9/10/2017 Create Fault Logic Contact and Coil

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Create Fault Logic

This is part of an RSLogix 5000 Tutorial.

Someone recently said to me, what we needed on that project was more planning and less complaining about what we
couldnt do. Perhaps its fitting that were on step 9 out of 12 of this tutorial, and were only now about to write some
actual logic. PLC programming, just like PC programming, is all about having a place for everything, and everything in its
place. That takes planning.

When you write logic, youre making a commitment thats expensive to undo. Planning, structure and architecture are
about building a strong foundation thats going to support more than you initially intend to build on it. What Ive
presented in the tutorial up to this point is an architecture for your program that can grow with your program without
becoming unwieldy and hard to maintain.

We already created a Faults program previously in the tutorial:

Start by adding an Aa_Main routine and setting it as the main routine of the Faults program like we did previously in the
tutorial:

Fault Severity
Faults are any condition that stops the machine from operating. Its normal to break down you faults into different levels
of severity:
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Critical
Normal
Warning

You have to come up with your own severity levels based on your needs. These should correspond to how your
machine will react when a fault occurs.

For instance, I normally differentiate between critical faults and normal faults like this: a critical fault requires the machine
to stop immediately and a normal fault requires the machine to stop after completing the next cycle. Its obviously better
to stop at a nice stopping point, like a home or pounce position if you can, so you want more faults in the normal
category than in the critical category.

Examples of critical faults:

An emergency stop signal is received or guard door is opened

Loss of communication to I/O modules
Loss of encoder feedback signal (you cant finish the cycle if you dont know where you are)

Examples of normal faults:

Sequence fault (expected part A but detected part B)

Low air pressure signal
Motor over-temperature signal

Which fault goes in which category is completely dependent on your application. If you have a very long cycle time, you
may want to make an over-temperature fault into a critical fault because you cant safely finish the cycle without causing
damage.

Warnings generally dont cause the machine to stop. In some sense theyre not faults at all, but we piggyback them on
the fault system because we normally have an alarm system built on top of the fault system and we want warnings to
show up as alarms on our operator interface. A warning might be something like its time to change the oil filter.

Fault Zones
In addition to fault categories, you also need to consider fault zones. For instance if youve separated your machine into
different zones correctly, then some faults should only affect one zone, not the whole machine. Its quite normal for one
fault to be a critical fault in one zone, but be a normal fault at the machine level. For instance, if you have an assembly line
with 10 stations, losing the encoder feedback on an axis at station 3 might be a critical fault for the station 3 zone, but
would only be a normal fault for the machine, which would allow the other 9 stations to finish their cycle. On the other
hand, receiving and e-stop signal or losing the communication bus that services the entire assembly line are machine level
critical faults that should immediately stop all stations.

Alarms
We sometimes think of alarms as synonymous with faults, but thats simply not true. A fault is an internal condition of the
machine that may or may not cause various actions. An alarm is simply a message to the operator to notify them of an
action they need to take. These are fundamentally different, but its also good practice to setup your faults so you can
have a one-to-one mapping between faults and alarms. For instance, if you have a fault called motor over-temperature,
youll likely want an alarm for this condition as well. However, I would suggest phrasing the alarm more like an

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instruction: Motor Over-temperature Fault (number XXX), wait for 2 minutes, then reset the fault and restart the
machine. If this fault occurs again, call maintenance.

Now our washing machine example is a relatively simple machine. We dont have much of an operator interface and the
sequence is so simple and completely automatic that if something goes wrong theres nothing the person using the
machine can do except call a technician. Therefore were going to categorize everything as a critical fault, and theres
only one zone: the machine.

Create a second routine in the Faults program called Fa_Critical:

If you have more than just critical faults, you could add Fb_Normal and Fc_Warning routines, or whatever you need.
The F prefix denotes faults in this case. You might have F routines in other sections of your code too, if you need to
categorize your faults into fault zones. Its best to implement that categorizing logic in the zones themselves.

Remember to open Aa_Main and add a JSR instruction to call the Fa_Critical routine:

Now open the Fa_Critical routine. For readability, its nice to start off the routine with a summary rung that creates a no
faults bit. Now if you wanted to create an any fault bit, youd have to OR together all the fault conditions with parallel
branches, and that means the rung is going to get really tall in the vertical direction, meaning youll have to scroll more.
The power of online PLC programming is the ability to monitor the status while its running. I prefer not to scroll unless
absolutely necessary, and I like having as much information on the screen at once as I can. Therefore I prefer the
following type of structure:

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So the logic is: if not fault 1 and not fault 2 and not fault 3 etc. then I have no faults (or in this case, no critical
faults).

