INDRAMAT SYNCHRONIZATION OF MACHINE AXES SY05_WAR1.pdf

8/20/2019 INDRAMAT SYNCHRONIZATION OF MACHINE AXES SY05_WAR1.pdf

1/72

SYNAX

Decentralized System for the

Synchronization of Machine Axes

DOK-SYNAX*-SY*-05VRS**-WAR1-EN-P

Trouble Shooting Guide

278040

http://close/


2/72

About this documentation SYNAX


SYNAX Decentralized System for the Sychronization of Machine Axes

Trouble Shooting Guide


• Mappe 40-05V-EN / Register 7

• SY105E_S.doc

• Drawing number 209-0061-4339-01

This documentation supports trained maintenance personnel

• in the rapid identification of faults

• outlining carefully-directed steps for the quick elimination of faults

• to quickly and effectively take up contact with either the manufacturer

of the machine or INDRAMAT customer service

This document should be placed in the control cabinet where it can beeasily accessed by maintenance personnel.

Document designation of previouseditions

Status Comments

209-0061-4308-00 02.96 Version 02VRS

DOK-SYNAX*-SY*-03VRS**-WAR1-EN-P 07.96 Version 03VRS



INDRAMAT GmbH, 1998

Copying this document, and giving it to others and the use or

communication of the contents thereof without express authority, areforbidden. Offenders are liable for the payment of damages. All rights arereserved in the event of the grant of a patent or the registration of a utilitymodel or design (DIN34-1).

All rights are reserved with respect to the content of this documentationand the availability of the product.

INDRAMAT GmbH • Bgm.-Dr.-Nebel-Str. 2 • D-97816 Lohr a. Main

Telefon 09352/40-0 • Tx 689421 • Fax 09352/40-4885

Dept. ESP (STS, SKR, SAS, TI)

This document is printed on paper bleached without the use of chlorine.

Title

Type of documentation

Document type code

Internal file reference

The purpose of this

documentation

Editing sequence

Copyright

Validity

Published by

Note


3/72

SYNAX Contents I


Contents

1 SYNAX diagnostics 1-1

1.1 Summary of SYNAX diagnostics ......................................................................................................... 1-1

1.2 Global SYNAX diagnostics................................................................................................................... 1-1

SynTop: connection....................................................................................................................... 1-1

SynTop: Fault finding .................................................................................................................... 1-2

Diagnostics system ....................................................................................................................... 1-3

Overview of the diagnostic displays.............................................................................................. 1-8

Interpreting the CLC diagnostics parameters................................................................................ 1-9Clearing an error ........................................................................................................................... 1-9

CLC ready to operate.................................................................................................................. 1-10

CLC Watchdog............................................................................................................................1-11

1.3 Diagnostics display on the CLC-D ..................................................................................................... 1-12

7-Segment Display......................................................................................................................1-12

1.4 Diagnosis on the Dual Port RAM....................................................................................................... 1-13

Local error messages on the dual port RAM...............................................................................1-13

Global error messages of the dual port RAM.............................................................................. 1-13

Procedure with an error............................................................................................................... 1-14

1.5 Diagnostics on the serial interface..................................................................................................... 1-14

Diagnostics on 3964R................................................................................................................. 1-14

Diagnostics on ARCNET............................................................................................................. 1-15

1.6 Diagnosis parameters ........................................................................................................................ 1-17

2 Diagnoses and Fault Numbers arranged as per the display on the CLC-D 2-1

2.1 Overview ..............................................................................................................................................2-1

3 Diagnoses and Fault Numbers arranged as per Fault Number (Parameter

C-0-0048) 3-13.1 Overview ..............................................................................................................................................3-1

4 Definition of the Error Messages 4-1

(16) "CLC EPROM defective" ................................................................................................... 4-1

(17) "CLC SRAM defective" ..................................................................................................... 4-1

(19) "CLC hardware defective"................................................................................................. 4-1

(25) "CLC in test mode zero bit stream" ................................................................................ 4-1

- - (26) "CLC in test mode continuous light" ................................................................................. 4-1

01 (01) "SERCOS interface - ring break"..................................................................................... 4-2

02 (02) "SERCOS interface - no drives connected"..................................................................... 4-2


4/72

II Contents SYNAX


03 (03) Error on switching to phase 3 Example: "Parameter incomplete (-> S-0-0021)"......... 4-2

04 (04) Error on switching into operating mode Example: "Error master encoder"..................4-2

05 (05) "SERCOS interface - double drive telegram failure"........................................................4-3

06 (06) "Fiber optic ring not closed" ............................................................................................. 4-3

07 (07) "Drive addresses not correct (see C-0-0002, C-0-0086)"................................................ 4-3

08 (08) "Max. number of drives exceeded" .................................................................................. 4-4

09 (09) "Emergency reaction ’Phase 0’ - mode change not possible" ..................................... 4-4

12 (12) "CLC Parameter exceeds min./max. value (see C-0-0068)" ........................................... 4-4

13 (13) "CLC battery defective".................................................................................................... 4-4

14 (14) "CLC checksum error (see C-0-0068)" ............................................................................ 4-5

15 General procedure with this CLC display................................................................................ 4-5

15 (15) "CLC Parameter not correct (see C-0-0068)".................................................................. 4-5

15 (152) "Process data are invalid (C-0-0129 / C-0-0128 / C-0-0127 / C-0-0126 / C-0-0131 / C-0-0132 and DBs)" ...................................................................................................................... 4-5

15 (153) "Parameter channel is not possible (see C-0-0126 and C-0-0129)".......................... 4-6

15 (154) "Multiplex channel is not possible (see C-0-0126/C-0-0129/C-0-0132) " .................. 4-615 (160) "More than one register controller per axis not possible" ............................................... 4-7

15 (161) "Winding axis must be in speed synchronization (A-0-0003, A-0-0025)" .................... 4-7

15 (170) "C-0-0039/C-0-0040: Number of entries not equal"........................................................ 4-7

15 (171) "A-0-0008/C-0-0039: Activated analogue channel not linked"........................................ 4-7

15 (175) "A-0-0030: Process control P-gain too high" .................................................................. 4-7

15 (176) "A-0-0025: Analogue channel for tension control not defined" ................................... 4-8

15 (177) "A-0-0025: Analogue channel for the tension control not activated"........................... 4-8

15 (178) "Tension controlled axis must be speed synch. (A-0-0003, A-0-0025, A-0-0087)" ..... 4-8

