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656 views180 pages

Mark Vie-GEH-6721-Vol-III PDF

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Ridho Heriyanto

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GE Energy

Mark* VIe Control Vol. III

Diagnostics and Troubleshooting
GEH-6721K
These instructions do not purport to cover all details or variations in equipment, nor
to provide for every possible contingency to be met during installation, operation,
and maintenance. The information is supplied for informational purposes only,
and GE makes no warranty as to the accuracy of the information included herein.
Changes, modifications and/or improvements to equipment and specifications are made
periodically and these changes may or may not be reflected herein. It is understood that
GE may make changes, modifications, or improvements to the equipment referenced
herein or to the document itself at any time. This document is intended for trained
personnel familiar with the GE products referenced herein.
GE may have patents or pending patent applications covering subject matter in this
document. The furnishing of this document does not provide any license whatsoever
to any of these patents.
This document contains proprietary information of General Electric Company, USA and
is furnished to its customer solely to assist that customer in the installation, testing,
operation, and/or maintenance of the equipment described. This document shall not be
reproduced in whole or in part nor shall its contents be disclosed to any third party
without the written approval of GE Energy.
GE provides the following document and the information included therein as is and
without warranty of any kind, expressed or implied, including but not limited to any
implied statutory warranty of merchantability or fitness for particular purpose

© 2009 General Electric Company, USA. All rights reserved.

Issued: 090315

* Trademark of General Electric Company

To :
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Safety Symbol Legend

Indicates a procedure, condition, or statement that, if not strictly

observed, could result in personal injury or death.

Indicates a procedure, condition, or statement that, if not strictly

observed, could result in damage to or destruction of equipment.

Indicates a procedure, condition, or statement that should be

strictly followed in order to optimize these applications.

Note Indicates an essential or important procedure, condition, or statement.

This equipment contains a potential hazard of electric shock or
burn. Only personnel who are adequately trained and thoroughly
familiar with the equipment and the instructions should install,
operate, or maintain this equipment.
Isolation of test equipment from the equipment under test
presents potential electrical hazards. If the test equipment cannot
be grounded to the equipment under test, the test equipment’s
case must be shielded to prevent contact by personnel.
To minimize hazard of electrical shock or burn, approved
grounding practices and procedures must be strictly followed.

To prevent personal injury or equipment damage caused by

equipment malfunction, only adequately trained personnel
should modify any programmable machine.
Contents 1-1
Alarms 2-1
Mark VIe Controller Alarms .............................................................................................................................................2-1
Controller Specific Alarms.........................................................................................................................................2-1
Specific I/O Pack Alarms ................................................................................................................................................2-21
PAIC Specific Alarms...............................................................................................................................................2-21
PAMB Specific Alarms ............................................................................................................................................2-26
PAMC Specific Alarms ............................................................................................................................................2-27
PAOC Specific Alarms .............................................................................................................................................2-31
PCAA Specific Alarms.............................................................................................................................................2-33
PCLA Specific Alarms .............................................................................................................................................2-42
PCNO Specific Alarms.............................................................................................................................................2-48
PDIA Specific Alarms ..............................................................................................................................................2-50
PDII Specific Alarms................................................................................................................................................2-51
PDIO Specific Alarms ..............................................................................................................................................2-53
PDOA Specific Alarms ............................................................................................................................................2-55
PEFV Specific Alarms..............................................................................................................................................2-58
PGEN Specific Alarms.............................................................................................................................................2-60
PHRA Specific Alarms.............................................................................................................................................2-62
PPDA Specific Alarms .............................................................................................................................................2-77
PPRA Specific Alarms ...........................................................................................................................................2-101
PPRF Specific Alarms ............................................................................................................................................2-110
PPRO Specific Alarms ...........................................................................................................................................2-114
PRTD Specific Alarms ...........................................................................................................................................2-121
PSCA Specific Alarms ...........................................................................................................................................2-123
PSVO Specific Alarms ...........................................................................................................................................2-124
PTCC Specific Alarms ...........................................................................................................................................2-134
PTUR Specific Alarms ...........................................................................................................................................2-136
PVIB Specific Alarms ............................................................................................................................................2-141
Common I/O Pack Alarms ............................................................................................................................................2-144
Common Alarms ....................................................................................................................................................2-144

GEH-6721K Diagnostics and Troubleshooting Contents i

Notes

1-1 GEH-6721K Mark* VIe Control Vol. III

Alarms

Mark VIe Controller Alarms

Controller Specific Alarms

The controller detects certain system errors during startup, download, and normal
operation. These diagnostic alarms can be displayed and reset from the ToolboxST
application, and are recorded in historical manner using WorkstationST* Recorder.
The following alarms are specific to the Mark VIe Controller.

20
Description I/O communication failure between [ ] and controller.

Possible Cause

• I/O pack did not complete Start

• I/O pack configuration files missing
• I/O pack restarted
• I/O pack configured for dual networks, but only one network is connected
• Network issue

Solution

• If the Control/Status communication is working correctly, any additional diagnosics should indicate the cause of the
problem.
• Build and download parameters to the I/O pack.
• Download firmware and parameters to the I/O pack.
• Verify that the Ethernet cables and network switch are operating correctly.
• Manually restart the I/O pack.

21
Description Control/Status communication failure between [ ] and controller.

Possible Cause

• Asynchronous Drive Language (ADL) communication unhealthy

• Terminal board barcode typed incorrectly in the ToolboxST configuration
• Wrong terminal board is configured in the ToolboxST application
• Pack is plugged into wrong Jack on terminal board, or wrong jack number is configured in the ToolboxST application
• I/O pack configured in ToolboxST application, but configuration not downloaded to the controller
• I/O pack in program mode

Solution

• Verify that the I/O pack configuration (Type, HW Form, Bar Code, position) matches the actual hardware.
• Build and download the configuration to the controller, wait for pack communication status to change, then scan and
download to the I/O pack.
• Manually restart the I/O pack.

GEH-6721K Diagnostics and Troubleshooting Alarms 2-1

22
Description Diagnostic status signal (...L3DIAG and/or ...ATTN) is [ ]; therefore, diagnostic status for this I/O pack maybe
inaccurate, unknown, or indeterminate.

Possible Cause

• I/O status signal quality in warning state

• signal quality unhealthy, forced, or being simulated
• Status information inaccurate

Solution Check signal health, remove the force, or simulated condition.

23
Description [ ] controller state is not OK...(i.e. Major Difference).

Possible Cause major difference in controller application/configuration code

Solution Rebuild the system and download.

24
Description Cannot retrieve pack Information. [ ]

Possible Cause

• Cannot get requested information from I/O pack

• Communication program failure
• I/O pack unable to retrieve IP address
• Terminal board barcode typed incorrectly in ToolboxST configuration
• Wrong terminal board configured in ToolboxST application
• Pack plugged into wrong Jack on terminal board, or wrong jack number in ToolboxST configuration
• I/O pack configured in ToolboxST application, but configuration not downloaded to controller
• I/O pack in program mode

Solution

25
Description Control/Status communication Error: [ ]

Possible Cause

• Cannot get diagnostic information from I/O pack

• I/O pack not able to load firmware

Solution

• Verify the I/O pack configuration.

• Rebuild application and download firmware and application to the I/O pack.
• Check network cables for proper connection.
• Verify that the switch is functioning correctly.

2-2 Alarms GEH-6721K Mark* VIe Control Vol. III

259
Description Application Runtime Error - [ ] Frame overruns occurred

Possible Cause Overloaded controller or controller sequencer malfunction (one or more frame overruns occurred)

Solution Increase frame idle time by:

• Reducing application or by increasing EGD period

• Using a faster processor board (UCCC)
• Replacing the processor module

260
Description Application Runtime Error - [ ] Frame skips occurred

Possible Cause Overloaded controller or controller malfunction. Frame number skips detected. Frame number should
monotonically increase during Controlling state

Solution

• Reduce controller processor load by increasing EGD period or by reducing application.

• Use a faster processor board such as UCCC.
• Replace the processor module.

279
Description Could not determine platform type from hardware

Possible Cause During commissioning/maintenance:

• Incorrect firmware version or hardware malfunction (firmware could not recognize host hardware type)

During normal operation:

• Hardware failure

Solution

• Verify that all connectors are aligned properly and fully seated.
• Check the firmware version for compatibility with platform. If correct, replace the processor module.

280
Description Platform hardware does not match configuration

Possible Cause During commissioning/maintenance:

• Platform type identified in the application configuration does not match actual hardware

During normal operation:

• Hardware failure

Solution

• Fix the platform type in the ToolboxST application (General tab, General Properties, Platform).
• Rebuild and download the application.
• If problem persists, replace the processor module.

GEH-6721K Diagnostics and Troubleshooting Alarms 2-3

282
Description Firmware Load Error - application independent processes failed to initialize

Possible Cause Runtime malfunction. An application-independent firmware process could not be started successfully.

Solution

• Reload firmware and application and restart.

• Controller: If failure persists, remove the Compact Flash module and reprogram the boot loader using the ToolboxST
configuration. Download using the Device | Download | Controller setup | Format Flash selection. After reinstalling the
flash module and restarting, reload the firmware and application.
• Replace the module.
• I/O pack: Re-download the base load.

283
Description Firmware execution error - Internal process crashed

Possible Cause Runtime or hardware malfunction (runtime process failed)

Solution

• Reload firmware and application and restart.

