PRODUCT SAFETY ALERT
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1 1756-OF4 and 1756-OF8 Analog Output Modules, Firmware Revision 1.4 and Earlier 1756-OF6CI and 1756-OF6VI Analog Output Modules, Firmware Revision 1.8 and Earlier Dear Rockwell Automation Customer: The purpose of this letter is to inform you of a potential safety issue that exists with: 1756-OF4 and 1756-OF8 Analog Output Modules Revision 1.4 and Earlier 1756-OF6CI and 1756-OF6VI Analog Output Modules Revision 1.8 and Earlier shipped worldwide beginning in July This Product Safety Alert will help explain the current problem and the steps being taken to rectify the situation. With these ControlLogix Analog Output Modules: - Problem Description OF8, 1756-OF4, 1756-OF6CI and 1756-OF6VI The following two problems can occur. PROBLEM 1 Very large and/or out of range output values will cause either of two possible outcomes: The output polarity will reverse Output values remain at their current clamp limit rather than going to the User-Defined Program or Fault Value. The particular outcome depends upon the firmware revision of the affected output modules. Reverse Polarity Outcome
2 Page OF4 and 1756-OF8 Analog Output Modules Revision 1.3 and Earlier 1756-OF6CI and 1756-OF6VI Analog Output Modules Revision 1.7 and Earlier the output will reverse polarity if the module is sent an out-of-range value that is: A) x (High Engineering value - Low Engineering value)**, for Voltage mode Or B) x (High Engineering value - Low Engineering value)**, for Current mode, module: 0 ma and 21 ma (Current Mode) and V and V (Voltage Mode)). Example A: If a channel is configured as follows: High Engineering Value = 10 High Signal Value = 10V Low Engineering Value = -10 Low Signal Value = -10V then values greater than approx. 681,500 will cause the 10.4 Volt output to change to Volts (or its low clamp limit) and values less than approx. -681,500 will cause the Volt output to change to Volts (or its high clamp limit). NOTE = (32767 x Span of ~20.8V = 681,500). The output channel will operate properly if sent a value between approx. 681,500 and -681,500, Example B: If a channel is configured as follows: High Engineering Value = 100% Low Engineering Value = 0% High Signal Value = 20 ma Low Signal Value = 0 ma then values greater than approx. 6,881,000% will cause the +21 ma output to change to 0 ma (or its low clamp limit) and values less than approx. -6,881,000% will cause the 0 ma output to change to +21 ma (or its high clamp limit). NOTE = (65535 x Span of 105% = 6,881,000). The output channel will operate properly if sent a value between 6,881,000 and -6,881,000. Interim Solution to Reverse Polarity Outcome An interim solution (prior to updating the firmware) that prevents the above problem is to insert appropriate ladder logic that limits the output value to the above-described legal limits prior to sending that value to the module.
3 Page 3 Hold Last State Outcome 1756-OF4 and 1756-OF8 Analog Output Modules Revision OF6CI and 1756-OF6VI Analog Output Modules Revision 1.8 the output value remains at its current clamp limit rather than going to the User-Defined Program or Fault Value as intended. This occurs when the module is sent an output data value beyond the module's absolute range (+/ V or 0-21 ma). There is no suggested interim solution for this outcome. PROBLEM OF4 and 1756-OF8 Analog Output Modules Revision 1.3 and Earlier 1756-OF6CI and 1756-OF6VI Analog Output Modules Revision 1.7 and Earlier the output polarity will be reversed and clamped when the module receives very large High Clamp Limit or Low Clamp Limit values. If an Output High Clamp Limit configuration value is sent to the module where: A. High Limit Value = (32767 x (High Engineering value - Low Engineering value)**), for Voltage mode B. High Limit Value = (65535 x (High Engineering value - Low Engineering value)**), for Current mode, the output will "peg" to the minimum value (0 ma for Current / Volts for Voltage) and will stay clamped, regardless of what output value is sent to the module. module: 0 ma and 21 ma (Current Mode) and V and V (Voltage Mode)). If an Output Low Limit configuration value is sent to the module where: C. Low Limit Value = ( x (High Engineering value - Low Engineering value)**), for Voltage mode D. Low Limit Value = ( x (High Engineering value - Low Engineering value)**), for Current mode, the output will "peg" to the maximum value (21 ma for Current / Volts for Voltage) and will stay
4 Page 4 clamped, regardless of what output value is sent to the module. module: 0 ma and 21 ma (Current Mode) and V and V (Voltage Mode). There is no suggested interim solution for problem 2. - Product Identification - Product affected by this Product Safety Alert includes analog shipped from September 1998 with the following Catalog Revision and Firmware Revision Numbers: 1756-OF4 Analog Output Module Catalog Revision B01, Firmware Revision 1.4 and Earlier 1756-OF8 Analog Output Module Catalog Revision C01, Firmware Revision 1.4 and Earlier 1756-OF6CI Catalog Revision E01, Firmware Revision 1.8 and Earlier 1756-OF6VI Analog Output Modules Catalog Revision E01, Firmware Revision 1.8 and Earlier The Catalog Revision Number can be identified by examining the module packaging and product labeling. On the packaging label, the catalog revision is shown in the area of the catalog number to the right of the bar code, while the firmware revision number is shown to the right of catalog revision. On the product label on the left side of the controller, the catalog revision is shown next to the product catalog number, while the firmware revision is in the upper right corner of the white product identification label. The problems have been corrected in the following versions of these products: 1756-OF4 Analog Output Module Catalog Revision C01, Firmware Revision OF8 Analog Output Module Catalog Revision D01, Firmware Revision OF6CI Catalog Revision F01, Firmware Revision OF6VI Analog Output Modules Catalog Revision F01, Firmware Revision 1.9 -Required Customer Action- We are requesting that you perform the following actions: Confirm that you have the affected modules. Immediately contact your local Rockwell Automation Sales and Support office to determine the appropriate course of action. Together, the local office and you will determine which of the two courses of action outlined below is appropriate for their situation.
5 Page 5 1. You perform the FLASH update using the update kit that you or your Area Manager ordered via the fax back form. You can order the update kit directly from Technical Service using the fax back order form included with this notification letter. 2. Contact the local Rockwell Automation Sales and Support office to have the update completed for you by GTS. NOTE: The update procedure requires: A PC running Windows 95 or Windows NT to communicate to the Logix5550 controller. The FLASH update of the controller can be accomplished directly through the RS232 port on the front of the controller across the chassis backplane via the appropriate communications card in the PC to either a 1756-DHRIO, 1756-ENET or 1756-CNB communication module. NOTE: Improperly performed updates could leave the device inoperable. Having GTS perform the update should be the recommended course of action if there is any uncertainty. As a valued Rockwell Automation customer, your immediate cooperation with this product safety alert and exchange/repair effort is highly recommended and greatly appreciated. We regret any inconvenience this may cause you. Sincerely, Pete Delic Logix5550 Product Manager Rockwell Automation pmdelic@ra.rockwell.com Tom Hudak Commercial Programs Manager Rockwell Automation tbhudak@ra.rockwell.com
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