15 (179) "More than one tension controller per axis not possible"................................................ 4-9

15 (180) "Parameter A-0-0038 not correct" (in preparation) ......................................................... 4-915 (181) "C-0-0013: Non-permissible DEA address (see C-0-0002)"........................................... 4-9

15 (182) "C-0-0013: Synchronization mode not permissible (A-0-0003)" ................................. 4-9

15 (183) "C-0-0013: Addressed X-I/O not permissible (see C-0-0024/C-0-0033)" ................. 4-10

15 (184) "C-0-0013: Idle mode not permissible (see A-0-0009)" ................................................ 4-10

15 (185) "C-0-0013: Setup mode not permissible (see A-0-0009)" ............................................ 4-10

15 (186) "C-0-0013: Special mode not permissible (see A-0-0070)" .......................................... 4-10

15 (187) "C-0-0013: Non-permissible version of PARA.EXE"..................................................... 4-10

15 (188) "C-0-0013: Data integrity violated"................................................................................4-11

15 (189) "C-0-0013: Non-permissible DEA address (e.g., ECODRIVE)"................................ 4-11

15 (190) "CLC-link - other link master already active" ................................................................4-11

15 (191) "CLC link not possible (CLC hardware)"....................................................................... 4-11

15 (192) "C-0-0013: PLC-interface not allowed on CLC-D and CLC-P01" ............................. 4-12

15 (193) "No different feedbacks selectable (A-0-0003/A-0-0009/A-0-0070)"........................ 4-12

15 (194) "Phase synchronization & absolute format not possible (see A-0-0001/A-0-0003)". 4-12

15 (195) "A-0-0003: Drive does not support selected sync. mode" ............................................ 4-12

15 (196) "A-0-0070: Drive does not support selected special mode".......................................... 4-12

15 (197) "S-0-0103: Modulo value = 0 is invalid (see A-0-0001)" ............................................... 4-13

15 (198) "Special mode only with CLC-P possible (A-0-0070/A-0-0071/A-0-0072/A-0-0073)"4-13

15 (199) "Pattern control & modulo format not permissible (see A-0-0001/A-0-0003)" .......... 4-1315 (220) "A-0-0025: Too many register controllers activated" .................................................... 4-13

15 (221) "Port A (X27) multiple assigned (C-0-0011/C-0-0033/C-0-0104/Jumper)" ............... 4-13


5/72

SYNAX Contents III


15 (222) "Port B (X28) multiple assigned (C-0-0011/C-0-0033/C-0-0104/Jumper)" ............... 4-14

15 (223) "Cam and register control not possible (see A-0-0003/A-0-0025)".......................... 4-14

15 (224) "Register cont. and oscilloscope not possible (see A-0-0025/C-0-0107)" ................ 4-14

15 (225) "Cam/register/Osci. not possible (see A-0-003/25/C-0-0107)" ..................................... 4-15

15 (226) "Drive does not support oscilloscope function"............................................................. 4-15

15 (227) "C-0-0013: Addressed DEA28 not plugged in".............................................................4-15



15 (232) "A-0-0009: Drive does not support selected set up mode"........................................... 4-16

15 (233) "Drive locked with password (S-0-0267)" ..................................................................... 4-16

15 (234) "Electr. gear ratio not possible (s. S-0-0236, S-0-0237)".............................................. 4-16

15 (235) "A-0-0107: Master drive gear not available (P-0-0156/P-0-0157)" ............................ 4-16

15 (236) "Register control only possible with modulo axis (see A-0-0001, A-0-0025)"............ 4-16

15 (237) "Register controlled axis without synchronization (see A-0-0003)".......................... 4-17

15 (240) "HS waypoints and I/O to DEA4.1 not possible (C-0-0013, C-0-0049, A-0-0036)"... 4-17

15 (241) "HS waypoints and I/O to DEA28.1 not possible (C-0-0013, C-0-0049)".................. 4-1715 (242) "C-0-0013: DEA 4.1 and DEA 8.1 simultaneously not possible"............................... 4-17

15 (243) "Drive does not support DEA8.1 card".......................................................................... 4-18

15 (244) "Combination of used functions not possible (real time bits)".................................. 4-18

15 (250) "Target axis must be phase sync or cam axis (A-0-0133) ".......................................4-18

15 (251) "More than one group parameter per axis not possible"............................................... 4-18

16 (20) "Non-supported drive type ............................................................................................. 4-19

16 (21) "Non- supported drive firmware".................................................................................... 4-19

17 (17) "Virtual master axis error" .............................................................................................. 4-19

17 (105) "Virtual master axis - position value corrupted" ........................................................... 4-19

17 (110) "C-0-0050 too short for selected HS-waypoints (C-0-0049)" ........................................ 4-20

17 (111) Too many DEA cards for HS waypoints activated (C-0-0049, A-0-0036)................. 4-20

18 (18) "Real master axis moved".............................................................................................. 4-20

18 (100) "Real master axis - master encoder error" ................................................................... 4-21

18 (101) "Real master axis - redundant encoder error" ..............................................................4-21

21 (230) "SERCOS transmission error (no drive responds) ....................................................... 4-21

21 (231) "SERCOS interface - transmission error during initialization"................................... 4-22

32 (140) "3964R Serial interface overrun"................................................................................... 4-22

32 (141) "3964R Serial interface parity error" ............................................................................. 4-22

32 (142) "3964R Serial interface transmission error (Frame)".................................................... 4-23

33 (150) "Communication via the fieldbus is impossible"............................................................ 4-23

33 (151) "Non-supported firmware version of the interface board"............................................. 4-23

34 (34) "DEA28: External power supply error ............................................................................ 4-23

35 (35) "DEA29: External power supply error ............................................................................. 4-24

36 (36) "DEA30: External power supply error ............................................................................ 4-24

40 (40) "CLC-link - ring break (primary ring)"............................................................................. 4-24

42 (42) "CLC-link - master position fault (MDT)"........................................................................4-24

43 (43) "CLC-link - master position fault (AT)"........................................................................... 4-25

44 (44) "CLC-link - selected link address not permitted" ........................................................... 4-25

80 (80) "More than one extension card not possible (CLC hardware)".................................. 4-2590 General procedure with this CLC-D display .......................................................................... 4-25

90 (200) "Pattern control serial interface overrun" ...................................................................... 4-26


