Product Safety Group 1201 South Second Street Milwaukee, WI USA 53204 productsafety@ra.rockwell.com PRODUCT SAFETY ADVISORY Notice of Potential Unsafe Condition DELIVER IMMEDIATELY TO RESPONSIBLE PERSON(S) IN YOUR ORGANIZATION 1756-OB16IS, ControlLogix Scheduled DC Modules Addressed by a Motion Arm Output Cam (MAOC) Instruction Ref: PSA 2008-04-001 Date: April 2008 Dear Valued Customer, The purpose of this Product Safety Advisory is to inform you of a potential safety issue that exists with: 1756-OB16IS ControlLogix Scheduled DC Modules, when used in certain scenarios as described in this document. If you are not using an OB16IS ControlLogix Scheduled DC Module, this Product Safety Advisory does not apply to you. This Product Safety Advisory explains the potential safety issue and the steps being taken to rectify the situation.
Page 2 of 7 PRODUCT IDENTIFICATION The purpose of this Product Safety Advisory is to inform you of a potential safety issue that exists if: You are using any of these Logix5000 Controllers: With a: Addressed to a: Controller Revision 1756-L1, -L1Mx 12.30 thru 16.xx 1756-L55, L55Mxx 12.27 thru 16.xx 1756-L60M03SE 13.11 thru 16.xx 1756-L61 12.34 thru 16.xx 1756-L62 12.34 thru 16.xx 1756-L63 12.34 thru 16.xx 1756-L64 16.21 1756-L6xS and LSP 16.06 thru 16.xx GuardLogix Motion Arm Output Cam (MAOC) Instruction * Note that this potential safety issue has been corrected in v17 and later firmware revisions. 1756-OB16IS, ControlLogix Scheduled DC (10-30V) module, Series A, Firmware Revision 1.1 or 1.2 Products affected (1756-OB16IS modules) were shipped between June 2003 and present. This potential safety issue can only occur through a unique sequence of events as described in this article To verify if your controller is affected, use this information: Confirm that you are using a 1756-OB16IS module with an MAOC instruction. If you are not using this exact combination, your system(s) are not affected by this PSA. To identify the firmware revision for the controller: 1. Open the project in RSLogix 5000 software. 2. Select the controller in the Controller organizer. 3. Right-click and select Properties from the menu. The firmware revision is listed on the Properties dialog. - ISSUE DESCRIPTION - The MAOC instruction was designed to work with an OB16IS module configured as "Scheduled Output Data per Point". Changing the default communications format, or incorrectly referencing a tag other than "Data" in the module Output Image, may result in memory data being overwritten when the MAOC instruction is executed. With the 1756-L1, -L1M1, -L1M2, -L1M3, 1756-L55M12, -L55M13, -L55M14, -L55M16, -L55M22, -L55M23, -L55M24, 1756-L60M03SE, 1756-L61, -L62, -L63, -L64, and 1756-L6xS and LSP GuardLogix controllers, hereafter referred to as Logix5000 controllers, the following potential safety issue exists: Memory data can be overwritten if and only if an MAOC instruction is used with a 1756-OB16IS module, and either of these configurations occurs:
Page 3 of 7 Configuration 1 Configuration 2 The default communications format for the 1756- OB16IS module was changed from the default ( Scheduled Output Data per Point ) to either Listen Only Output Data or Output Data. The user selects the "Data" element of the 1756- OB16IS data structure for the MAOC Output operand. -Local.0:O - Local.0:O.Data - Local.0:O.ScheduleMask - Local.0:O.Schedule The MAOC instruction is armed and has updated one or more of the scheduled outputs (0-7). The default communications format for the 1756-OB16IS module was not changed from the default setting of ( Scheduled Output Data per Point ). The user does not select the "Data" element of the 1756-OB16IS data structure for the MAOC Output operand. For example, the user selects the "ScheduleMask". -Local.0:O - Local.0:O.Data - Local.0:O.ScheduleMask - Local.0:O.Schedule The MAOC instruction is armed and has updated one or more of the scheduled outputs (0-7). Configuration 1 Example Configuration 2 Example
Page 4 of 7 The anomaly can affect customers in any industry if and only if Logix5000 Controllers with the following firmware revisions are using 1756 OB16IS, ControlLogix Scheduled DC Module, Series A, Firmware Revision 1.1 or 1.2: Logix5000 Controller 1756-L1, -L1Mx 1756-L55, L55Mxx 1756-L60M03SE 1756-L61 12.34 thru 16.xx 1756-L62 12.34 thru 16.xx 1756-L63 12.34 thru 16.xx Firmware Revision 12.30 thru 16.xx 12.27 thru 16.xx 13.11 thru 16.xx 1756-L64 16.21 1756-L6xS and LSP GuardLogix 16.06 thru 16.xx If you are not using the above versions of Logix5000 AND the 1756 OB16IS with an MAOC instruction, you will not be affected by this anomaly. If either of the above configurations occurs, a safety hazard exists that can result in a major fault, serious personal injury, or property damage. - TEMPORARY WORKAROUND - To avoid this issue, verify that when using the 1756-OB16IS module and a MAOC instruction that the: Communication format for the 1756-OB16IS module is configured as Scheduled Output Data per Point. MAOC instruction correctly references the Data tag of the 1756-OB16IS module output image. - ISSUE CORRECTION -
Page 5 of 7 The potential safety issue described above will be corrected in the following versions of the firmware: Logix5000 Controller Firmware Revision 1756-L1, -L1Mx 17.00 1756-L55, L55Mxx 17.00 1756-L60M03SE 17.00 1756-L61 17.00 1756-L62 17.00 1756-L63 17.00 1756-L64 17.00 1756-L6xS and LSP GuardLogix 17.00 Firmware version 17.00 is expected to become available in early August 2008. This PSA is posted on the Rockwell Automation Knowledgebase www.rockwellautomation.com/knowledgebase as ID number 51625. If you would like to receive an e-mail notification when firmware v17.00 is available, click the Firmware Notification link on the bottom of the Knowledgebase article and submit your request (you will need create or log into your account to sign up for this notification). Rockwell Automation is committed to quality improvement. Issues such as this undergo a rigorous improvement process where a root-cause analysis and preventive / corrective actions are completed. This is to increase overall customer satisfaction and increased reliability. We welcome your feedback on our product safety notification process along with your experiences and suggestions for improvement. Please email us at productsafety@ra.rockwell.com.