• Controller: If failure persists, remove the Compact Flash module and reprogram the boot loader using ToolboxST.
Download using the Device | Download | Controller setup | Format Flash pick, then, after reinstalling the flash module
and restarting, reload firmware and application.
• If this does not work, replace processor module.
• IoPack: Redownload the base load.

292
Description Application Error - application overruning the frame

Possible Cause Application cannot start within frame

Solution Check application loading and reduce the amount of application code or frequency of execution. Build application
and download to all processors.

294
Description Controller CPU overtemperature, Temp [ ] degC, Threshold [ ] degC

Possible Cause

• Fan loss
• Excessive ambient temperature
• Hardware malfunction

Solution Check the fan, including the ambient temperature, and any dust on the processor module. If okay, replace the
processor module.

2-4 Alarms GEH-6721K Mark* VIe Control Vol. III

300
Description Application Code Load Failure

Possible Cause During commissioning/maintenance:

• Invalid application configuration

During normal operation:

• Firmware or hardware malfunction

Solution

• Rebuild and download the application to all processors .

• Reload firmware and application.
• if problem persists, replace processor module.

320
Description Process Alarm Buffers Full - MarkVIe can miss alarm transitions

Possible Cause

• Multiple alarm variables changing state too quickly to transmit all transitions
• Excessive alarms in queue (Plant-wide system failures)

Solution During commissioning/maintenance:

• Reduce the number of alarms that can change state at the same time (filter alarm variables in the application code).

During normal operation:

• Eliminate the conditions causing excessive process alarms.

321
Description Internal Runtime error - Process Alarms not being scanned

Possible Cause Runtime malfunction: alarms not being scanned. Processor may restart on software watchdog timeout
due to processor overload

Solution

322
Description Configuration Load error - Too many consumed EGD variables for Fault Tolerant EGD

Possible Cause Number of relevant, consumed UDH EGD variables exceeds fault tolerant EGD limitation of 1400 bytes of
data.
Normal UDH EGD operation not affected; however, in the event of UDH EGD failure, some consumed variables may not
be transmitted to redundant controllers over the IONet.

Solution During commissioning/maintenance:

• Reduce the amount of relevant, consumed UDH EGD data by removing the appropriate number of variables from
EGD pages.

GEH-6721K Diagnostics and Troubleshooting Alarms 2-5

323
Description EGD Error - Fault Tolerant EGD activated

Possible Cause EGD exchange timeout occurred on requesting processor. Redundant processor unable to receive UDH
EGD inputs and requested that EGD data be transferred over the IONet.

Solution

• Verify that all redundant processors on the UDH network are receiving all expected EGD exchanges.
• that all relevant devices are powered up and producing data on the network.

324
Description EGD Error - Fault Tolerant EGD data requested

Possible Cause An EGD exchange timeout occurred on the requesting processor. Redundant processor unable to receive
UDH EGD inputs and has requested that EGD data be transferred over the IONet.

Solution

• Check UDH network and verify that all redundant processors are receiving all of the expected EGD exchanges.
• Verify that all relevant devices are powered on and producing data on the network.

326
Description Communication lost from R processor

Possible Cause

• IONet or hardware malfunction

• S or T processor in redundant system lost communication with R processor

Solution

• Go online with the R processor. Verify that the processor is in the Controlling state. If not communicating or in
Controlling state, restart the processor.
• Check for disconnected IONet cables or malfunctioning switches.
• Rebuild and download application.
• Check for bad ethernet cable to network switch.
• Check for bad network switch: place ethernet cable into empty port. If problem persists, replace network switch.

327
Description Communication lost from S processor

Possible Cause

• IONet or hardware malfunction

• R or T processor in redundant system lost communication with S processor

Solution

• Go online with the S processor. Verify that the processor is in the Controlling state. If not communicating or in
Controlling state, restart the processor.
• Check for disconnected IONet cables or malfunctioning switches.
• Rebuild and download the application.
• Check for a faulty ethernet cable-to-network switch.
• Check for bad network switch: place ethernet cable into empty port. If problem persists, replace network switch.

2-6 Alarms GEH-6721K Mark* VIe Control Vol. III

328
Description Communication lost from T processor

Possible Cause

• IONet or hardware malfunction

• R or S processor in redundant system lost communication with T processor

Solution

• Go online with the T processor. Verify that processor is in the Controlling state. If not communicating or in Controlling
state, restart the processor.
• Check for disconnected IONet cables or malfunctioning switches.
• Rebuild and download the application.
• Check for a faulty ethernet cable-to-network switch.
• Check for a faulty network switch by placing the ethernet cable into an empty port. If problem persists, replace the
network switch.

329
Description Startup sequence failed - Data initialization timeout R processor

Possible Cause Controller unable to complete startup data initialization

• IONet malfunction
• Controllers have different application revisions
• One or more controllers powered down
• Controller overloaded by external command messages

Solution

• Check for disconnected IONet cables or malfunctioning network switches.

• Rebuild and download the application.
• Verify that all controllers are powered on.
• Disable all other command senders (e.g., Modbus masters) until controller is online.

330
Description Startup sequence failed - Data initialization timeout S processor

Possible Cause Controller is unable to complete startup data initialization.

• IONet malfunction
• Controllers have different application revisions
• One or more controllers are powered down
• Controller is overloaded by external command messages.

Solution

• Check for disconnected IONet cables or malfunctioning network switches

• Rebuild and download application
• Ensure all controllers are powered up
• Disable all other command senders (e.g., Modbus masters) until controller is online.

GEH-6721K Diagnostics and Troubleshooting Alarms 2-7

331
Description Startup sequence failed - Data initialization timeout T processor

Possible Cause Controller is unable to complete startup data initialization.

• IONet malfunction
• Controllers have different application revisions
• One or more controllers are powered down
• Controller is overloaded by external command messages.

Solution

• Check for disconnected IONet cables or malfunctioning network switches

• Rebuild and download application
• Ensure all controllers are powered up
• Disable all other command senders (e.g., Modbus masters) until controller is online.

332
Description Overtemperature - Processor rebooted and throttled

Possible Cause

• Fan loss.
• Excessive ambient temperature
• Hardware malfunction.

Solution

• Check ambient temperature

• Check for dust buildup on cabinet filters
• Check fans
• Check for dust buildup on processor module, power supply

334
Description Application Error - [ ] Frame skips detected

Possible Cause

• Hardware or IONet malfunction.

• Frame number skips detected. Frame number should monotonically increase until rollover; alarm occurs following a
single frame number skips in successive frames.

Solution

• Check IONet (switches, cables);

• Replace processor module.

335
Description Memory Verification failed - Firmware processes

Possible Cause Hardware memory failure. A modification has occurred in the code segment for one of the processes. This
indicates that a hardware memory failure has occurred.

Solution Replace processor module.

2-8 Alarms GEH-6721K Mark* VIe Control Vol. III

336
Description Controller is unlocked

Possible Cause Mark VIeS: leaving Data Init control state and not locked or the controller is unlocked through the
ToolboxST application.

Solution Lock the controllers from ToolboxST application before executing safety functions.

337
Description Output exchange disagreement detected

Possible Cause IONet malfunction or hardware problem. For at least one output, a difference was detected between the
controller outputs. This alarm remains active until the controllers agree on all outputs. A difference for non-Boolean data
generally indicates a deviation of more than 10% from the median value or no IONet EGD configuration is present. For
median values near zero, the variation exceeds integer 2 or real value 0.2.

Solution

• For the Mark VIe runtime, use the ToolboxST disagreement display (View | Disagreements) to determine which variables
are in disagreement.
• In the application, avoid use of global variable ’ControllerID’ and avoid the use of sequencing block ’USB_HB’.
• Check IONet (switches, cables); rebuild and download application to all processors. If the problem persists, replace the
processor module.

347
Description Running Application does not match the BRANDed Application

Possible Cause Mark VIeS: Application not branded or different from branded version.
Note: The purpose of branding is to label a verified safety application, and to ensure that it is running.

Solution Reload the branded application to the controller and I/O packs, or use the ToolboxST application to brand
currently running application.

348
Description Intermittent communications on I/O Net 1 - Packet loss exceeded [ ]%

Possible Cause

• Power cycled on I/O producer (controller or I/O pack)

• IONet malfunction
• I/O message corruption
• Communication errors occurred on more than 5% of data transmissions on IO Net 1

352
Description Memory Validation failed - Blockware data structures

Possible Cause Hardware memory failure (application process data that should not change after the controller goes
online was modified; indicates hardware memory problem)

Solution Replace the processor module.

353
Description Memory Validation failed - Configuration shared memory

Possible Cause Hardware memory failure (system process data that should not change after the controller has gone
online was modified)

Solution Replace the processor module.

354
Description Memory Validation failed - EGD data structures

Possible Cause Hardware memory failure (IONet-EGD process data that should not change after the controller has
gone online has been modified)

Solution Replace the processor module.

2-10 Alarms GEH-6721K Mark* VIe Control Vol. III

355
Description State Exchange Voter disagreement detected

Possible Cause

• State Exchange disagreement found.

• Application sequencing error
• IONet malfunction or hardware problem.

Solution

• Use the ToolboxST disagreement display (View | Disagreements) to determine which variables are in disagreement.
• In the application, avoid use of global variable ’ControllerID’ and avoid the use of ’USB_HB’ block.
• Check IONet (switches, cables). If problem persists, replace the processor module.

356
Description NANs in CALC or NAN_BREAKER Block detected

Possible Cause

• NaN (Invalid floating point number) received from I/O interface

• Hardware problem

Solution

• Check for external devices that may be sending NaNs to the controller.
• If conditions persists, replace the processor module.