6/72

IV Contents SYNAX


90 (201) "Pattern control serial interface parity error" .................................................................4-26

90 (202) "Pattern control serial interface frame error" ................................................................4-26

90 (203) "Pattern control data buffer overrun" ............................................................................ 4-26

90 (204) "Pattern data start byte faulty"....................................................................................... 4-26

90 (205) "Pattern data undefined target position" ....................................................................... 4-26

90 (206) "Pattern data error in number of axes" ......................................................................... 4-27

90 (207) "Pattern data checksum error"......................................................................................4-27

90 (208) "Pattern data not in order"............................................................................................. 4-27

90 (209) "Pattern data positive pattern limit exceeded" ..............................................................4-27

90 (210) "Pattern data negative pattern limit exceeded"............................................................. 4-27

90 (211) "Pattern data limits between received target pos. exceeded" .........................................4-27

90 (213) "Pattern data transmission not in pattern control operating mode - in preparation... 4-28

91 (91) "SERCOS interface - ASIC: initialization error"..............................................................4-28

92 (92) "CLC-P - DUAL PORT RAM error" ................................................................................ 4-28

93 (93) "DAQ: SERCOS interface - ASIC: initialization error"....................................................4-28

94 (94) "CLC hardware version incorrect"..................................................................................4-2995 (4000+x) "Operating system error".........................................................................................4-29

96 "Fieldbus card - hardware failure" ......................................................................................... 4-29

98 (3000+y) Drive error Example: "Motor overtemperature".................................................. 4-29

5 SYNAX Reference List 5-1

5.1 Referenced firmware............................................................................................................................ 5-1

5.2 Supplementary documentation ............................................................................................................ 5-2

6 Index 6-1

Directory of Customer Service Locations


7/72

SYNAX SYNAX diagnostics 1-1


1 SYNAX diagnostics

1.1 Summary of SYNAX diagnostics

The diagnostics system of the CLC breaks down as follows:

• There are entities (master axes, system management, etc.) that can,independent of each other, identify errors.

• These entities can directly overwrite binary inputs which areexclusively allocated to them.

• They can simultaneously send diagnoses to the diagnostics system.

SY5FB109

masteraxis

drivediagnostics

patterngearbox

diagnosticssystem

I/Ologic

internalI/Os

systemmanagement

CLCand

otherdisplays

terminal

parallel/ serialuser

interface

diagnosticsparameters

Fig. 1-1: Diagnostics overview on the CLC

1.2 Global SYNAX diagnostics

SynTop: connection

The standard displays in the SYNAX system are 1 or 2 place displays.SynTop may have to be connected in order to be able to read diagnosticsparameters. This requires a serial cable and a PC (e.g., Notebook).

For further information, see attachment C, "SynTop".


8/72

1-2 SYNAX diagnostics SYNAX


SynTop: Fault findingThe following is the procedure for finding faults:

1. read display H4 on CLC-D

2. read display H1 on the DIAX03 drive controller

3. locate the relevant entry in diagnostics in section 4.

4. If the error has not been cleared with steps 1 to 3, then it is necessaryto read the diagnostics parameters (see "Diagnostics display on theCLC-D", page 1-12) .

Fault Cause Remedy

SynTop signals, at program start,the message "SERCOS moduledoes not respond"..."nocommunication possible"

Service cable not plugged, notcorrectly plugged.

Check whether the connector of theservice cable has been plugged intothe correct interface.

Service cable defective With the help of Fig. 1-1 of SynTopdescription check to make sure theservice cable has no breaks.

Incorrect interface parametrizationin SynTop In upcoming dialog box, pressbutton "setup" and check whetherthe selected loop is configured forthe correct connection.

Incorrect interface parametrized toCLC

Switch power to CLC off and pullout. Bridge jumper S2 or I6 (at CLC-P02). Switch on again and connectservice cable to X27. Checkparameter with SynTop: C-0-0011,C-0-0033, C-0-0104. If SynTop iscommunicating via X28 then setC-0-0104 correspondingly. Switchpower to CLC off, remove jumper,switch CLC on and plugin servicecable to X28

SynTop signals, at program start,the message "COM-Port... in use orcannot be initialized correctly"...."Nocommunications possible."

The selected part B is already inuse by another windows application.

End all applications except SynTopand press the button "Retry". - or- press button "Setup" in dialog boxand change the selected loop in theconnection.

The interface configured in SynTopdoes not exist.

In the dialog box, press the button"setup" and change the selectedloop in the connection.

SynTop signals back after switch ofcommunication the message"SERCOS module does notrespond"...."No Communicationpossible"

CLC must be switched off andpulled out. Bridge jumper S2 or I6(at CLC-P02). Power up again andconnect service cable to X27.Check parameter with SynTop: C-0-

0011, C-0-0033, C-0-0104. IfSynTop is to communicate with X28,then set C-0-0104 accordingly,switch CLC off, remove jumper,switch CLC on and plug in servicecable at X28

At program start, SynTop signalsmessage "hardware device is not aSERCOS module" ..."Communication telegrammescontain strange data"

The selected part is already in useby another hardware device. Thisdevice responds with correctprotocol syntax.

End all applications except SynTopand then press the "Retry" button -or press button "setup" in dialog boxand change the connection in theselected loop

SynTop suddenly signals duringoperation the message

"transmission on the linedisturbed"..."faulty communicationtelegrams".

Individual bits in transmissionprotocol have been kipped so that

the checksums are incorrect.SynTop recognizes this and hasrequested the repeat telegramswhich were also faulty.

Increase resistance to interferenceof transmission path, e.g., by using

a service cable that is bothgrounded and shielded


9/72



SynTop signals during operation themessage "SERCOS module doesnot respond"...."No communicationpossible"

Service cable no longer correctlyplugged.

Check whether the connector of theservice cable is correctly plugged.

During a parameter request, thedrive was switched off or the fiberoptic cable removed.

execute CLC reset and then press"Retry" button in dialog window.

SynTop cannot establishcommunications with CLC, adifferent interface on the CLC isbeing operated with a baud rate of38400

Operations with 38400 and 19200 isnot possible for technical reasons

Smaller baud rates must be set inC-0-0011 and C-0-0038

- or -

use terminal and work withoutSynTop

Abb. 1-2: Fault clearance

Diagnostics system

The diagnostics system is active in every mode of the CLC.

Error messages to the diagnostics systemEvery entity that detects an error, signals this to the diagnostics system.An error is a negative diagnosis.