Now you may be thinking, why would you put each individual contact in that rung? Why not just put all your fault bits
into DINT tags and then use EQU instructions to compare 32 bits at a time? Well, then Id say you havent been
listening to anything Ive been saying about readability. Your program will be written once and read many times, and
nobodys going to be reading it for a little light bedtime reading. Theyll be trying to decipher it when the machine is
down and the company is losing hundreds or even thousands of dollars a minute and a plant manager is standing over
their shoulder yelling at them to make them go faster. Theyll be sitting there counting bits in your DINT tag and cursing
your name. Trust me on this. If I can impart one useful piece of knowledge to you about programming in general, its this:
NEVER try to save time while writing a program if that time comes at the expense of readability. Learn to use
tools like copy/paste/search/replace or export the code to an L5K format and write scripts to edit it there, but never
sacrifice readability. That would be like a painter buying the most expensive paint and then throwing buckets of it on
the wall because its faster than rolling it on.

Were going to need a bunch of bits to use to store our faults. An array of DINT tags is a good idea. Decide how many
you need (256 is a common round number but its going to depend on your application). I suggest creating the tag
array (lets say an array of 8 DINTs) but skipping bit 0. You can use it as your summary bit, or you can just ignore it, but
its good to start numbering your faults at 1, and it helps with the readability if your bit numbers line up with your fault
numbers. Its quicker to just put a generic description (FAULT 001) on the first bit (array index 0, bit 1), and then use
the import/export feature to export that tag to a file, open it in excel, and create descriptions for all 254 other faults, then
import it back in. Then youll have all your bits numbered correctly in the tag descriptions.

At the same time, I suggest creating a matching array of timers, because its so common to need timers in your fault logic,
and its nice if the timer number matches your fault number. Therefore, create an array of 256 TIMERs. I wouldnt
bother doing the export/import trick on the timers. Just give the array tag a comment like FAULT TIMERS and be
done with it.

Creating Fault Logic

Now we can get down to business creating fault logic. During the first pass its a good idea to look through all your
I/O and for each input or output ask yourself, how would I know if the device hooked up to this input or output isnt
functioning correctly? For instance, our first two inputs (LI01.0 and LI01.1) are INLET Cold Water Valve On and
INLET Cold Water Valve Off respectively. This is a two position valve with two inputs to tell us the position of the
valve. Since we have two inputs, we have an obvious consistency check we can do: we should either have one input or
the other input on at a time, but never both, and the only time they should both be off is for a very short duration while
the valve is changing between the on and off positions.

In our Fa_Critical routine, press Control-R to add a new rung:

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Now lets add the condition for when both of the inputs are on. Find the normally open contact on the toolbar above
the editing window:

Click it twice to add two normally open contacts:

Click on the question mark above the first contact and type LI01.0 and then press enter. Then click on the question
mark above the second contact and type LI01.1 and press enter. Since you already entered descriptions for these bits
when you created the I/O mapping, the descriptions will show up above the contacts if it recognizes the tag:

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That covers the first fault condition, when both inputs are on, but we also need to cover the condition when both inputs
are off. We could add this condition on a separate fault, but Im not going to get that fancy. But this means we need to
add this second condition as a parallel branch. With the rung header selected (in the left margin where you see the
number 1), click the branch icon in the toolbar:

That will give you a rather funny looking branch-around-nothing at the beginning of your rung:

Notice that the right hand side of the branch is highlighted. In order to get the branch to go around the two contacts you
just created, click down on the highlighted side of the branch and drag it over to the right side of the two contacts. As
soon as you start to drag, small gray rectangles will show up between and around the contacts, and these indicate valid
places where you can attach your branch. When you drag it over near the small rectangle on the right side of the
contacts, the rectangle will turn into a green oval:

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That green oval means youre close enough to let go of the mouse button and it will attach the branch to that spot. Go
ahead and release the mouse button:

Now we want to insert two normally closed contacts, but if we did that with the right side of the branch highlighted,
they would be inserted to the right of the branch. Thats not what we want. We want them inserted in the branch itself.
First, click on the bottom left corner of the branch. It will highlight the corner like this:

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Now find the normally closed contact on the toolbar and click it twice:

That will give you two new normally closed contacts on the branch:

Now select the question mark above the first normally closed contact and type LI01.0 and press enter, and then select
the question mark above the second normally closed contact and type LI01.1 and press enter. You now have a
completed branch:

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Now when these conditions are true, we want to turn on our fault, but only after a short time delay (because we want to
ignore the case where the valve is actually changing states). Therefore we need a timer. Start by selecting the right side of
the branch:

Then we need to insert an on delay timer. The code for this timer is TON (tee-on). In the toolbar, you have to select
the Timer/Counter tab, and then you can find the TON instruction icon:

Click the TON icon and youll see a new timer instruction inserted on the right side of your rung:
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Were going to need to create a new tag for this timer. In fact, we should create an array of tags for fault timers like I
mentioned earlier. Start by right clicking on the question mark next to the word Timer in the new TON instruction, and
click New Tag from the context menu:

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That will display a New Tag window. Lets call the new array tag FC_TMR (meaning Faults Critical Timers). Put
that in the name field. Enter CRITICAL FAULT Timers in the Description field. Now this tutorial is using a rather small
example and I think we can get away with just 31 faults (bits 1 to 31 in a DINT tag), so lets make this timer tag an array
of length 32 (which will be indexes 0 to 31). Then we can use FC_TMR[1] for fault 1, FC_TMR[2] for fault 2, etc. To
setup an array tag, change the Data Type field from TIMER to TIMER[32]:

Click OK when youre done. That created a new array tag, but it inserted just the name of the array into Timer field of
the instruction:

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We need to tell it to use timer number 1 from the array. Select where it says FC_TMR and type FC_TMR[1] and press
enter:

That corrected the Timer field, and it conveniently moved us to the Preset field. The Preset is the number of milliseconds
that the timer will time before it turns on the DN (done) bit. In our case, enter 250 and press enter (that advances us to
the Accumulator just leave it at zero and press enter again):

Great. Youll notice that since this is now a completely valid rung, the es on the left have disappeared. Now we need
to create our fault bit coil. When our fault conditions are true they start the timer and when the timer runs for 250 ms it
will turn on the done bit (FC_TMR[1].DN). Use Control-R to create another rung, and then use the normally open

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and coil instruction icons in the toolbar to create a contact and a coil (remember you have to go back to the Favorites
tab of the toolbar instead of the Timer/Counter tab):

You should have this:

Now select the question mark above the contact and type FC_TMR[1].DN:

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Now for our fault bit. Well need a new tag to store the fault bit, and as I mentioned its a good idea to put them in DINT
tags because its more efficient when youre mapping those to some kind of user interface later (communications with
DINT tags seems more efficient than reading one BOOL tag at a time). Right click on the question mark above the coil
and click New Tag:

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That will pop up the New Tag dialog box. Lets give our tag the name FC (Faults Critical). Enter a Description:
CRITICAL FAULTS. Then change the Data Type from BOOL to DINT:

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Click OK. This creates the same issue we had with the timer array above it inserted the new DINT tag as if it was a
BOOL in the coil:

The coil needs a BOOL. Select where it says FC above the coil, then type FC.1 and press enter:

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At least that got rid of the es along the left side, so its a valid rung now. However, theres still more work to be done.
First of all, FC.1 needs a description (without one it just defaults to the description of the parent tag). To add a
description for this particular fault, with the FC.1 text selected, press Control-D. That will open a description editor
just above the logic window. Enter the description shown for the FC.1 coil:

To exit the description editor, either click the green checkmark, or click anywhere down in the ladder logic again.

Looking at our logic again, theres a problem. When the condition that causes the fault is true for 250 ms it will turn on
our fault bit, but as soon as the condition isnt true anymore the fault will go away. There are a few cases where this is
OK, but normally when a fault happens, we want the fault condition to seal in until the fault is reset. This prevents the
machine from restarting until someone verifies that its OK. It also makes sure that an intermittent fault doesnt keep
stopping and starting the machine. In some cases stopping the machine can make a fault go away.

To seal in the FC.1 coil we need to create a branch around the FC_TMR[1].DN contact. You already know how to
do this from above, so I wont repeat it. Create a branch around the timer done bit, and then add a new normally open
contact to that branch:

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Sealing in means were going to use the coil itself as the condition in the branch. Heres a shortcut to copy the name of
the coil to the contact. Select where it says FC.1 above the coil then click and drag it over to the new contact:

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Youll know when youre close enough because the green oval will show up next to the contact. Release the mouse
button to drop:

