Controller Error and Alarm Descriptions

E01

AKD PDMM and PCMM:

• After 20 seconds, the controller operation is stopped.
• The CPU is put to sleep.
• Critical temperature reached.
  • Critical temperature limit is 127 °C.

PCMM2G:

• After 20 seconds, the PLC application is stopped.
• The CPU is throttled.
• Critical temperature reached.
  • Critical temperature limit is 83 °C.

Controller temperature exceeds the safe operating temperature limit.

• Power-off.
• Check airflow and operating environment are within hardware specifications.
• Allow unit to cool before power-on.

E02

Out of memory.

KAS Runtime is stopping.

Memory leak, memory corrupted, or hardware memory failure.

• Power-off/on.
• If the problem is recurrent, check the Release Notes for firmware updates.
• If the problem persists, return the hardware for repair.

E03

Fan failure.

CPU cooling fan is not able to operate properly.

• Check temperature and monitor for High temp alarm (see A01).
• Return the hardware for fan replacement.

E10

Firmware is corrupted.

Flash memory corrupted during firmware download or flash hardware failure.

• Re-download firmware.
• Boot into recovery mode, download firmware, and power-off/on.
  See Recover Using the Web server for more information.
• If the problem persists, return the hardware for repair.

E11

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.

• Reset to factory defaults.
• If the problem persists, return the hardware for repair.

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.

E13

Out of NVRAM space to Retain Variables.

NVRAM is full.

Change application to reduce the amount of retained variables.

E14

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.

• Reset to factory defaults again from power-on.
• If the problem persists, return the hardware for repair.

E15

Cannot read / write files from/to an SD card / USB flash drive.

• PLC function failures do not cause this error.
• SD card / USB flash drive is not plugged in.
• The file system is corrupt and cannot be mounted.

AKD PDMM and PCMM

1. Insert a valid SD card.
2. Reformat the SD card using the Settings > SD Card > Format button.

PCMM2G

1. Plug-in a valid USB flash drive.
2. Reformat the USB flash drive using the Settings > USB Flash Drive > Format button.

E16

Not enough space available on the SD card / USB flash drive.

• SD card / USB flash drive is full, unable to write to the SD card / USB flash drive.
• PLC function failures.

AKD PDMM and PCMM

• Clean-up the SD card space by deleting files.
• Reformat the SD card using the Settings > SD Card > Format button.

PCMM2G

• Clean-up the USB flash drive space by deleting files.
• Reformat the USB flash drive using the Settings > USB Flash Drive > Format button.

E17

Cannot connect to a shared directory.

• Improper shared directory configuration on remote computer or the controller.
• Improper permissions, access control, or security policy for computer’s share configuration.
• Computer is not accessible via Ethernet network.

• Verify the computer's shared directory is accessible.
• Check and Apply the KAS Application > Shared Directory configuration.
• Power-off/on the controller.

E20

Runtime 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 (e.g., temperature alerts) and resolve them.
2. Power cycle the device.
3. If E20 is still reported, reset to factory defaults.
4. If the problem is recurrent, check the Release Notes for firmware updates.
5. Download firmware.

E21

Runtime process, thread, or driver 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.

• Power-off/on.
• If the problem is recurrent, check the Release Notes for firmware updates.

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 and controller Runtime versions are compatible.
• Re-compile the application, download, and re-start.

E23

CPU is overloaded.

Either:

• The motion engine did not complete.
• The PLC program did not complete within the timeout period due to excessive CPU load.

• Stop the application.
• Power-off/on.
• Reduce the sample rate, simplify the application, or reduce the application cycles and restart the application.
• See CPU Overload (E23).

E24

PLC application cannot be started

PLC application cannot be started because of an existing condition.

Possible reasons:

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

1. Check the 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. Check the EtherCAT network topology by using the Scan network button in the web-server’s Restore tab.
   Correct the physical topology and re-execute an AKD-x restore.
4. The IDE version (only major.minor.micro) should match with runtime version.
   To correct, install the correct version of IDE or Runtime.
5. Connect the IDE and download application.

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 the IDE Controller log for more information.

• Read the AKD-x 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.

E31

EtherCAT communication failure during pre-op mode.

EtherCAT network operation failed due to a network communication error.

• Check the EtherCAT network wiring and devices state.
• Re-start the application.

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.

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 the IDE Controller log for more information.

• Check the EtherCAT network wiring and devices state.
• Re-start the application.
• See Why am I getting an E33 error?.

E34

EtherCAT failed to initialize into pre-op mode.

EtherCAT network initialization failed due to a network communication error.

• Check the EtherCAT network wiring and devices state.
• Re-start the application.

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.

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.

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.

E50

Backup to SD card / USB flash drive failed.

An unrecoverable error occurred during the backup operation.

AKD PDMM and PCMM

• Repeat the backup to SD card operation.
• If it fails again, replace the SD card.

PCMM2G

• Repeat the backup to USB flash drive operation.
• If it fails again, replace the USB flash drive.

E51

Restore from SD card / USB flash drive 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 the hardware for repair.

E52

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

• Perform a backup operation before the restore.
• Use an SD card with valid backup files.

PCMM2G

• Perform a backup operation before the restore.
• Use a USB flash drive with valid backup files.

E53

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.

• Use a different SD card with Backup files from a compatible controller.

A01

High temperature exceeded.

CPU temperature near the safe operating temperature limit for:

• PCMM = 120 °C.
• PCMM2G = 78 °C

Check airflow and operating environment are within hardware specifications.

A02

Low on memory.

Memory leak or corruption.

• Power-off/on.
• If the problem is recurrent, check the Release Notes for firmware updates.
• If the problem persists, return the hardware for repair.

A04

Low input voltage.

+24 volt input power is +19 volts or less.

Check power supply voltage and connection to the controller.

A05

PCMM2G only.

The system time was not set on startup.

PCMM2G only.

• Network Time Protocol (NTP) is disabled.
  • The time could not be retrieved at startup.
• This is most likely caused by a dead or missing battery.

PCMM2G only.

Either:

• Insert a good battery and set the time.
• Enable NTP.
• See Date/Time tab for more information.

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.

A21

Recoverable process or thread failed to respond during operation.

KAS non-runtime code failed during normal operation and was automatically restarted.

• Power-off/on.
• If the problem is recurrent, check the Release Notes for firmware updates.

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.

A30

EtherCAT missed a send 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 to send EtherCAT frames every cycle.

A31

EtherCAT received a frame with a wrong Working Counter value.

See Actual Position Interpolation.

• The slave EtherCAT device does not exist or cannot be physically reached due to connector and/or 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.

See Actual Position Interpolation.

The EtherCAT master did not receive, or received too late, a frame for one or more cycles.

• Read the AKD-x 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.
• Decrease the EtherCAT cycle rate.

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.