A message contains

• an internal diagnostics number

• the drive number (0 = CLC-System, 1..n = drive)

• a diagnostics text

The diagnostics system specifies the diagnostics parameter using thetext of the error which occurs first.

If this error is in a drive, then the parameter "SYNAX - error source"(C-0-0046) contains the address of the drive.

If this error is in the CLC system, then the diagnostics informationcontains the value 10,000 h.

Any other errors are ignored until a positive diagnosis ("clear error") issent.

Positive diagnostics signalled to the diagnostics system

A positive diagnosis overwrites an existing error message, i.e., the errormessage is cleared. Various entities produce positive diagnoses, e.g.:

• system management (e.g., "CLC parametrization mode")

• ...

A positive diagnosis is identified in terms of error number 0. A messagecontaining error number 0 means

• a positive operating mode has been achieved

• an error message has been cleared

• a cleared error message

for either an axis or the CLC system.

The diagnostics system then corrects the diagnostics parameters.


10/72



Overview of the diagnostics system

The following depicts the logical sequence of the diagnostics system:

start

furtherdiagnosticsmessages? no

yes

yes, clearerror message

positivediagnosticsmessage?

old diagnosticsmesagepositive?

overwrite diagnosis

"SYNAX - error source" (C-0-0046)"SYNAX - diagnostics text" (C-0-0047)"SYNAX - error number" (C-0-0048)

no (error)

no

yes

updatedisplay(s)

SY5FB110

Fig. 1-3: Messages to the diagnostics system

Errors occuring before reaching operating mode

Errors that occur prior to reaching operating mode and can cause thesystem to fail are primarily configuration errors, for example:

• hardware (connector not attached, no external voltage, etc.)

• parameter (incorrect number of drives or addresses, unacceptablemode, etc. )

This type of error message means that the CLC cannot switch into anoperating mode.

The entity which detects the error also signals it to the diagnosticssystem.

The diagnostics system

• issues an error message using the available display media of the CLC

• describes the diagnostics parameter giving detailled information.

A re-start is necessary once the error is cleared.

Re-start can be initiated by:

• switching supply voltage on and off

• switching into parameter mode and then back into opertaing mode


11/72



If additional configuration errors are still present after the re-start, thenthese are signalled. Otherwise, the CLC will now assume operatingmode.

Error in operating mode

Once in operating mode, the occurrence of an error also means

• a binary input will be set,

in addition to the behavior just described. This can lead to a quickreaction on the part of the entire system.

These outputs are set directly by the relevant entity. Every entity has I/Oson which exclusively it may write.

Drive error

If the drive signals an error, of the SERCOS status class 1, then thefollowing ensues:

• the diagnostics system is activated• the number of the drive issuing the first error is written into parameter

C-0-0046

• parameter "diagnostic message" (S-0-0095) of the relevant drive iscopied into parameter C-0-0047

• parameter "error message number" (P-0-0009) is copied, afterreceiving an offset of 3000, into parameter C-0-0048

• output drive error is set

Initialization sequence of the CLC system

The following figure depicts the initialization sequence of the CLCsystem. The corresponding displays which appear on the 7-segmentdisplay are also shown:


12/72



power up CLC

checking check-sums of all

CLC parameters

display: 0CLC in initialization

mode

error all invalid parametersare set on defaults, butremain invalid

Start up delay time

(C-0-0001)

battery test(parameter storage,

SRAM)

error set internal marker forbattery failure

EPROMchecksum

check

error error 16display: __ CLC EPROM defective

switching toinitialization mode

SERCOS phase 0

display: 0

CLC in initialization mode

SERCOS phase 1

display: 1

SERCOS phase 1

error

error 1display: 01SERCOSring failure

errorerror 2display: 02SERCOSno drive connected

switch mode


13/72



SY5FB111

cyclical check ofSERCOS ring

errorerror 1

display: 01SERCOSring failure

SERCOS phase 3

display: 3

SERCOS phase3

SERCOS phase 4

display: 6

CLC in operating mode

checking min./ max. values

checking min./ max. values

SERCOS phase 2

display: P

CLC in parametrization mode

switch mode

marker for batteryfailure evaluated

errorerror 13display 13

CLC battery defective

checking all A and C parameters - checksum - min./max. values

- plausibility

checksum

check

error

error 14display: 14CLC parameter

checksum error(see C-0-0068)

checkingmin./max. values

error

error 12display: 12CLC parameterexceeding min./max.values (see C-0-0068)

plausibilitycheck

error

error 15display: 15CLC parameterincorrect(see C-0-0068)

error

error 12

display: 12CLC parametersexceeding min./max.values (see C-0-0068)

error

error 12display: 12CLC parametersexceeding min./ max.values (see C-0-0068)

Fig. 1-4: Initialization of a CLC-D


14/72



Overview of the diagnostic displays

The system displays diagnoses at the following positions:

• 7-segment display H4 on the CLC-D (single-digit)

• 7-segment display H1 on the DIAX03 drive controller (two-digit)

• SYNAX system parameter (visible via various bus systems or auxiliary

commissioning aids)

DDS DDSDDS DDS DDSDDS

CLC-D CLC-P

SERCOS

SERCOS

H1 flashes alternatively once attwo positions (e.g., F2/01).

H4 flashes in the event of a fault

alternatively once at each position.

Parameter C-0-0046through C-0-0048

SY5FB112

Fig. 1-5: Diagnostic displays


15/72



Interpreting the CLC diagnostics parameters

See following figure.

yes

no

Operating system error

C-0-0047: "operating systemerror"

Recovery

C-0-0048 readC-0-0041 readC-0-0041 clearContact INDRAMAT

Drive error

C-0-0046 contains drive addressC-0-0048 contains 3000 + contents of P-0-0009

C-0-0047 contains diagnostics text(contents of S-0-0095)

RecoverySee DIAX03 documentation for fault clearance

CLC error

C-0-0046 = 10,000h: error allocated to CLCC-0-0046 = n: error allocated to drive

C-0-0048 contains error numberC-0-0047 contains diagnostics text

Recovery

See SYNAX documentation for fault clearance

No error

C-0-0047 may be read: statussignalled

C-0-0048 < 4000 ?

C-0-0048 < 3000 ?

C-0-0046 = 0 ?

yes

yes

no

no

SY5FB113

Fig. 1-6: Sequence diagram for CLC diagnostics

Clearing an error

Clearing a configuration error

If a configuration error occurs, then the CLC will not assume operatingmode.

