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‡
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 runtimeClosed 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). 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 NVRAMClosed "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. PLCClosed "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 EthernetClosed Ethernet 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 RuntimeClosed 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). 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.
  1. Check the web server for other alarms or errors, such as temperature alerts, and resolve them.
  2. Power cycle the device
  3. If E20 is still being reported, reset to factory defaults.
  4. If the problem is recurrent, check release notes for firmware updates, or download firmware.
 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 IDEClosed "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:

  1. Maintenance operation is in progress.
  2. Controller is in Online Configuration Mode.
  3. AKD Restore failed.
  4. The IDE version of the compiled PLC code and controller runtime version do not match.
  5. Previous download failed.

Check the following:

  1. Controller web-server home page for any maintenance operation in-progress. Wait for the operation to finish.
  2. Connect to the controller with the IDE and disable Online Configuration Mode.
  3. EtherCATClosed ***EtherCAT is an open, high-performance Ethernet-based fieldbus system. The development goal of EtherCAT was to apply Ethernet to automation applications which require short data update times (also called cycle times) with low communication jitter (for synchronization purposes) and low hardware costs network topology by using the Scan network button in the web-server’s Restore tab. Correct the physical topology and re-execute an AKD restore.
  4. IDE version (only major.minor.micro) should match with runtime version. To correct, install the correct version of IDE or Runtime.
  5. Connect IDE and download application.
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
  • Read AKD parameter ECAT.DIAG for more information on where in the EtherCAT network the issue may be occurring. See Debugging Intermittent EtherCAT Communication Issues on KDN for more information.
  • Check the EtherCAT network wiring and devices state. Re-start the application.
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‡
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.
  • The slave EtherCAT device does not exist or cannot be physically reached due to connector/cable failure.
  • Slave hardware failure
  • Slave is still busy with a previous command and is not ready.
  • Check the EtherCAT cables and the connectors.
  • Check the EtherCAT devices for any device errors.
  
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.
  • Read AKD parameter ECAT.DIAG for more information on where in the EtherCAT network the issue may be occurring. See Debugging Intermittent EtherCAT Communication Issues on KDN for more information.
  • Check the EtherCAT network wiring and devices, or decrease the EtherCAT cycle rate.
 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.