherCAT communication failure during bootstrap mode. | EtherCAT network operation failed due to a network communication error. | Check the EtherCAT network wiring and devices state. Re-start the application. | SW |
E33 | EtherCAT failed to initialize into operational mode. | EtherCAT network initialization failed. This is commonly caused by the Ethercat configuration in the project not matching the actual hardware. See IDE Controller log for more information. | Check the EtherCAT network wiring and devices state. Re-start the application. | SW |
E34 | EtherCAT failed to initialize into preop mode. | EtherCAT network initialization failed due to a network communication error. | Check the EtherCAT network wiring and devices state. Re-start the application. | SW |
E35 | EtherCAT failed to initialize into bootstrap mode. | EtherCAT network initialization failed due to a network communication error. | Check the EtherCAT network wiring and devices state. Re-start the application. | SW |
E36 | EtherCAT failed to discover the expected devices. | EtherCAT network discovery failed due to a mismatch between the discovered and expected devices. | Check the EtherCAT devices and wiring order. Correct the device order wiring or re-scan the network, re-compile, and download the updated application. Re-start the application. | SW |
E37 | EtherCAT failed to return to init state. | EtherCAT network initialization failed due to a network communication error. | Check the EtherCAT network wiring and devices state. Re-start the application. | SW |
E50 | Backup to SD card failed | An unrecoverable error occurred during the backup operation. | Repeat the backup to SD card operation. If it fails again, replace the SD card. | SW |
E51 | Restore from SD card failed | An unrecoverable error occurred during the restore operation. | Do not reboot the Controller! Repeat the restore operation. If it fails again, reset the Controller to factory defaults. If the problem persists, return hardware for repair. | SW |
E52 | SD Backup files are missing or corrupt | The restore operation failed due to missing, incomplete, or corrupt files on the SD card. | Perform a backup operation before the restore or use and SD card with valid backup files. | SW |
E53 | SD Backup files are not compatible | Backup files on the SD card are not compatible. | Use a different SD card with Backup file(s) from a compatible controller. | SW |
‡ Items labeled "SW" can be cleared from the web server. Items labeled "HW" require a reboot to be cleared.
PCMM and PDMM Alarms
Code | Description | Cause | Remedy | Clear‡ |
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A01 | High temperature exceeded | CPU temperature near the safe operating temperature limit (120°C). | Check airflow and operating environment are within hardware specifications. | SW |
A02 | Low on memory. | Memory leak or corruption. | Power-off/on. If problem is recurrent, check release notes for firmware updates or return hardware for repair. | SW |
A04 | Low input voltage | +24 volt input power is +19 volts or less. | Check power supply voltage and connection to the controller. | SW |
A12 | 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 |
A21 | Recoverable process or thread failed to respond during operation. | KAS non-runtime code failed during normal operation and was automatically restarted. | If problem is recurrent, power-off/on. Check release notes for firmware updates. | SW |
A23 | 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 |
A30 | EtherCAT missed a send frame during operation mode. | 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 to send EtherCAT frames every cycle. | SW |
A31 | EtherCAT received a frame with a wrong Working Counter value. |
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A38 | EtherCAT missed a receive frame during operation mode. | EtherCAT master did not receive, or received too late, a frame for one or more cycles. |
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SW |
A40 | Local digital IO missed a cyclic update | Local digital IO was not updated during a cycle or the updates are no longer synchronous. | Reduce the sample rate, simplify the application, or reduce the application cycles. | SW |
A53 | The Controller was replaced with a higher performance model. | The 1.2GHz model was restored using backup files from an 800MHz model. | Either replace the controller with an 800MHz model or use the functionally compatible, higher performance 1.2GHz model. | SW |
‡ Items labeled "SW" can be cleared from the web server. Items labeled "HW" require a reboot to be cleared.