Depending on the error, the CLC remains

• in initialization or

•parametrization mode


16/72



The user must go through the following steps:

• the cause(s) of the configuration error must be eliminated

• with a hardware error, the machine must be turned on and off once

• if a parameter was corrected, then it is necessary to switch intooperating mode

Causes Action to be taken

Parameter faulty - correct parameter- switch into operating mode

Hardware configuration error(cable not connected, etc.)

- eliminate error- switch power on and off

Fig. 1-7: Table overview

Clearing errors with an error in operating mode

If the CLC is in operating mode, then it is certain that a configuration

error did not cause the error message.In operating mode, errors are eclusively cancelled via the relevant clearerror inputs which are ready by that entity that signalled the error.

Cause

Clear errorinput

Procedure

Master axis error _E:L01.16 Input clears master axis error. If amaster axis error was active in thediagnosis, then it is cleared as well.

Drive error _E:F#.14 Input clears the drive error with

address #. If a drive error with address’ was active in the diagnosis, then it iscleared as well.

System error _E:C01.01 system error see table in section 2

Communicationerror (interfaces)

_E:C01.03 Errors associated with externalcommunications via interface 3964Rcan be cleared via this input.

CLC link _E:C01.04 This error serves to clear oracknowledge an error on the CLC.

Pattern controlerror

_E:M01.01 Input clears error of the pattern controlfunction. If a pattern control error wasactive in the diagnosis, then it iscleared as well.

Fig. 1-8: Table: clearing errors

CLC ready to operate

The system output "CLC ready timing signal" (_A:C1.01) is on theCLC. It signals when the CLC is ready to operate. This signal is cyclicallytoggled by the CLC once the CLC is ready to operate.

Overview:


17/72



CLC ready (timing signal)

T < 100 ms

T < 100 ms

SY5FB114

Fig. 1-9: CLC ready to operate (timing signal)

The toggling of this signal is interrupted, for example, if:

• the CLC is not in operating mode (Sercos phase 4)

• there is a break in the Sercos ring (CLC error reaction 01)

• there is a double drive telegram failure (CLC error reaction 05)

• there is an operating system error (CLC error reaction 95)

A detailed description about when this clocking signal is deactivated (ornot even activated) is outlined in the tables in section 2.

There is a circuit on the DEA4.1 (starting with circuit board 06) whichmonitors this toggling on the hardware. The output of this circuit isdesignated CLC ready to operate.

CLC ready timing signal (_A:C1.1, DEA4.1 pin 31 output 16)

CLC ready (DEA4.1 pin 32)

SY5FB115

Fig. 1-10: CLC ready to operate (functional principle)

CLC Watchdog

There is a watchdog on the CLC. It monitors microprocessor functions. ifa processor error is signalled, then a dot - as seen below - appears onthe display of the CLC-D and the 7-segment display gets dark:

H4 CLC-D front plate

SY5FB116

Fig. 1-11: Watchdog message on the CLC


18/72



1.3 Diagnostics display on the CLC-D

7-Segment Display

There is a 7-segment display (H4) on the CLC-D. It displays the current

operating state.

H4 CLC-D front plate

SY5FB117

Fig. 1-12: 7-segment display on the CLC-D

A differentiation is made between two types of displays which depict thecurrent operating state:

• the display of a static, single-position display (normal operating state)

• the display of a dynamic, two-position display (error state)

Normal operating mode display

If the CLC is in a normal operating state, then there is only one position inthe display which

• does not flash but remains static.

Display Definition

P CLC in parametrization mode3 SERCOS phase 3

b CLC in operating mode

0 CLC in initialization mode

1 SERCOS phase 1

Fig. 1-13: Table of a normal operating state

Displaying a faulty operating mode

The CLC indicates an error by issuing a two-digit error number on thedisplay. This means

• it displays the first position

• then there is a short break without display

• then the second position is displayed

• followed by a longer break without display

• and so on.

This is how the two-position display is communicated. For the viewer, thisappears to be blinking. The following figure depicts the chronologicalsequence using the number 14 as an example.

Example:


19/72



200ms

100ms

200ms 700ms 200ms

100ms

200ms

SY5FB118

Fig. 1-14: Example: an error is depicted using the number 14

The displays are listed in the tables in section 2.

1.4 Diagnosis on the Dual Port RAM

Local error messages on the dual port RAM

Local error messages are triggered by communication errors. They donot cause the diagnostics parameters to be overwritten.

An error interrupt is triggered on the dual port RAM.The error number is then listed in register ERROR_REG.

ERROR_REG Definition

0 see diagnostics parameters

6 error during required data transmission (see ERR_INFO)

7 error during phase switching (see ERR_INFO)

8 timeout 1 with required data transmission (seeERR_INFO)

9 timeout 1 with required data transmission (see

ERR_INFO)Fig. 1-15: Table: local error messages on the dual port RAM

Global error messages of the dual port RAM

To recognize errors in the CLC system, relevant error outputs are set onthe dual port RAM.

The diagnostics parameters can be read once these outputs respond.

The diagnostics parameters are available to the host computer fordiagnostics.

Neither register ERR_INFO nor ERR_REG is relevant.

Example:


20/72



Procedure with an error

The following figure depicts how the dual port RAM evaluates an error:

ERROR_INT

readout of

C-0-0046C-0-0047C-0-0048

evaluating

ERROR_REGERROR_INFO

I/O error messagein operating mode

ERROR _REG=0

readout of

C-0-0046C-0-0047C-0-0048

before reaching

operating mode

NO

YES

SY5FB119

Fig. 1-16: Error message on the dual port RAM

1.5 Diagnostics on the serial interface

Diagnostics on 3964R

The interface 3964R represents a point-to-point connection between theCLC and an external NC control unit. A reaction telegram follows every

command telegram.

Local error message on 3964R

There is no global error message on the CLC in the presence of acommunications error at the 3964R interface. There is an error numberin each reaction telegram (byte no. 4). The error is signalled to theexternal NC control.

This error number is stored in parameter C-0-0057 for diagnosticspurposes. This parameter is cleared upon successful completion oftransmision

In this case, the display of the CLC-D does not display an error.