357
Description Internal Runtime error - Sequencer out-of-order execution detected

Possible Cause Possible hardware malfunction. Sequencer critical clients scheduled out of order. Alarm occurs following
three successive frames of sequencer critical client out-of-order execution detections; after five, controller put in FAILURE
control state.

Solution Replace the processor module.

358
Description Internal Runtime error - Sequencer client execution underrun

Possible Cause Possible hardware malfunction. Sequencer critical client underrun detected. Alarm occurs after a
sequencer critical client has been run slower than its nominal rate three times in a row; after five, controller put in FAILURE
control state.

Solution

• Ignore alarm if it occurs during a restartof the controller.

• Replace the processor module, if the alarm occurs during normal operation.

359
Description Internal Runtime error - Sequencer client execution overrun

Possible Cause Possible hardware malfunction. Sequencer critical client overrun detected. Alarm occurs after a sequencer
critical client has been run faster than its nominal rate three times in a row; after five, controller put in FAILURE control state.

Solution

• Ignore alarm if it occurs during a restart of the controller.

• Replace the processor module, if the alarm occurs during normal operation.

During normal operation:

• Check for network switch malfunction

• Check for loose or defective network cables
• Replace processor module.

363
Description Memory Validation failed - Sequencer data structures

Possible Cause Hardware memory failure (sequencer process data that should not change after the controller is online
was modified)

Solution Replace the processor module.

364
Description Too many state voter disagreements detected

Possible Cause

• State exchange voter disagreement overflow. System exceeded the limit of 128 simultaneous disagreements at once.
• Application error
• IONet malfunction or hardware problem

Solution

2-12 Alarms GEH-6721K Mark* VIe Control Vol. III

462
Description Hardware Reconfigured: Reboot by removing and reapplying power.

Possible Cause Flash file system corruption.

Solution

• After reapplying power, Rebuild and download baseload, firmware and application.
• If the problem persists, replace processor module

463
Description Internal runtime error - Could not create CEL log file

Possible Cause Internal runtime error. Could not create the Command and Event log file.

Solution

• Rebuild and download baseload, firmware and application to the processor.

• If the problem persists, replace processor module

464
Description Ethernet Interface [ ] disabled due to excessive traffic.

Possible Cause The network interface has been disabled to protect itself from excessive activity on the network.

Solution

• Check for network loops

• Monitor network activity and remove excessive traffic

465
Description Ethernet Interface [ ] disabled due to excessive traffic.

Possible Cause The network interface has been disabled to protect itself from excessive activity on the network.

Solution

• Check for network loops

• Monitor network activity and remove excessive traffic

466
Description Ethernet Interface [ ] disabled due to excessive traffic.

Possible Cause The network interface has been disabled to protect itself from excessive activity on the network.

Solution

• Check for network loops

• Monitor network activity and remove excessive traffic

467
Description Ethernet Interface [ ] disabled due to excessive traffic.

Possible Cause The network interface has been disabled to protect itself from excessive activity on the network.

Solution

• Check for network loops

• Monitor network activity and remove excessive traffic

GEH-6721K Diagnostics and Troubleshooting Alarms 2-13

468
Description Ethernet Interface [ ] disabled due to excessive traffic.

Possible Cause The network interface has been disabled to protect itself from excessive activity on the network.

Solution

• Check for network loops

• Monitor network activity and remove excessive traffic

• Pack restarting or restarted

• I/O pack application/configuration is missing.
• Application/configuration does not match in the pack and controller.
• Failed ethernet connection between pack and controller.
• Ethernet cable inserted into wrong connector on pack

Solution

• Reset all diagnostic alarms.

• Rebuild and download application to all controllers and I/O packs.
• Reload firmware and application.
• Verify that Ethernet cable on I/O pack matches the ToolboxST configuration.
• Check for faulty Ethernet cable from pack to network switch and/or from switch to controller. Replace cable(s) if
necessary.
• Replace the pack.
• Bad network switch, place pack’s ethernet cable into empty port. If problem persists, replace network switch.

GEH-6721K Diagnostics and Troubleshooting Alarms 2-15

1000-2024
Description Inputs unhealthy on IO Module [ ], S pack IONet [ ] - Message Timeout

Possible Cause

• Pack restarting or restarted

• I/O pack application/configuration missing
• Application/configuration does not match in pack and controller
• Failed ethernet connection between pack and controller
• Ethernet cable inserted into wrong connector on pack

Solution

• Reset all diagnostic alarms.

• Rebuild and download application to all controllers and I/O packs.
• Reload firmware and application
• Verify that Ethernet cable on I/O pack matches the ToolboxST configuration.
• Check for faulty Ethernet cable from pack to network switch and/or from switch to controller. Replace cable(s) if
necessary.
• Replace the pack.
• Bad network switch, place pack’s ethernet cable into empty port. If problem persists, replace network switch.

1000-2024
Description Inputs unhealthy on IO Module [ ], T pack IONet [ ] - Message Timeout

Possible Cause

• Pack restarting or restarted

Solution

• Reset all diagnostic alarms.

• Rebuild and download application/parameters to all controllers and I/O packs.

• Reload firmware and parameters to the affected I/O pack.
• Reload firmware and application to all controllers.
• If problem persists, replace affected I/O pack, then replace controller.

GEH-6721K Diagnostics and Troubleshooting Alarms 2-17

1000-2024
Description Inputs unhealthy on IO Module [ ] IONet [ ] - Message Length not valid

Possible Cause Application/configuration does not match in pack and controller

Solution

• Rebuild and download application/parameters to all controllers and I/O packs.

• Reload firmware and parameters to the affected I/O pack.
• Reload firmware and application to all controllers.
• If problem persists, replace affected I/O pack, then replace controller.

• Reload firmware and parameters to the affected I/O pack.
• Reload firmware and application to all controllers.
• If problem persists, replace affected I/O pack, then replace controller.

• Reload firmware and parameters to the affected I/O pack.
• Reload firmware and application to all controllers.
• If problem persists, replace affected I/O pack, then replace controller.

• Reload firmware and parameters to the affected I/O pack.
• Reload firmware and application to all controllers.
• If problem persists, replace affected I/O pack, then replace controller.

2-20 Alarms GEH-6721K Mark* VIe Control Vol. III

Specific I/O Pack Alarms

PAIC Specific Alarms

The following alarms are specific to the PAIC I/O pack.

32-41
Description Analog Input [ ] unhealthy.

Possible Cause

• Excitation to transducer is wrong or missing.

• Transducer is defective.
• Analog input current/voltage input is beyond the specified range.
• Terminal board jumper settings do not match the ToolboxST configuration.
• Open or short-circuit on input.

Solution

• Check the field wiring and connections to indicated analog input channel.
• Check the field device for failure.
• Verify that the configuration matches terminal board jumper settings for the indicated analog input channel.

44-45
Description Output [ ] individual current feedback unhealthy.

Possible Cause

• Commanded output is beyond the range of the output.

• Field wiring problem
• Field device problem
• Open loop or too much resistance in the loop.
• I/O pack failed.
• Terminal board failed.

Solution

• Verify that the commanded output is within the range of the output.
• Confirm the correct I/O pack 28 V input power.
• Check the field wiring and device.
• Replace the I/O pack.

46-47
Description Output [ ] total current feedback unhealthy.

Possible Cause

• Commanded output is beyond the range of the output.

• Field wiring problem
• Field device problem
• Open loop or too much resistance in the loop.

Solution

• Verify that the commanded output is within the range of the output.
• Confirm the correct I/O pack 28 V input power.
• Check the field wiring and the component.
• Replace the I/O pack.

GEH-6721K Diagnostics and Troubleshooting Alarms 2-21

48-49
Description Output [ ] Internal reference current unhealthy.

Possible Cause

• I/O pack failure

• Check the field wiring and device.

• Check the J0 jumper setting on the terminal board.
• Verify that the value of D/A_ErrLimit is set correctly.
• Verify that the commanded output is within output range.
• Replace the pack.

2-22 Alarms GEH-6721K Mark* VIe Control Vol. III

82-83
Description Output [ ] Suicide relay non-functional.

Possible Cause The analog output suicide relay command doesn’t match the feedback.

• Relay failure on the acquisition board.

• Hardware failure

Solution Replace the I/O pack.

86
Description Output [ ] 20/200 mA selection non-functional.

Possible Cause The analog output has been configured for 200 mA but the hardware is not responding to the configuration.

Solution Replace the I/O pack.

90-91
Description Output [ ] 20/200 mA suicide active.

Possible Cause

• Suicide is enabled on analog output.

• Review any additional diagnostics for possible causes.
• TMR_SuicLimit is set too low.
• Field wiring problem
• Command is beyond the range of the output.
• Analog output configuration does not match hardware jumpers.

Solution

• Verify that the value of TMR_SuicLimit is set correctly.

• Verify that the value of D/A_ErrLimit is set correctly.
• Verify the field wiring connections.
• Verify that the commanded output is within output range.
• On PAICH2A, verify that terminal board jumper (JO) settings for analog output match the configuration (20mA/200mA).

92-93
Description Output [ ] Suicide on overcurrent, check terminal board jumper.

Possible Cause

• Incorrect setting of terminal board 20/200 mA jumper

• Hardware failure in I/O pack.

Solution

• Check the terminal board jumper (JO).

• Replace the I/O pack.

97
Description Hardware form (PAICH1A) does not support 200mA on Output 01.

Possible Cause Analog Output 1 is configured for 0-200 mA, but the hardware form of the pack (PAICH1A) does
not support 200 mA.