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There you go! Our first fully functional fault is done. Ok, but weve just created a fault that can never go away once its
been tripped right? Once its sealed in, nothing can ever break the circuit, so it stays on forever. Normally we would put
a normally closed contact in the branch as well with a fault reset signal of some kind that would let the operator reset the
fault condition after they had checked to make sure the machine was OK. This is a washing machine though, and we
dont have a fault reset button. How do you reset the fault then? Im taking advantage of a feature of the OTE (Coil)
instruction in PLCs: whenever power is removed and then turned back on, the program does a pre-scan that sets the
state of all Coils to off. Therefore if this washing machine faults, it stays faulted until the owner pulls the plug out for a
few seconds and plugs it back in. It may not be the most user-friendly design, but without an operator interface or a fault
reset button, it works

So, one more step: lets hook the new fault into our summary rung. Use the click-drag method to copy the FC.1 coil
name up to the first normally closed contact in the summary rung. We might as well use FC.0 as the No Faults coil in
the summary rung too:

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Notice that I also added a Description to FC.0: NO CRITICAL FAULTS.

So, thats fault #1 done! Go ahead and finish going through all of your inputs and outputs and creating faults that cover all
of them. At the end of the tutorial Ill provide an example of the completed program for you to compare against. In the
next tutorial section well be using the fault summary bit (FC.0) in our rungs that control the actual outputs.

13

24 comments

ivirban February 11, 2011 at 3:31 pm

Superb!
This post made me think of superreadability in case of someone doesnt have comments on his intervention laptop
for whatever reasons we can just make aliases from important tags to dummy tags with symbolic names, such
as z_Valve_x_Fault_OnOff

cyureus August 31, 2011 at 10:51 am

I would just like to note:

You cannot simply type the Contacts tags and have a description automatically appear UNLESS you make the
input tags from Routine LI01 **CONTROLLER** tags. Because you created the tags in the MapInputs section,
they are program tags, which only appear in that section of logic.
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Author comment by Scott Whitlock August 31, 2011 at 11:08 am

@cyureus: Actually, if you go about half-way down the page on mapping your inputs, you can clearly see that I
created the LI01 tag at Controller Scope. Mapped I/O tags are typically (but dont have to be) controller scope.

Writing alarms and interlocks in PLC programs April 2, 2012 at 5:19 pm

[] This is just a basic explanation, but you can find a more detailed explanation about fault logic
here: http://www.contactandcoil.com/rslogix-5000-tutorial/create-fault-logic/ []

william June 26, 2012 at 5:11 am

The green colour under some of the contacts like inlet cold water valve off valve means what? I assumed the coil
is set at an energized state. Is that so? Real life stuff is definately different from book material we are taught in
school coz at this points the books have so many NO and NC contacts while in this tutorial its almost purely NO
contacts being used. If my assumption is true, does it mean every time an input like LI01.1 changes, the NO turns
into NC and the already energized output relay for (INLET COLD WATER VALVE OFF) turns off. I think i am
missing a basic concept somewhere. Any help?

Author comment by Scott Whitlock June 26, 2012 at 7:30 am

@william if youre learning about this stuff in school then youre luckier than I was. Yes, in the case of the
green highlight around each contact, that indicates if that contact is making a completed circuit. In the case of a
NO contact, it means the referenced bit/coil is on, and in the case of a NC contact, it means the referenced coil is
off. However, the NO contact doesnt actually change to a NC contact when the coil changes state. If its
normally open that means the circuit is incomplete when the coil is off (normal state). This is all based on
electrical relays, so if youve worked a lot with relays then this would be second nature. If not, I can see where it
might be confusing.

william June 26, 2012 at 10:02 am

@Scott. You are right i havent worked with electrical relays before. What i dont get about this is the transition of
the NO and NC contacts in this examples. I expect that the contacts will flip flop on their states ones the input
signal they represent comes on of off. Such that a NO contact would change to NC on signal application. For
instance in the example above, what is really happening to LI01.0 and LI01.1? My biggest issue is with the
background shading. If i toggle an NO contact it gets a green highlight in my program. Is this to say that it the

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NO0 now will act as a wire to the contacts or relay that follows it? Why not just use a NC contact and have it
toggled by an input signal? This tutorial makes me appreciate real life practice.

Author comment by Scott Whitlock June 26, 2012 at 12:11 pm

@william again it comes down to history. Real electrical diagrams dont update in real time, so an NO or NC
contact is always an NO or NC contact, and represents different physical paths within the device. So what
changes is the coils state, and the state is represented by green or not green. However, the green doesnt mean
the coil is on or off, it means the contact is on or off. A normally closed contact is on if the coil is off. Therefore
if you see all green across your rung, then the circuit is complete and your output instruction will be executed.