Error number 3964R (local error)

C-57Error Cause

1 the telegram head does not agree with the specification

2 a following telegram was received, but not expected or afollowing telegram was expected but a normal telegram received

3 the number of usable data does not agree with:the anticipated number (as is the case with following telegrams)or the block length signalled (as is the case with normal

telegrams)

4 the following applies to the demand specified in the usable datahead: the demand is unknown or it is not yet supported


21/72



5 the demand cannot presently be performed, as the required dataqueue is occupied

6 error upon accessing A/C parameters

7 error uon accessing S/P parameters

9 the data block indicated is not available

10 the length of the data block does not agree with the specification

14 error when writing I/O data (too man inputs)

Fig. 1-17: Table legend

Global error messages on 3964R

If communications at the hardware level are faulty, then a global errormessage is used.

"3964R serial interface parity error"

To be able to recognize a global error via the serial interface, which hasnot affected serial communications (e.g., a drive error), it is necessary

• to read parameter C-0-0046 cyclically or after every transmission or

• to read error outputs via the serial interface.

If an error has occurred, then further information can be obtained via thediagnostics parameter, after parameter C-0-0046 has been analyzed.

Diagnostics on ARCNET

ARCNET interface has a bus structure. In other words, the arrival ofreceived data is immediately either positively or negatively acknowledgedby the CLC. This makes the bus immediately available again.

Local error messages on ARCNET

If errors occur in the sequence, then these are stored in parameter "serialinterface error number" (C-0-0057). This parameter always contains thestatus of the most recent transmission. It can also be read by theexternal NC control unit.

It does not, however, have to be read.

• If the telegram received is correct, then there is a response telegramwith positive acknowledgement or, if necessary, with the requesteddata.

⇒ C-0-0057 = 0

• If the telegram received is not correct, then there is no responsetelegram.

⇒ C-0-0057 ≠ 0

• If a following error is discovered after a write command (e.g., S or Pparameters write protected), then there is no message.

⇒ Parameter C-0-0057 is set to ≠ 0.

Example:


22/72



Error number ARCNET (local error)

C-57Error Cause

4 the following applies to the demand specified in the user datahead, namely, the demand is unknown or it is not supported

5 the demand cannot presently be executed because the queue is

full

6 error upon accessing A/C parameters

7 error upon accessing S/P parameters

8 switch mode not successful

9 the data block given is not available

10 data block length does not agree with the specification

14 error when writing I/O data (too many inputs)

21 the telegram header does not agree with the specification

22 a following telegram was received, but not expected or afollowing telegram was expected but a normal telegram received(Note: support of following telegrams)

23 the number of usable data does not agree with the expectednumber (as is the case with following telegrams) or the expectedblock length (as is the case with normal telegrams)

24 the ARCNET partner is sending excessive NAKs

25 the selected partner is not an ARCNET participant

Fig. 1-18: ARCNET error number (local error)

Global error messages on ARCNET

If communications are malfunctioning at a hardware level, then no global

error message is issued.

To be able to recognize a global error via the serial interface, which hasnot affected serial communications (e.g., a drive error), it is necessary

• to read parameter C-0-0046 cyclically or after every transmission or

• to read error outputs via the serial interface.

If an error has occurred, then further information can be obtained via thediagnostics parameters, after parameter C-0-0046 has been analyzed.


23/72



1.6 Diagnosis parameters

Parameternumber Parametername

C-0-0041 INDRAMAT service information

C-0-0046 SYNAX - error source

C-0-0047 SYNAX - diagnosis text

C-0-0048 SYNAX - error number

C-0-0068 List of invalid A and C parameters

C-0-0071 SYNAX - current mode

C-0-0105 CLC-link - MDT error counter

A-0-0095 Drive type

A-0-0108 AT error counter

S-0-0021 IDN list of invalid operating data for communications phase 2

S-0-0022 IDN list of invalid operating data for communications phase 3

S-0-0095 Diagnostic messageS-0-0390 Diagnostic message number

P-0-0009 Error message number

Fig. 1-19: Diagnosis parameters


24/72




25/72

SYNAX Diagnoses and Fault Numbers arranged as per the display on the CLC-D 2-1


2 Diagnoses and Fault Numbers arranged as per thedisplay on the CLC-D

2.1 Overview

Dis-play

C-0-0048errornumber

C-0-0047diagnosis text of CLC system

C-0-0046Diagnosisinfo

Binaryoutput

Clearwith

0 0 "CLC in initialization mode" 0 A:C01.01 --

1 0 "SERCOS interface - phase 1" 0 A:C01.01 --

P 0 "CLC in parameter mode" 0 A:C01.01 --


b 0 "CLC in operation mode" 0 A:C01.01 --

16 "CLC EPROM defective" 10000h A:C01.01 --

17 "CLC SRAM defective" 10000h -- --

19 "CLC hardware defective" 10000h -- --

25 "CLC in test mode zero bit stream" 10000h A:C01.01 --

-- 26 "CLC in test mode continuous light" 10000h A:C01.01 --

01 01 "SERCOS interface - ring break" 10000h A:C01.01 --

02 02 "SERCOS interface - no drive connected" 10000h A:C01.01 --

03 03 Ex.: "Parameter incomplete"Error after switch into phase 3 (-> S-0-0021

n = address A:C01.01 --

04 04 Ex.: "master encoder error"

Error with switch into operating mode, copyparameter S-0-0095


05 05 "SERCOS interface - double drive telegramfailure"


06 06 "Fiber optic ring not closed" 10000h A:C01.01 --

07 07 "Drive addresses not correct(see C-0-0002, C-0-0086)"

10000h A:C01.01 --

08 08 "Max. number of drives exceeded" 10000h A:C01.01 --

09 09 "Emergency reaction ’Phase 0’ - mode changenot possible"

10000h A:C01.01 --

12 12 "CLC parameter exceeds min/max value(see C-0-0068)"

10000h A:C01.01 --

13 13 "CLC battery defective" 10000h _A:C01.02 _E:C1.01

14 14 "CLC checkum error" (see C-0-0068)" 10000h A:C01.01 --

15 15 "CLC Parameter not correct (see C-0-0068)" 10000h A:C01.01 --

15 152 "Process data are invalid (C-0-0129 / C-0-0128 / C-0-0127 / C-0-0126 / C-0-131 / C-0-0132 andDBs)"

10000h A:C01.01 --

15 153 "Parameter channel is not possible (seeC-0-0126 and C-0-0129)"

10000h A:C01.01 --

15 154 "Multiplex channel is not possible (seeC-0-0126 / C-0-0129 / C-0-0132)"