Solution Configure the analog output 1 to be 0-20 mA or if 200 mA is required, the pack must be replaced with the
correct hardware form (PAICH2A).

GEH-6721K Diagnostics and Troubleshooting Alarms 2-23

98
Description PAICH2A 200mA driver temperature ([ ] deg F) exceeds the max limit ([ ] deg F).

Possible Cause The internal temperature on a PAICH2A has exceeded the maximum temperature limit of 185 °F (85°C).

Solution Check the environmental controls applied to the cabinet containing the I/O pack. The pack operation will continue
correctly beyond these temperature limits but long-term operation at elevated temperatures may reduce equipment life.

99
Description Pack internal power supply status not OK.

Possible Cause The internal power supply that provides analog circuit control power is not operating correctly.

Solution

• Check the I/O pack ground quality through mounting bolts.

• Confirm that 28 V input power is within 26.6 - 29.4 V range.
• Replace I/O pack.

100
Description Dither Time is frozen or out of range - [ ].

Possible Cause The time signal used to generate a dither on the valve output signal does not appear to being changing.
This could cause a frozen valve.

Solution

• Cycle the power on I/O pack.

• Replace the I/O pack.

101
Description Pack internal reference voltage out of limits.

Possible Cause The calibration reference voltage for the analog inputs is more than +/-5% from the expected value,
indicating a hardware failure.

Solution

• Check the I/O pack ground quality through mounting bolts.

• Cycle power on I/O pack.
• Replace the I/O pack.

102
Description Pack internal null voltage out of limits.

Possible Cause The calibration Null voltage for the analog inputs is more than +/-5% from the expected value, indicating
a hardware failure.

Solution

• Check the I/O pack ground quality through mounting bolts.

• Cycle power on the I/O pack.
• Replace the I/O pack.

128
Description Logic Signal [ ] Voting Mismatch.

Possible Cause N/A

Solution N/A

2-24 Alarms GEH-6721K Mark* VIe Control Vol. III

224-235
Description Input Signal [ ] Voting Mismatch, Local=[ ], Voted=[ ].

Possible Cause

• Voter disagreement between the R, S and T I/O packs

• Check the sensor for issues.

120
Description BAPA ADC Reference input calibration failure.

212
Description HSSL Comm link [ ] Communication Failure, Code [ ].

Possible Cause The PAMC/UCSA cannot communicate with the remote acquisition hardware (terminal board and BAPA)
through the High-Speed Serial Link (HSSL) cable. The code indicates a specific failure type.
Common codes include:

• 51xxxxxx: Remote acquisition target returning bad id

• 52xxxxxx: Download to BAPA failed
• 53xxxxxx: Link loss detected
• 54xxxxxx: Receive packet error detected
• 55xxxxxx: Transmit packet error (excessive naks)
• 57xxxxxx: No data received from BAPA in 5 seconds

Solution

• Verify that the BAPA is connected to the SL1 connector on the PAMC UCSA.
• Check the HSSL cables. If a problem still exists, replace the PAMC UCSA module.
• Check the power on the BAPA.
• Replace the BAPA.

2-28 Alarms GEH-6721K Mark* VIe Control Vol. III

213
Description HSSL Comm link [ ] Initialization Failure.

Possible Cause The PAMC UCSA cannot properly initialize the BAPA through the HSSL.

Solution

• Verify that the BAPA is connected to the appropriate HSSL connector on the PAMC UCSA.
• Check the HSSL cables. If a problem still exists, replace the PAMC UCSA module.
• Check the power on the BAPA.
• Replace the BAPA.

214
Description HSSL Comm link [ ] Configuration Failure, Code [ ].

Possible Cause The PAMC UCSA interface to the HSSL failed to initialize properly.

Solution Replace the PAMC UCSA.

215
Description BAPA plugged into wrong SAMx connector on HSSL [ ].

Possible Cause The SAMB or SAMC connector that the BAPA is plugged into does not agree with HSSL connector
configured in the ToolboxST application.

Solution

• Verify that the HSSL cable is plugged into the PAMC UCSA SL1 connector.
• Verify that the HSSL cable is plugged into the correct BAPA.
• Verify that the SAMC/SAMB configured connections in the ToolboxST application match the BAPA connection to
the terminal board.

216
Description BICA (JA1) On Board power supply failure, expected [ ] V, read [ ] V.

Possible Cause The BICA power supply failed.

Solution Replace the BICA plugged into the JA1 connector.

217
Description BICA (JB1) On Board power supply failure, expected [ ] V, read [ ] V.

Possible Cause The BICA power supply failed.

Solution Replace the BICA plugged into the JB1 connector.

218
Description Bad power supply on connector P28 [ ](1=A,2=B,3=C) in charge amp junction box.

Possible Cause There is no 28 volt power connected to the P28B or the P28C in the junction box.

Solution

• Parameter JuncBox is set for the wrong type.

• Verify the power supply connection to the P28B or the P28C in the junction box.
• Replace the power supply cable/connector.
• Replace the power supply.

GEH-6721K Diagnostics and Troubleshooting Alarms 2-29

219
Description Bad power supply on connector P28B or P28C in charge amplifier junction box.

Possible Cause The junction box power supply is faulty.

Solution

Possible Cause

• D/A_ErrLimit is not configured properly (set too low).

• Field wiring problem
• Open-circuit on output or total loop resistance is too high.
• Possible hardware failure in pack

Solution

• Verify the D/A_ErrLimit settings.

• Check the field wiring and device.
• Replace the I/O pack.

54-61
Description Output [ ] feedback current is excessive.

Possible Cause The analog output current feedback is greater than 30mA. This will typically cause the output to suicide.

• Field wiring problem

• Possible hardware failure in pack

Solution

• Verify the analog output connections and field wiring.

• Replace the I/O pack.

62-69
Description Output [ ] Suicide relay non-functional.

Possible Cause The analog output suicide relay command doesn’t match the feedback.

• Possible relay failure on the acquisition board

• Possible hardware failure in pack

Solution Replace the I/O pack.

GEH-6721K Diagnostics and Troubleshooting Alarms 2-31

70-77
Description Output [ ] Suicide Active.

Possible Cause

• Suicide is enabled (Suicide_Enab) for analog output.

• Review any additional diagnostics for possible causes.
• Analog output current feedback is too high (30mA).
• Field wiring problem
• Command is beyond the range of the output.

Solution

• Verify that the commanded output is within output range.

• There may be a field wiring issue or an LVDT sensor failure.
• There may be an internal hardware failure.

Solution

• Check the field wiring, including shields, for LVDT excitation output. The problem is usually not a PCAA or terminal
board failure if other LVDT excitation outputs are working correctly.
• Check the LVDT sensor.
• If the problem is a hardware failure, replace the PCAA.

2-34 Alarms GEH-6721K Mark* VIe Control Vol. III

123-134
Description LVDT [ ] Excitation voltage out of range.

Possible Cause ExcitMonCal is set during servo regulator calibration, and is a nominal excitation value. If actual LVDT
excitation goes out of range (+/- 10% of ExcitMonCal), this alarm is generated.

• There may be a terminal board failure.

Solution

• Measure the excitation voltage, and verify against the configuration parameter.
• Check the LVDT sensor.
• Recalibrate the servo.
• Replace the PCAA.

135-146
Description LVDT [ ] Position Out of Limit.

Possible Cause

• There may be an issue with excitation to the LVDT, a faulty transducer, or an open or short-circuit.
• The LVDT input is out of range.
• The LVDT has not been calibrated.

Solution

• Check the field wiring, including the shields and the LVDT excitation. The problem is usually not a PCAA or terminal
board failure if other LVDT inputs are working correctly.
• Check the LVDT sensor.
• Calibrate the servo regulator with the proper LVDT.
• Verify the configuration limits: MinVrms and MaxVrms.
• Verify that the LVDT excitation terminal board connections match the configured excitation source specified in
ExcitSelect.
• Verify that PosMargin is set to the proper value.

147-148
Description Invalid Monitor [ ] Configuration.

Possible Cause

• The configuration for the selected servo and regulator type is invalid.

Solution

• Verify that the monitor regulator type matches the regulator type of the selected servo.
• Rebuild and download the configuration.

149
Description More than One Servo Requested for Calibration.

Possible Cause

• The user has requested more than one servo calibration (only one servo can be calibrated at a given time).

Solution

• Check the variables in the Variables tab to verify that only one CalibEnab# for only one servo is set to True at a
given time.

GEH-6721K Diagnostics and Troubleshooting Alarms 2-35

150
Description Calibration : Selected LVDT Max / Min Pos Limit Out of Range.

Possible Cause Used to ensure that all selected LVDTs are scaled to the same units.

• The parameter MaxPosValue or MinPosValue for the selected LVDT configured in the regulator configuration is
out of range (+/-50%, encountered during calibration).

Solution

• Check the regulator configuration for the parameter PositionInput#1 for the particular servo.
• Check the parameters MaxPosValue and MinPosValue for the LVDT# selected input in PositionInput#1.
• The parameter MaxPosValue for LVDT input should be between 50% to 150%.
• The parameter MinPosValue for LVDT input should be between -50% to 50%.

151-154
Description FlowRate [ ] Input unhealthy.

Possible Cause

• There may be a broken wire on the flow rate input.

• There may be a faulty sensor.