Page 6 of 7 We request that you take the following actions: - REQUESTED CUSTOMER ACTION - Verify that you have the affected controller and are using a 1756-OB16IS Output Module o If you are not using the 1756-OB16I6 Output Module, this PSA does not affect your controller(s) If you are using the MAOC instruction in the configuration(s) described above, download revision 17.00 firmware o Firmware version 17.00 is expected to become available in early August 2008. If you require further technical assistance, please contact Rockwell Automation Technical Support. Use the number provided with your service contract, or the appropriate telephone number as listed on Appendix A (page 7 of this document). Additional contact numbers and email addresses can be found on http://support.rockwellautomation.com under Phone Support / Email Support. To download the firmware update(s): Access the Rockwell Support web page at http://support.rockwellautomation.com. On the left side of the page, click on the Firmware updates* link located in the Downloads section. Click on the Control Hardware. Enter your User Name and Password or register for a new account on the Rockwell Online Registration System web page. Locate the firmware revision file for your controller on the Flash Firmware Update web page. Download and then read the technical Release Notes available for the firmware update by clicking on the.pdf icon. Note: If you are not personally impacted by this Product Safety Advisory, as the products are no longer in your possession, Rockwell Automation requests that you forward a copy of this notice along with any identifying documentation, immediately to the person or organization that the product has been transferred to. We appreciate your immediate cooperation in this matter. If you have any questions, please contact us. Sincerely, ROCKWELL AUTOMATION * Did you know that you can sign up for Automatic Product Notifications from Rockwell Automation via email? Go to Support web page at http://support.rockwellautomation.com. Under Self-Service Support Knowledgebase Technical questions? Start here!, you can subscribe to important product updates including Product Safety Advisories and Product Notices.
Page 7 of 7 Appendix A Regional Technical Support Information The following list can help you to contact the correct technical support center for your location. If your country or region is not listed please call 1.440.646.3223, or find a customer support number for your location on http://www.rockwellautomation.com/support/ under Phone Support / Email Support (located on the left edge of your screen) If you have a TechConnect Contact, please use the number(s) supplied to you with the contact. Country / Region E-Mail Questions to: Phone Number ( ) International Code Austria esupport1@ra.rockwell.com (49) 02104 960630 Brazil rabrsuporte@ra.rockwell.com (55) 11 3618 8900 Czech Republic esupport3@ra.rockwell.com (420) 28401 5911 Denmark esupport2@ra.rockwell.com (45) 43 466 006 France rasupportfr@ra.rockwell.com (33) 825303132 Germany esupport1@ra.rockwell.com (49) 02104 960630 Hungary esupport3@ra.rockwell.com (420) 28401 5911 Ireland esupport2@ra.rockwell.com (44) 01908 635245 Italy (Brescia, Milano e Padova) (39) 199 11 99 00 Italy (Napoli, Roma e Torino) (39) 199 11 99 22 Latin America RACleAskTheExpert@ra.rockwell.com (1) 440-646-3223 Marocco rasupportfr@ra.rockwell.com (33) 825303132 North America RACleAskTheExpert@ra.rockwell.com (1) 440 646 3223 Poland esupport2@ra.rockwell.com (48) 2232 60770 Portugale RACleAskTheExpert@ra.rockwell.com (1) 440 646 3223 Slovakia esupport3@ra.rockwell.com (420) 284015911 Spain esupport2@ra.rockwell.com (34) 902 30 93 30 Sweden esupport2@ra.rockwell.com (46) 771 219 219 Switzerland esupport1@ra.rockwell.com (49) 02104 960630 United Kingdom esupport2@ra.rockwell.com (44) 01908 635245