10000h A:C01.01

15 160 "More than one register controller per axis not

possible"

n = address -- --

15 161 "Winding axis must be in speedsynchronization (A-0-0003, A-0-0025)"

n = address -- --


26/72

2-2 Diagnoses and Fault Numbers arranged as per the display on the CLC-D SYNAX


15 170 "C-0-0039/C-0-0040: Number of entries notequal"

10000h A:C01.01 --

15 171 "A-0-0008/C-0-0039: Activated analoguechannel not linked"


172-174

reserved

15 175 "A-0-0030: Process control P-Gain too high" n = addressA:C01.01

--

15 176 "A-0-0025: Analogue channel for tensioncontrol not defined"


15 177 "A-0-0025: Analogue channel for tensioncontrol not activated"


15 178 "Tension controlled axis must be speed synch.(A-0-0003, A-0-0025, A-0-0087)"

n = address -- --

15 179 "More than one tension controller per axis notpossible"

n = address -- --

15 180 "Parameter A-0-0038 not correct" (in prep.) n = address A:C01.01 --

15 181 "C-0-0013: Non-permissible DEA address(see C-0-0002)"


15 182 "C-0-0013: Synchronization mode notpermissible (A-0-0003)"


15 183 "C-0-0013: Adressed X-I/O not permissible(see C-0-0024/C-0-0033)"

10000h A:C01.01 --

15 184 "C-0-0013: Idle mode not permissible (seeA-0-0009)"


15 185 "C-0-0013: Set-up mode not permissible (seeA-0-0009)"


15 186 "C-0-0013: Special mode not permissible (seeA-0-0070)"


15 187 "C-0-0013: Non-permissible version ofPARA.EXE"

10000 h A:C01.01 --

15 188 "C-0-0013: Data integry violated" 10000 h A:C01.01 --

15 189 "C-0-0013: Non-permissible DEA address (e.g.ECODRIVE)"


15 190 "CLC link - other link master already active" 10000 h _A:C01.01 --

15 191 "CLC link not possible (CLC hardware)" 10000 h A:C01.01 --

15 192 "C-0-0013: PLC-interface not allowed on CLC-D and CLC-P01"

10000h A:C01.01 --

15 193 "No different feedbacks selectable(A-0-0003/A-0-0009/A-0-0070)"


15 194 "Phase synchr. & absolute format not possible(see A-0-0001/A-0-0003)"


15 195 "A-0-0003: Drive does not support selectedsync. mode"


15 196 "A-0-0070: Drive does not support selectedspecial mode"


15 197 "S-0-0103: Modulo value = 0 is invalid (seeA-0-0001)"


15 198 "Special mode only with CLC-P possible(A-0-0070/A-0-0071/A-0-0072/A-0-0073)"


15 199 "Pattern control & modulo format notpermissible (see A-0-0001/A-0-0003)"


15 220 "A-0-0025: Too many register controllersactivated"


15 221 "Port A (X27) multiple assigned(C-0-0011/C-0-0033/C-0-0104/Jumper)"

10000 h A:C01.01 --


27/72

SYNAX Diagnoses and Fault Numbers arranged as per the display on the CLC-D 2-3


15 222 "Port B (X28) multiple assigned(C-0-0011/C-0-0033/C-0-0104/Jumper)"

10000 h A:C01.01 --

15 223 "Cam and register control not possible(see A-0-0003/A-0-0025)"


15 224 "Register cont. And oscilloscope not possible(see A-0-0025/C-0-0107)"


15 225 "Cam/register/osci. Not possible(see A-0-0003/A-0-0025/C-0-0107)"

n = addressA:C01.01

--

15 226 "Drive does not support oscilloscope-function " n = address A:C01.01 --

15 227 "C-0-0013: Addressed DEA28 not plugged in" 10000h A:C01.01 --



15 232 "A-0-0009: Drive does not support selected setup mode"


15 233 "Drive locked with password (S-0-0267)" n = address -- --

15 234 "Electr. gear ratio not possible (S -0-0236,S-0-0237)"

n = address -- --

15 235 "A-0-0107: Master drive gear not available(P-0-0156/P-0-0157)"

n = address -- --

15 236 "Register control only possible with modulo axis(A-0-0001, A-0-0025)"

n = address -- --

15 237 "Register controlled axis withoutsynchronization (see A-0-0003)"

n = address -- --

15 240 "HS waypoints and I/O to DEA4.1 not possible(C-0-0013, C-0-0049, A-0-0036)"

n = address -- --

15 241 "HS waypoints and I/O to DEA28.1 not possible(C-0-0013, C-0-0049)"

10000h -- --

15 242 "C-0-0013: DEA 4.1 and DEA 8.1simultaneously not possible"

n = address -- --

15 243 "Drive does not support DEA8.1 card" n = address -- --

15 244 "Combination of used functions not possible(relative bits)"

n = address -- --

15 250 "Target axis must be phase sync or cam axis(A-0-0133)"

n = address -- --

15 251 "More than one group parameter per axis notpossible"

n = address -- --

16 20 "Non-supported drive type " n = address A:C01.01 --

16 21 "Non-supported drive firmware" n = address A:C01.01 --

17 105 "Virtual master axis - position value corrupted" 10000h _A:L01.03 _A:L01.01

_E:L1.16

17 110 "C-0-0050 too short for selected high speedcams" (C-0-0049)"

10000h -- --

17 111 "Too many DEA cards for HS-waypointsactivated " (C-0-0049, A-0-0036)"

10000h A:C01.01 --

18 18 "Real master axis moved" 10000h _A:L01.08 _E:L1.16

18 100 "Real master axis - master encoder error" 10000h _A:C01.02 _E:L1.16

18 101 "Real master axis - redundant encoder error" 10000h _A:C01.02 _E:L1.16

21 230 "SERCOS transmission error (no driveresponds)"

1000h _A:C1.02A:C01.01

--

21 231 "SERCOS interface - transmission error duringinitialization"


32 140 "3964R serial interface overrun" in prep. 10000h _A:C01.03 _E:C01.0332 141 "3964R serial interface parity error" in prep. 10000h _A:C01.03 _E:C01.03

32 142 "3964R serial interface transmission error 10000h _A:C01.03 _E:C01.03


28/72

2-4 Diagnoses and Fault Numbers arranged as per the display on the CLC-D SYNAX


(frame)" - in preparation

33 150 "Communication via the fieldbus is impossible" 10000h _A:C01.03 _E:C01.03

33 151 "Non-supported firmware version of theinterface board"