Solution

• Verify the field wiring, including shields. The problem is usually not a PCAA or terminal board failure if other flow
rate inputs are working correctly.
• Check the gap for the magnetic pickup sensor.
• For the TTL sensor, verify the power to the sensor and the gap.
• Replace the hardware.

155-160
Description Servo [ ] Disabled: Configuration error.

Possible Cause

• The servo position input is connected to an unused LVDT.

• The configuration for the position input is incorrect.
• The servo flow input is connected to an unused PR.
• The configuration for the flow input is incorrect.
• The servo pressure input is connected to an unused analog input.
• The configuration for the pressure input is incorrect.

Solution

• Check and correct, if necessary, the configuration parameters relating to the list of possible causes.
• Verify that the regulator inputs are connected to used the sensor inputs in configuration.
• In the ToolboxST configuration, right-click the PCAA, then select the parameter Troubleshooting->Advanced Diagnostics.
Navigate through the PCAA Commands to the parameter Servos->Servo Cfg Error. Send the command to the PCAA
for a list of configuration errors that were detected in the servo regulator settings.

2-36 Alarms GEH-6721K Mark* VIe Control Vol. III

161-166
Description Servo [ ] Output Suicide Active.

Possible Cause

• The servo position input is connected to an unused LVDT.

Solution

• Check and correct, if necessary, the configuration parameters relating to the list of possible causes.
• Verify that the inputs are connected to used sensor inputs in the configuration.
• It is a LVDT feedback issue; check the position sensor connections.
• Verify the position sensor mechanical integrity to the valve.
• Check the wiring of the servo output loop for an open or short circuit.
• Check for a short or open servo coil.

167-173
Description Pack internal reference voltage out of limits ([ ]).

Possible Cause The calibration reference voltage is more than +/-5% from the expected value, which indicates a hardware
failure.

Solution

• Cycle power on the PCAA.

• Replace the PCAA.

174-180
Description Pack internal null voltage out of limits ([ ]).

Possible Cause The null voltage is more than +/- 5% from the expected value which indicates a hardware failure.

Solution

• Cycle power on the PCAA.

Solution

• Check the field wiring and the status of the connected device.
• If there is a hardware failure, replace the PCAA.

2-38 Alarms GEH-6721K Mark* VIe Control Vol. III

191-193
Description Analog Output (TCAT) [ ] 20 mA suicide active.

Possible Cause

• Review any additional diagnostics for possible causes.

• The TMR_SuicLimit parameter is set too low.
• There may be a field wiring problem.
• The command is beyond the range of the output.
• There may be a terminal board failure.

Solution

• Check the field wiring and the status of the connected device.
• Verify that the TCAT-PCAA cables are fully seated in the connectors.
• Verify that the value of the parameter TMR_SuicLimit is set correctly.
• Verify the field wiring connections.
• Verify that the commanded output is within output range.
• Replace the PCAA module.
• Replace the TCAT terminal board.

194-195
Description Analog Output (TCAS) [ ] Suicide relay non-functional.

Possible Cause The analog output suicide relay command does not match the feedback.

• There may be a relay failure on the acquisition board.

• There may be a hardware failure.

Solution If there is a hardware failure, replace the PCAA.

196-198
Description Analog Output (TCAT) [ ] Suicide relay non-functional.

Possible Cause The analog output suicide relay command does not match the feedback.

• There may be a relay failure on the acquisition board.

• There may be a hardware failure.

Solution If there is a hardware failure, replace the PCAA.

199-204
Description Servo [ ] Position Feedback out of range.

Possible Cause

• The LVDT position feedback is outside the specified range.

Solution

• Check the LVDT configuration settings.

• Calibrate the affected regulator.
• Check the field wiring.
• Check for a shorted or open-position sensor coil.
• Verify the mechanical integrity of the position sensor.
• Verify that the TCAT-PCAA cables are fully seated.

GEH-6721K Diagnostics and Troubleshooting Alarms 2-39

205-210
Description Servo [ ] Pressure Feedback out of range.

Possible Cause

• The pressure feedback used in a servo regulator is outside the specified range.

Solution

• Check the source of the pressure signal, including the sensor, field wiring, and configuration.
• Verify the terminal board jumper settings for the analog inputs.

211-216
Description Servo [ ] Flow Feedback out of range.

Possible Cause

• The flow feedback used in a servo regulator is outside the specified range.

Solution

• If the out-of-range flow input is connected to the parameter FlowRate3 or FlowRate4 (TTL Pulse input), check the
power to device, the field wiring, the sensor, and the configuration.
• If the out-of-range flow input is connected to the parameter FlowRate1 or FlowRate2 (Magnetic pickup), check the
device, the field wiring, the input configuration, and the TCAT-PCAA cables.
• Check the gap between the sensor and the flow wheel.

217
Description TCAT Configuration and Hardware Mismatch.

Possible Cause This diagnostic is only generated on power-up.

• The TCAT is configured in the ToolboxST application, but the terminal board is not connected.
• The TCAT is not configured in the ToolboxST application, but the terminal board is connected.

Solution

• Verify that the TCAT selection in the ToolboxST configuration matches the actual hardware.
• Verify that the P1 and P2 cable connections are not swapped.
• Verify the the TCAT terminal board P1 and P2 cable connections are screwed down, and all terminal boards are
properly grounded.
• Perform a power-down reset to clear.

218
Description TCAT Connector P1 and P2 Types Mismatch.

Possible Cause The Type ( for example, R/R or S/S or T/T) of P1 and P2 connections between the TCAT and the TCAS
do not match. The Valid combinations are:

• P1(TCAS)-PR1(TCAT) & P2(TCAS)-PR2(TCAT)

• P1(TCAS)-PS1(TCAT), P2(TCAS)-PS2(TCAT)
• P1(TCAS)-PT1(TCAT), P2(TCAS)-PT2(TCAT)

Solution

• Check the ToolboxST configuration, as well as the TCAT terminal board P1 and P2 cable connections between the
TCAS and the TCAT.
• Verify that there is no Type (R/R,S/S,T/T) mismatch.

2-40 Alarms GEH-6721K Mark* VIe Control Vol. III

221
Description Calibration Mode Enabled.

Possible Cause

• One of the CalibEnab# outputs is set to True.

Solution

• This alarm is active to annunciate that the board is in a special mode (the servo suicide protection has been disabled,
and the user needs to take special precautions).
• Set CalibEnab# to False.

1050-1145
Description Logic Signal [ ] Voting Mismatch.

Possible Cause N/A

Solution N/A

1146-1238
Description Input Signal [ ] Voting Mismatch, Local [ ], Voted [ ].

Possible Cause

• A voter disagreement was detected between the R, S and T controllers.

Solution Adjust the specified parameter below for each input type:

• If the input variable is AnalogInput[ ], adjust the TMR_DiffLimit.

• If the input variable is PulseInput[ ], adjust the TMR_DiffLimit.
• If the input signal is LVDT[ ], adjust the LVDT_TMR_DiffLimit on the Parameters tab.
• If the input variable is ServoOutput[ ]:

- Adjust the TMR_DiffLimit on the Regulators tab.

- Also check for a mismatch in the coil resistance between the R, S and T servo coils.

- Reg#_Gain is set too high for specified TMR_DiffLimit value.

GEH-6721K Diagnostics and Troubleshooting Alarms 2-41

PCLA Specific Alarms
The following alarms are specific to the PCLA I/O pack.

33-36
Description Analog Input (Simplex) [ ] unhealthy.

Possible Cause

• Excitation to transducer wrong or missing

• Transducer faulty
• Terminal board jumper settings do not match ToolboxST configuration
• Analog input current/voltage input beyond specified range
• Open or short-circuit on input

Solution

• Check the field wiring and the connections to the indicated analog input channel.
• Check the field device for failure.
• Check the ground select jumper for the input.
• Verify that the inputs are in operable range (3.0-21.5mA,+/-5.25 V,+/-10.5 V).
• Verify that the configuration matches the terminal board jumper settings for the indicated analog input channel.

37-40
Description Analog Input (SCLT) [ ] unhealthy.

Possible Cause

• Excitation to transducer wrong or missing

• Transducer faulty
• Analog input current/voltage input beyond specified range
• Terminal board jumper settings do not match ToolboxST configuration
• Open or short-circuit on input

Solution

• Confirm the correct I/O pack 28 V input power.

• Replace the PCLA module.

GEH-6721K Diagnostics and Troubleshooting Alarms 2-43

61
Description Analog Output (Simplex) [ ] 20 mA suicide active

Possible Cause

• Suicide parameter enabled on analog output

• Review any additional diagnostics for possible causes.
• Analog output current feedback too high (30 mA)
• Parameter TMR_SuicLimit set too low
• Field wiring problem
• Command is beyond range of output

Solution

• Verify that the value of the parameter TMR_SuicLimit is set correctly.

• Verify that the value of the parameter D/A_ErrLimit is set correctly.
• Verify that the commanded output is within output range.

62-67
Description Analog Output (SCLT) [ ] 20 mA suicide active.

Possible Cause

• Suicide parameter enabled on analog output

• Review any additional diagnostics for possible causes.
• Analog output current feedback too high (30 mA)
• Parameter TMR_SuicLimit set too low
• Field wiring problem
• Command beyond range of output

Solution

• Verify that the value of the parameter TMR_SuicLimit is set correctly.

• Verify that the value of the parameter D/A_ErrLimit is set correctly.
• Verify that the commanded output is within output range.

68
Description Analog Output (Simplex) [ ] Suicide relay non-functional.

Possible Cause

• Analog output suicide relay command does not match feedback

• Relay failure on acquisition board
• There is a hardware failure.