Juan October 4, 2012 at 1:22 pm

Hi, I am trying to create the contact LI01.0 and LI01.1, but the description wont show up as you suggested. I
have been following this tutorial so far, but I cant this part to work. What Im missing? Thank you.

Brian January 12, 2013 at 9:39 am

Im not sure if this was available in the version you did this in, but if youre creating a system with FactoryTalk
View SE, its really helpful to use Rockwells ALMD and ALMA instructions. These have built-in timers as well
as a plethora of options, but the biggest advantage is that FactoryTalk View SE can actually subscribe to those
alarms directly. Whatever you type in as the message in the ALM instruction will pop up in the FT Alarm and
Event server, plus the built-in faceplates integrate directly with the instructions. Doing it this way with that HMI
system will mean you will have to set up all of your alarms manually in FTView.

Escrevendo alarmes em programas de PLC | Renato Reis February 27, 2014 at 6:31 am

[] http://www.contactandcoil.com/rslogix-5000-tutorial/create-fault-logic/ []

Chris C January 5, 2015 at 2:09 pm

I was just wondering why you did not use a latched output in Rung 2 so FC.1 could not change. What is the
advantages of doing it the way you did?

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Author comment by Scott Whitlock January 5, 2015 at 2:46 pm

@Chris C. I explain a little later on the page that this washing machine has no fault reset button, so theres no
way to clear the fault. However, the difference between a sealed-in coil (like I created in rung 2) and a latch is that
if you powered off the PLC and powered it back up again, the PLC performs a pre-scan that will set all coils (aka
OTE instructions) to off, but it wont touch latches. Thats a subtle difference between a normal coil and a latch
that Im trying to teach here. Coils revert to off after a power outage but latches are a more permanent form of
memory that retain their state. So in our case, I want the fault to reset if you unplug the machine and plug it back
in.

Chris C January 5, 2015 at 3:13 pm

Scott,

Thanks for your quick response. I was unaware that latched coils were not reset on start up. Thanks for this
clarification.

Padraic G March 15, 2015 at 9:40 am

Hi Scott, Im using your tutorial to set up my first PLC program. However Im having trouble selecting my
mapped inputs when writing my fault logic, it looks like I have them created as program tags instead of controller
tags. Can I change them or how do I select them.
Any help would be greatly appreciated.

Author comment by Scott Whitlock March 15, 2015 at 2:06 pm

@PadraicG RSLogix 5000 defaults to creating a program tag, but you can choose (in the Create Tag dialog
box) to create a Controller Tag instead. Once you do this, it should default to creating Controller tags all the time.
There is no way that Im aware of to change the Program Tags into Controller tags except to Cut them (CTRL-X)
from the Program Tags list and paste them (CTRL-V) into the Controller Tags editor. If that wont work youll
have to re-create them manually.

Don Fitchett June 20, 2015 at 2:45 pm

Great work Scott. Pleased to see you stress Readability to your readers. (User friendly to maintenance staff
who will have to use to troubleshoot equipment for its life cycle.) This exercise of yours conforms to the Best
Practices of http://plc-training.org Thanks
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Dalal Muqatash May 9, 2016 at 2:57 pm

I was wondering where I could find the completed project link, because the final part of the tutorial is no longer
hyperlinked. Any help would be appreciated. I wanted to look at the completed project link to check if these are
all sensor faults, or should there be other faults programmed in?

Thank you in advance,

Dalal

Author comment by Scott Whitlock May 9, 2016 at 5:06 pm

@DalalMuqatash The completed file wasnt available for download. There is only the tutorial.

Dalal Muqatash May 11, 2016 at 12:34 pm

I was referring to the end of this portion At the end of the tutorial Ill provide an example of the completed
program for you to compare against.

Where can I find the example of the complete program?

Sorry for the confusion.

Khan November 2, 2016 at 1:46 am

Hello Mr. Scott:

You have done a beautiful job. I am amazed at your work and the little details you have provided for everything
possible. Really appreciate your coursework and explanations.

christian ngonyani September 9, 2017 at 3:35 am

thank you for the good recture you have provided to us, but have one problem, dont know the diffrent btn
program tags and controller tag.
please help on ths

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christian ngonyani September 9, 2017 at 3:36 am

hi! all

christian ngonyani September 9, 2017 at 3:41 am

hi! mr scott, thank you for good recture lam using Rslogix 5000 but i dont know difrent btn program tag and
controller tag and what time you require to use program tag during programming.
please help me on this
good day

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