320-0424

Access PLC program editor

Press MOD key, select 'PLC program' from machine parameters menu, then access the PLC editor to review spawned processes.

Identify SPAWN processes with events

Search for SPAWN statements in the PLC code and examine each spawned process for EVENT definitions using the search function (CTRL+F).

Count and consolidate events

Count EVENT statements in each SPAWN process. If >15 found, consolidate similar events or split the process into multiple SPAWN tasks.

Use event flags or combine multiple conditions into single events to reduce count.

Recompile PLC program

After modifications, recompile the PLC program using 'Compile PLC' function and restart the control to clear the alarm.

Enable PLC debugging mode

Access MOD menu, select 'PLC program', enable 'Debug mode' to monitor real-time event creation and process execution.

Monitor SPAWN process execution

Use PLC monitor to observe the problematic SPAWN process and identify where events are being created repeatedly or in loops.

Review loop conditions and counters

Examine FOR loops, WHILE loops, or conditional statements that may be creating events without proper exit conditions or counters.

Infinite loops in PLC can cause system instability and require immediate attention.

Implement event creation limits

Add counter variables and conditional checks to prevent excessive event creation within loops or recursive functions.

Backup and restore PLC program

Create backup of current PLC program via 'File management' menu, then restore from a known good backup version.

Clear PLC memory

Access MOD menu, select 'PLC program', use 'Clear PLC memory' function to reset all PLC variables and event handlers.

This will reset all PLC variables to default values - ensure machine is in safe state.

Reload and recompile PLC

Reload the PLC program from backup, recompile using 'Compile PLC' function, and verify syntax checking passes without errors.

Test SPAWN processes individually

Temporarily disable other SPAWN processes and test each one individually to isolate the problematic process.

Review SPAWN termination logic

Check PLC code for proper SPAWN process termination using END_SPAWN or equivalent termination statements.

Monitor active SPAWN processes

Use PLC status display in MOD menu to monitor active SPAWN processes and verify they terminate properly.

Add explicit process cleanup

Implement explicit cleanup routines in SPAWN processes to clear events and variables before process termination.

Use KILL_SPAWN function to forcibly terminate stuck processes during troubleshooting.

Implement process synchronization

Add semaphores or flags to ensure only one instance of event-heavy SPAWN processes runs at a time.