Solution Replace the PCLA.

69-74
Description Analog Output (SCLT) [ ] Suicide relay non-functional.

Possible Cause

• Analog output suicide relay command does not match feedback

Solution

• If hardware is in the normal temperature range, then possible hardware failure of cold junction sensor on the SCLS
board. Replace terminal board.
• Replace PCLA.

150
Description Cold Junction (SCLT) Unhealthy, Using Backup.

Possible Cause

• Local cold junction signal from SCLT terminal board out of range. The normal range is -30 to 65 deg C (-22 - 145 deg F).

Solution

• Verify that the cable between the SCLT - PCLA module is fully seated in the connector.
• If hardware is in the normal temperature range, then a possible hardware failure of cold junction sensor on the SCLT
board. Replace the terminal board.

2-46 Alarms GEH-6721K Mark* VIe Control Vol. III

151-158
Description RTD [ ] Unhealthy.

Possible Cause

• RTD wiring/cabling open or high impedance

• Open on connections to the terminal board
• RTD device failed
*PCLA module internal hardware problem
• Current source on PCLA for RTD faulty or measurement device failed
• Wrong type of RTD configured or selected by default
• High-resistance values created by high voltage and/or low current

Solution

• Check the field wiring for open circuit or high impedance.

• Verify the proper connections to the terminal board.
• Check the RTD for proper operation.
• Verify that the RTD type configuration matches the attached device type.
• Replace the PCLA.

159
Description SCLT Configuration & Hardware Mismatch.

Possible Cause

• If the issue persists, replace the pack.

37
Description CANopen module failure

Possible Cause From the PCNO firmware perspective, the CANopen watchdog timed out (indicating failure of the
CANopen firmware).

Solution

• Rebuild and download the firmware to the PCNO.

• If the issue persists, replace the pack.

2-48 Alarms GEH-6721K Mark* VIe Control Vol. III

38
Description CANopen module failure - Module shutdown

Possible Cause The CANopen module has shut down, indicated by a loss of READY/RUN. CANopen READY indicates
that the firmware is running, and RUN indicates that a valid configuration has been processed. Loss of READY/ RUN
implies that the CANopen module has shut down.

Solution

• Power cycle the pack.

• If the issue persists, replace the pack.

39
Description Unknown CANopen device identified on CANopen network

Possible Cause An identity check for one of the connected devices has failed. During startup, and when a new device is
detected, the I/O pack confirms the identity of expected devices before starting normal operation.

Solution Verify that the (re)connected device is the same as the ToolboxST configuration.

40
Description Waiting for all CANopen devices to connect

Possible Cause

• Not all required slaves are connected to the CANopen network.

• During startup, the IO Pack requires all slaves to be connected to confirm the identity of all required devices before
starting normal operation.
• During normal operation, the IO Pack generates this alarm if a disconnected device is reconnected with a duplicate ID.

Solution

• Verify that the number of connected devices matches the number configured in the ToolboxST application.
• Verify that all connected devices have power applied and are operating correctly.
• Verify that the connected devices are configured correctly (for example, the device ID and baud rate).
• Check to see if any devices are configured with the same CANopen device ID.

41-45
Description CANopen slave device #[ ] communication error

Possible Cause

• Connected device is powered off or rebooting

• Failed CANopen bus connection between pack and controller.
• Connected device has not communicated or sent heartbeat message on CAN bus over at least five consecutive
MarkVIe frames.

Solution

• Verify that the connected device has power applied.

• Verify that the CANopen cable is properly connected.
• Troubleshoot the connected device for internal errors, refering to its manual. If problem persists, replace the connected
device.

GEH-6721K Diagnostics and Troubleshooting Alarms 2-49

PDIA Specific Alarms
The following alarms are specific to the PDIA I/O pack.

56-79
Description Contact Input [ ] not responding to high self-test mode.

Possible Cause The input hardware internal to the I/O pack has experienced a failure.

Solution Replace the I/O pack.

80-143
Description Logic Signal [ ] Voting Mismatch.

Possible Cause In a TMR application, the values for the specified contact do not agree between the R, S, and T I/O packs.

Solution

• Verify that R, S, and T I/O packs are equal with ToolboxST configuration.
• Check the I/O pack power and networking.
• Check the I/O pack mounting on terminal board.
• Replace the I/O pack.

240
Description Excitation Voltage not valid, Contact Inputs not valid.

Possible Cause The contact excitation voltage applied to the terminal board is not within the acceptable range for the board.

Solution Check power distribution and wiring to ensure that the correct excitation voltage is applied to the terminal board.

2-50 Alarms GEH-6721K Mark* VIe Control Vol. III

PDII Specific Alarms
The following alarms are specific to the PDII I/O pack.

34-49
Description Contact Input [ ] Invalid excitation voltage

Possible Cause This diagnostic occurs for contact inputs that are configured as ’Isolated’ inputs, OR if configured with a
standalone SDII terminal board.

• Configured excitation voltage for the contact input does not match the applied excitation voltage.
• Applied excitation voltage for the contact is outside its valid range.

Solution

• Verify that the contact input configuration matches the external excitation voltage.
• Verify that the external excitation voltage power supply voltage is within the expected voltage range.
• Refer to the PDII help documentation for more information.

50-65
Description Line to line short on contact [ ]

Possible Cause This alarm is only valid for SDII+WDIIH2 or SDII+WDIIH3.

• ToolboxST configuration does not match the actual hardware.

• Parameter, LineMonitoring/FuseDiag (SDII+WDIIH2) or LineMonitoring (SDII+WDIIH3), is set incorrectly.
• Series and/or the parallel resistor have an incorrect resistance.
• Shorted wire between the contact and the terminal board screws

Solution

• Verify that the actual hardware matches the ToolboxST configuration.

• Verify the value and location of the connected series and parallel resistors with respect to the contact.
• Verify that LineMonitoring configuration is set to SeriesParResistor.
• Check and correct the wiring to clear the line fault.
• Refer to the PDII help documentation for more information.

66-81
Description Open field wire for contact [ ]

Possible Cause This alarm is specific to WDIIH3.

• Parallel resistor is not connected across the contact.

• Open wire between the contact and the SDII screw connections

Solution

• Verify the parallel resistor values and connection across the contact.
• Verify the wiring connections between the SDII and the contact.
• Refer to the PDII help documentation for more information.

GEH-6721K Diagnostics and Troubleshooting Alarms 2-51

98
Description Invalid Board excitation voltage connected to the WDII board

Possible Cause

• For WDIIH1: The BoardWettingV parameter does not match the actual excitation voltage applied to the WDII board.
• For WDIIH1/2/3: The board level excitation voltage applied to the WDII board is out of range.

Solution

• For WDIIH1: Verify that the BoardWettingV parameter matches the actual excitation voltage applied to the WDII board.
• Verify that the excitation voltage applied to the WDII board is within range.
• Refer to the PDII help documentation for more information.

99
Description GROUND FAULT

Possible Cause A ground fault has occurred in the WDPC.

Solution Replace the WDPC.

100-115
Description Line fault monitoring not possible for contact [ ]

Possible Cause This alarm is specific to WDIIH1.

• Board level excitation voltage is configured for 24 V dc, but the actual excitation voltage connected is ac instead of dc.

Solution

• Verify that the BoardWettingV parameter matches the actual excitation voltage applied to the WDII board.
• Apply 24 V dc to the excitation voltage connector on the WDIIH1 board.
• Refer to the PDII help documentation for more information.

116-131
Description Either wire open or fuse blown for contact [ ].

Possible Cause This alarm is specific to WDIIH1 and WDIIH2.

• Parallel resistor is not connected across the contact.

• Open wire between the contact and the SDII screw connections.
• Fuse of the associated contact input is blown.
• Isolated contact input (fuse pulled so that system excitation voltage is not applied) has been configured as
SystemWetted.

Solution

• Verify the parallel resistor values and connection across the contact.
• Verify the wiring connections between the SDII and the contact.
• Replace the blown fuse. Refer to help documentation for the correct part number.
• Verify that the isolated contact input has the parameter WettingV configured to the proper external excitation voltage
value (24 V dc, 48 V dc, 125 V dc, 250 V dc, 115 V ac, 230 V ac).
• Refer to the PDII help documentation for more information.

2-52 Alarms GEH-6721K Mark* VIe Control Vol. III

PDIO Specific Alarms
The following alarms are specific to the PDIO I/O pack.

34-45
Description Fuse [ ] blown.

Possible Cause

• I/O pack fuse status feedback indicates a possible blown fuse.

• Consult the relay terminal board help documentation on fuse configuration.

Solution Do the following in order:

• Check the indicated fuse.

• Check the power input to the terminal board.
• Check the terminal board configuration.
• Check the I/O pack configuration.
• Confirm that all connectors are aligned and fully seated.
• Replace the I/O pack.
• Replace the terminal board.

46
Description All Fuses Blown or No Terminal Board Excitation.

Possible Cause All fuse sensing indicates an open fuse. This may be due to loss of input power to the terminal board.
Without power to the fuses, the sensing may indicate a false open-fuse condition.

Solution

• Confirm the correct input power to terminal board.

• Check the pack connector alignment and seating.
• Check the pack configuration.
• Check all fuses.
• Replace the I/O pack.
• Replace the terminal board.

47-58
Description Relay Coil [ ] Failure.

Possible Cause Indication that relay feedback does not match commanded state.

Solution

• Clear the voter disagreements (for TMR).

• Check the I/O pack connector alignment and seating.
• Check the I/O pack configuration.
• Replace the terminal board.

59-70
Description Relay Output Driver [ ] Failure.

Possible Cause Relay command signal as seen at the I/O pack output connector to the terminal board does not match the
commanded state.

Solution The command signal feedback requires a properly connected terminal board.

• Check the pack-terminal board connector alignment and seating.

• Replace the I/O pack.
• Replace the terminal board.

GEH-6721K Diagnostics and Troubleshooting Alarms 2-53

72-95
Description Contact Input [ ] not responding to self-test mode

• Check the indicated fuse.
• Check the power input to the terminal board.
• Check the terminal board configuration.
• Check the I/O pack configuration.
• Confirm that all connectors are aligned and fully seated.
• Replace the I/O pack.
• Replace the terminal board.

142
Description All fuses blown or no terminal board excitation.

Possible Cause If fuse sensing indicates an open fuse, this may be due to loss of input power to the terminal board.
Without power to the fuses, the sensing may indicate a false open-fuse condition.

Solution

• Confirm the correct input power to the terminal board.

• Check the pack connector alignment and seating.
• Check the pack configuration.
• Check all fuses.
• Replace the I/O pack.
• Replace the terminal board.

143-154
Description Relay Output Coil [ ] does not match commanded state.

Possible Cause The relay feedback does not match the commanded state for TRLY__B, TRLY__F, or SRLY-specific
terminal boards.

Solution

• Clear the voter disagreements.

• Check the I/O pack connector alignment and seating.
• Check the I/O pack configuration.
• Replace the terminal board.

GEH-6721K Diagnostics and Troubleshooting Alarms 2-55

155-166
Description NO [Normally Open] contact [ ] voltage disagreement with command.

Possible Cause Voltage is not detected across an open TRLY__C or TRLY__E output contact.

Solution

• Clear the voter disagreements.

• Check the application to ensure that voltage should be present when relay is open.
• Check that the voltage is within the published detection range. Refer to the terminal board help documentation for
more information.
• Check the I/O pack configuration.
• Replace the terminal board.

167-178
Description Relay Driver [ ] does not match commanded state.

Possible Cause The relay command signal, displayed at the I/O pack output connector to the terminal board, does
not match the commanded state.

Solution The command signal feedback requires a properly connected terminal board.

• Check the pack-terminal board connector alignment and seating.

• Replace the I/O pack.
• Replace the terminal board.

179-184
Description Relay [ ] connected field device impedance outside of acceptable range.

Possible Cause A connected load does not fall within published impedance limits for TRLY__D-specific terminal boards.

Solution

• Clear the voter disagreements.

• Check for field wiring open or short circuits.
• Check the attached load to ensure that impedance is within the published limits for TRLY__D. Refer to the terminal
board help documentation for more information.
• Check TRLY input power.
• Replace TRLY__D.

191
Description Config Mismatch: TRLY__F terminal board is configured for SIMPLEX redundancy.

Possible Cause The TRLY__F board is connected to an I/O pack that is configured as simplex. Due to the redundant
nature of the TRLY__F terminal board, a TMR I/O pack module configuration is required.

Solution

• Configure the I/O pack redundancy as TMR. Build and download a new configuration.

2-56 Alarms GEH-6721K Mark* VIe Control Vol. III

192
Description Peer to Peer Communication Failure Code [ ].

Possible Cause PGEN peer-to-peer communication for the PLU function has been lost. Refer to the PGEN documentation
for a description of peer-to-peer communication.

Solution

• Select None for I/O Module Trip From as the source for a trip if the PLU function is not used. Build and download
parameters.
• If a PGEN is used as a source for I/O Module Trip From then check the online status of the PGEN and correct
if not online.
• If other communication diagnostic alarms are active, check for issues with network cables, switches, and such.

194
Description Peer to Peer Communication Compatibility mismatch: PDOA [ ], Received Message [ ].

Possible Cause The revision of PGEN used for the source of the PLU trip is not compatible with the PDOA revision.

Solution Upgrade PGEN and PDOA to the latest revision in the ControlST release, and download firmware and parameters
to both packs.

195
Description Peer to Peer Communication Initialization failure.

Possible Cause The peer-to-peer link with PGEN for the PLU function could not be initialized.

Solution Build and download parameters to PDOA and PGEN that are used for PLU function.

GEH-6721K Diagnostics and Troubleshooting Alarms 2-57

PEFV Specific Alarms
The following alarms are specific to the PEFV I/O pack.

32
Description No Ethernet ports could be setup for WGC valve driver.

Possible Cause

• Both Ethernet ports on the PEFV pack have already received an IP address through DHCP so the IP address for the
Woodward Governor Controls DVP (WGC) driver network could not be assigned.
• Both ports may be connected to the IONET-EGD network.

Solution

• Verify that network connections are correct.

• Verify that no DHCP server exists on the network connected to the WGC driver.

33
Description Problem with the WGC valve driver Ethernet port.

Possible Cause PEFV could not properly configure the Ethernet port.

Solution

• Re-download the base load and firmware to the I/O pack.

• Replace the I/O pack.

34
Description WGC valve driver communication error - packet mismatch.

Possible Cause The received Ethernet Global data is incorrect.

Solution

• Verify that network addresses are configured correctly.

• Verify that the WGC_IP_Addr is set to the IP address of the DVP.
• Verify that the Gateway_IP_Addr is set to the IP address of the PEFV gateway port.

35
Description Experiencing delay in reception of data from WGC valve driver.

Possible Cause The PEFV has not received data from the Woodward Governor Controls DVP for five frames (50 ms).

Solution

• Verify that network connections between the PEFV and the Woodward DVP are correct.
• Check for faulty or loose network cables.

38
Description No communication with WGC valve driver.

Possible Cause The PEFV has not received data from the Woodward Governor Controls DVP for three seconds.

Solution

• Verify that network connections between the PEFV and the Woodward DVP are correct.
• Verify that Woodward DVP power is on.
• Verify that Woodward DVP is sending data correctly.

2-58 Alarms GEH-6721K Mark* VIe Control Vol. III

39
Description Config Error - WGC and Gateway IP address subnet mismatch.

Possible Cause The subnet of configured IP addresses WGC_IP_Addr and Gateway_IP_Addr do not match.

Solution

• Verify that the configured IP addresses WGC_IP_Addr and Gateway_IP_Addr are on the same subnet.
• Verify that WGC_Subnet is set correctly.

GEH-6721K Diagnostics and Troubleshooting Alarms 2-59

PGEN Specific Alarms
The following alarms are specific to the PGEN I/O pack.

32
Description Unallowed VarIOCompatCode Change: Old - [ ]; New - [ ].

Possible Cause The .dll for the installed PGEN is incompatible with the firmware loaded on the I/O processor.

Solution

• Confirm the correct installation of the PGEN distributed I/O pack.

• Rebuild the application, then download the firmware and the application code to the affected I/O pack.

33-35
Description Analog Input [ ] Unhealthy.

Possible Cause The analog input 1-3 signal strength is outside the limits for the sensor type.

Solution

• For 4-20 mA analog inputs: Check the configuration parameters MaxMAInput and MinMAInput for proper values.
• For voltage analog inputs: the inputs voltage magnitude is greater than 9.24 V.
• Check the analog inputs 1-3 at the terminal points for in-range values.
• Replace the PGEN I/O pack or the TGNA terminal board if inputs are in range.

36-39
Description Generator Current Input [ ] Unhealthy.

Possible Cause The CT input current exceeds the configured CT input by 200%.

Solution

• Check the configuration parameter CT_Secondary for the correct setting.

• Check the compatibility of the generator CT secondary output to the TGNA 1 or the 5 A connections.
• Check the CT input currents for currents exceeding 200% of the configured (5 or 1 A).
• Replace the PGEN I/O pack or the TGNA terminal board if the inputs are in range.

40-46
Description Channel [ ] ADC Conversion Error.

Possible Cause The analog-to-digital conversion for the specified input failed to complete.

Solution Replace the PGEN I/O pack.

47
Description ADC Conversion Not Completed

Possible Cause The analog-to-digital conversion of the terminal board signals failed to complete before the next conversion
cycle was scheduled to start.

Solution Replace the PGEN I/O pack.

2-62 Alarms GEH-6721K Mark* VIe Control Vol. III

66-67
Description Output [ ] Individual current too high relative to total current.

Possible Cause A disagreement has been detected between the output current sensing inside the I/O pack and the
current sensing on SHRA.

• A hardware failure is causing the I/O pack to drive too much output current.

Solution

• Check the I/O pack mounting on the SHRA.

• Confirm that the field wiring and load are correct.
• Check the output configuration.
• Replace the SHRA and the I/O pack.

70-71
Description Output [ ] Total current varies from reference current.

Possible Cause

• There may be a field wiring problem.

• There may be an open-circuit on the output, or the total loop resistance is too high.
• The command is beyond the range of the output.

Solution

• Check the field wiring and the device.

• Check the output configuration.
• Verify that the commanded output is within output range.
• Check the I/O pack mounting on the SHRA.
• Replace the I/O pack.

74-75
Description Output [ ] Reference current error.

Possible Cause The difference between the commanded output current and current feedback on the terminal board
is greater than D/A_ErrLimit (%).

• There may be an open-circuit on the output.

• The command is beyond the range of the output.

Solution

• Check the field wiring and the device.

• Verify that the value of D/A_ErrLimit is set correctly.
• Verify that the commanded output is within the output range.
• Replace the I/O pack.

GEH-6721K Diagnostics and Troubleshooting Alarms 2-63

78-79
Description Output [ ] individual current feedback unhealthy.

Possible Cause

• The commanded output is beyond the range of the output.

Solution

• Verify that the commanded output is within the range of the output.
• Confirm the correct I/O pack 28 V input power.
• Check the field wiring and the device.
• Replace the I/O pack.

86-87
Description Output [ ] 20/200 mA selection non-functional.

Possible Cause N/A

Solution N/A

92-93
Description Output [ ] Suicide on overcurrent.

Possible Cause

• Hardware failure in I/O pack.

Solution

• Replace I/O pack.

99
Description Hart Input 1 Channel 1 not initialized.

Possible Cause An enabled Hart input channel does not respond.

Solution

• Verify that the field device is attached to the correct I/O point.
• Using a HART handheld communicator, confirm that the field device is operating correctly and communicating.

100
Description Hart Input 2 Channel 2 not initialized.

Possible Cause An enabled Hart input channel does not respond.

Solution

Solution

• Verify that the field device is attached to the correct I/O point.
• Using a HART handheld communicator, confirm that the field device is operating correctly and communicating.

GEH-6721K Diagnostics and Troubleshooting Alarms 2-65

107
Description Hart Input 8 Channel 9 not initialized.

Possible Cause An enabled Hart input channel does not respond.

Solution

• Verify that the field device is attached to the correct I/O point.
• Using a HART handheld communicator, confirm that the field device is operating correctly and communicating.

108
Description Hart Input 9 Channel 10 not initialized.

Possible Cause An enabled Hart input channel does not respond.

Solution

• Verify that the field device is attached to the correct I/O point.
• Using a HART handheld communicator, confirm that the field device is operating correctly and communicating.

109
Description Hart Input 10 Channel 11 not initialized.

Possible Cause An enabled Hart input channel does not respond.

Solution

• Verify that the field device is attached to the correct I/O point.
• Using a HART handheld communicator, confirm that the field device is operating correctly and communicating.

110
Description Hart Output 2 Channel 12 not initialized.

Possible Cause An enabled Hart output channel does not respond.

Solution

• Verify that the field device is attached to the correct I/O point.
• Using a HART handheld communicator, confirm that the field device is operating correctly and communicating.

111
Description Hart Input 1 Channel 1 address mismatch.

Possible Cause The device ID in the ToolboxST configuration does not match the field device.

Solution

• Verify that the correct field device is connected to the I/O point.
• If so, either set the three ID fields to zero, or upload the device ID from the field device.

112
Description Hart Input 2 Channel 2 address mismatch.

Possible Cause The device ID in the ToolboxST configuration does not match the field device.

Solution

• Verify that the correct field device is connected to the I/O point.
• If so, either set the three ID fields to zero, or upload the device ID from the field device.

2-66 Alarms GEH-6721K Mark* VIe Control Vol. III

113
Description Hart Input 3 Channel 3 address mismatch.

Possible Cause The device ID in the ToolboxST configuration does not match the field device.

Solution

• Verify that the correct field device is connected to the I/O point.
• If so, either set the three ID fields to zero, or upload the device ID from the field device.

114
Description Hart Input 4 Channel 4 address mismatch.

Possible Cause The device ID in the ToolboxST configuration does not match the field device.

Solution

• Verify that the correct field device is connected to the I/O point.
• If so, either set the three ID fields to zero, or upload the device ID from the field device.

115
Description Hart Input 5 Channel 5 address mismatch.

Possible Cause The device ID in the ToolboxST configuration does not match the field device.

Solution

• Verify that the correct field device is connected to the I/O point.
• If so, either set the three ID fields to zero, or upload the device ID from the field device.

116
Description Hart Output 1 Channel 6 address mismatch.

Possible Cause The device ID in the ToolboxST configuration does not match the field device.

Solution

• Verify that the correct field device is connected to the I/O point.
• If so, either set the three ID fields to zero, or upload the device ID from the field device.

117
Description Hart Input 6 Channel 7 address mismatch.

Possible Cause The device ID in the ToolboxST configuration does not match the field device.

Solution

• Verify that the correct field device is connected to the I/O point.
• If so, either set the three ID fields to zero, or upload the device ID from the field device.

118
Description Hart Input 7 Channel 8 address mismatch.

Possible Cause The device ID in the ToolboxST configuration does not match the field device.

Solution

• Verify that the correct field device is connected to the I/O point.
• If so, either set the three ID fields to zero, or upload the device ID from the field device.

GEH-6721K Diagnostics and Troubleshooting Alarms 2-67

119
Description Hart Input 8 Channel 9 address mismatch.

Possible Cause The device ID in the ToolboxST configuration does not match the field device.

Solution

• Verify that the correct field device is connected to the I/O point.
• If so, either set the three ID fields to zero, or upload the device ID from the field device.

120
Description Hart Input 9 Channel 10 address mismatch.

Possible Cause The device ID in the ToolboxST configuration does not match the field device.

Solution

• Verify that the correct field device is connected to the I/O point.
• If so, either set the three ID fields to zero, or upload the device ID from the field device.

121
Description Hart Input 10 Channel 11 address mismatch.

Possible Cause The device ID in the ToolboxST configuration does not match the field device.

Solution

• Verify that the correct field device is connected to the I/O point.
• If so, either set the three ID fields to zero, or upload the device ID from the field device.

122
Description Hart Output 2 Channel 12 address mismatch.

Possible Cause The device ID in the ToolboxST configuration does not match the field device.

Solution

• Verify that the correct field device is connected to the I/O point.
• If so, either set the three ID fields to zero, or upload the device ID from the field device.

123
Description PHRA Hart Module Modified.

Possible Cause The configuration of the HART multiplexer on the PHRA card was externally modified with either an AMS
or a HART handheld communicator.

Solution Determine what change was made and if OK, issue a system diagnostic reset to acknowledge the change
and clear the fault.

124
Description Hart Input 1 Channel 1 Field Device Modified.

Possible Cause The configuration of the HART field device was externally modified with either an AMS or a HART
handheld communicator.

Solution Determine what change was made and if OK, issue a system diagnostic reset to acknowledge the change
and clear the fault.

2-68 Alarms GEH-6721K Mark* VIe Control Vol. III

125
Description Hart Input 2 Channel 2 Field Device Modified.

Possible Cause The configuration of the HART field device was externally modified with either an AMS or a HART
handheld communicator.

Solution Determine what change was made and if OK, issue a system diagnostic reset to acknowledge the change
and clear the fault.

126
Description Hart Input 3 Channel 3 Field Device Modified

Possible Cause The configuration of the HART field device was externally modified with either an AMS or a HART
handheld communicator.

Solution Determine what change was made and if OK, issue a system diagnostic reset to acknowledge the change
and clear the fault.

127
Description Hart Input 4 Channel 4 Field Device Modified.

Possible Cause The configuration of the HART field device was externally modified with either an AMS or a HART
handheld communicator.

Solution Determine what change was made and if OK, issue a system diagnostic reset to acknowledge the change
and clear the fault.

128
Description Hart Input 5 Channel 5 Field Device Modified.

Possible Cause The configuration of the HART field device was externally modified with either an AMS or a HART
handheld communicator.

Solution Determine what change was made and if OK, issue a system diagnostic reset to acknowledge the change
and clear the fault.

129
Description Hart Output 1 Channel 6 Field Device Modified

Possible Cause The configuration of the HART field device was externally modified with either an AMS or a HART
handheld communicator.

Solution Determine what change was made and if OK, issue a system diagnostic reset to acknowledge the change
and clear the fault.

130
Description Hart Input 6 Channel 7 Field Device Modified.

Possible Cause The configuration of the HART field device was externally modified with either an AMS or a HART
handheld communicator.

Solution Determine what change was made and if OK, issue a system diagnostic reset to acknowledge the change
and clear the fault.

GEH-6721K Diagnostics and Troubleshooting Alarms 2-69

131
Description Hart Input 7 Channel 8 Field Device Modified.

Possible Cause The configuration of the HART field device was externally modified with either an AMS or a HART
handheld communicator.

Solution Determine what change was made and if OK, issue a system diagnostic reset to acknowledge the change
and clear the fault.

132
Description Hart Input 8 Channel 9 Field Device Modified.

Possible Cause The configuration of the HART field device was externally modified with either an AMS or a HART
handheld communicator.

Solution Determine what change was made and if OK, issue a system diagnostic reset to acknowledge the change
and clear the fault.

133
Description Hart Input 9 Channel 10 Field Device Modified.

Possible Cause The configuration of the HART field device was externally modified with either an AMS or a HART
handheld communicator.

Solution Determine what change was made and if OK, issue a system diagnostic reset to acknowledge the change
and clear the fault.

134
Description Hart Input 10 Channel 11 Field Device Modified.

Possible Cause The configuration of the HART field device was externally modified with either an AMS or a HART
handheld communicator.

Solution Determine what change was made and if OK, issue a system diagnostic reset to acknowledge the change
and clear the fault.

135
Description Hart Output 2 Channel 12 Field Device Modified.

Possible Cause The configuration of the HART field device was externally modified with either an AMS or a HART
handheld communicator.

Solution Determine what change was made and if OK, issue a system diagnostic reset to acknowledge the change
and clear the fault.

136
Description Hart Input 1 Chan 1 Control Parm Mismatch - configured: [ ] received: [ ].

Possible Cause The number of dynamic variables returned in Hart Message 3 (Read dynamic variables) does not agree
with the ToolboxST configuration.