10000h _A:C01.03 --

34 34 "DEA 28: External power supply error" 10000h _A:C01.02 _E:C01.01



40 40 "CLC link - ring break (primary ring)" 10000h _A:C01.04 _A:C01.05

_E:C01.04

42 42 "CLC link - master position fault (MDT)" 10000h _A:C01.04 _E:C01.04

43 43 "CLC link - master position fault (AT)" n = Adresse _A:C01.04 _E:C01.04

44 44 "CLC link - link address set - not permitted" 10000h A:C01.01 --

80 80 "More than one extension card not possible" 10000 h A:C01.01 --

90 200 "Pattern control serial interface overrun" 10000h _A:M01.01 _E:M01.01

90 201 "Pattern control serial interface parity error" 10000h _A:M01.02 _E:M01.01

90 202 "Pattern control serial interface frame error" 10000h _A:M01.03 _E:M01.01

90 203 "Pattern control data buffer overrun" 10000h _A:M01.04 _E:M01.01

90 204 "Pattern data start byte faulty" 10000h _A:M01.05 _E:M01.01

90 205 "Pattern data undefined target position" 10000h _A:M01.06 _E:M01.01

90 206 "Pattern data error in number of axes" 10000h _A:M01.07 _E:M01.01

90 207 "Pattern data checksum error" 10000h _A:M01.08 _E:M01.01

90 208 "Pattern data not in order" 10000h _A:M01.09 _E:M01.01

90 209 "Pattern data positive pattern limit exceeded" n = address _A:M01.10 _E:M01.01

90 210 "Pattern data negative pattern limit exceeded " n = address _A:M01.11 _E:M01.01

90 211 "Pattern data limits between received targetpos. exceeded"

n = address _A:M01.12 _E:M01.01

91 91 "SERCOS interface - ASIC: Initialization error" 10000h A:C01.01 --92 92 "CLC-P - DUAL PORT RAM error" 10000h A:C01.01 --

93 93 "DAQ: SERCOS interface - ASIC: intializationerror"

10000h A:C01.01 --

94 94 "CLC hardware version incorrect" 10000h A:C01.01 --

95 4000 + x "Operating system error" (x = error number) 10000h A:C01.01 --

96 96 "Fieldbus card - hardware failure" 10000h -- --

98 3000 +y Example: "motor overtemperature "drive error status class 1:copy of parameter S-0-0095(y = error number P-0-0009)

n = address _A:F#.10 _E:F#.14

Comments:

A:C01.01:CLC operating ready timing signal does not toggle ( = 0 or =1 static)

A:C01.01:CLC operating ready timing signal toggles

(CLC ready on DEA responds, if _A:C01.01 is on the DEA output _A:D#.16)


29/72

SYNAX Diagnoses and Fault Numbers arranged as per Fault Number (Parameter C-0-0048) 3-1


3 Diagnoses and Fault Numbers arranged as perFault Number (Parameter C-0-0048)

3.1 Overview

C-0-0048errornumber

Dis-play

C-0-0047diagnosis text of CLC system

C-0-0046Diagnosisinfo

Binaryoutput

Clearwith

0 0 "CLC in initialization mode" 0 A:C01.01 --


0 P "CLC in parameter mode" 0 A:C01.01 --


0 b "CLC in operation mode" 0 A:C01.01 --

01 01 "SERCOS interface - ring break" 10000h A:C01.01 --

02 02 "SERCOS interface - no drive connected" 10000h A:C01.01 --

03 03 Ex.: "Parameter incomplete"Error after switch into phase 3 (-> S-0-0021


04 04 Ex.: "master encoder error"

Error with switch into operating mode, copyparameter S-0-0095


05 05 "SERCOS interface - double drive telegramfailure"


06 06 "Fiber optic ring not closed" 10000h A:C01.01 --

07 07 "Drive addresses not correct(see C-0-0002, C-0-0086)"

10000h A:C01.01 --

08 08 "Max. number of drives exceeded" 10000h A:C01.01 --

09 09 "Emergency reaction ’Phase 0’ - mode changenot possible"

10000h A:C01.01 --

12 12 "CLC parameter exceeds min/max value(see C-0-0068)"

10000h A:C01.01 --

13 13 "CLC battery defective" 10000h _A:C01.02 _E:C01.01

14 14 "CLC checkum error" (see C-0-0068)" 10000h A:C01.01 --

15 15 "CLC Parameter not correct (see C-0-0068)" 10000h A:C01.01 --

16 "CLC EPROM defective" 10000h A:C01.01 --

17 "CLC SRAM defective" 10000h -- --

18 18 "Real master axis moved" 10000h _A:L01.08 _E:L01.16

19 "CLC hardware defective" 10000h -- --

20 16 "Non-supported drive type " n = address A:C01.01 --

21 16 "Non-supported drive firmware" n = address A:C01.01 --

25 "CLC in test mode zero bit stream" 10000h A:C01.01 --

26 -- "CLC in test mode continuous light" 10000h A:C01.01 --




40 40 "CLC link - ring break (primary ring)" 10000h _A:C01.04 _A:C01.05

_E:C01.04

42 42 "CLC link - master position fault (MDT)" 10000h _A:C01.04 _E:C01.04


30/72

3-2 Diagnoses and Fault Numbers arranged as per Fault Number (Parameter C-0-0048) SYNAX


43 43 "CLC link - master position fault (AT)" n = Adresse _A:C01.04 _E:C01.04

44 44 "CLC link - link address set - not permitted" 10000h A:C01.01 --

80 80 "More than one extension card not possible" 10000 h A:C01.01 --

91 91 "SERCOS interface - ASIC: Initialization error" 10000h A:C01.01 --

92 92 "CLC-P - DUAL PORT RAM error" 10000h A:C01.01 --

93 93 "DAQ: SERCOS interface - ASIC: intializationerror" 10000h A:C01.01 --

94 94 "CLC hardware version incorrect" 10000h A:C01.01 --

96 96 "Fieldbus card - hardware failure" 10000h -- --

100 18 "Real master axis - master encoder error" 10000h _A:C01.02 _E:L01.16

101 18 "Real master axis - redundant encoder error" 10000h _A:C01.02 _E:L01.16

105 17 "Virtual master axis - position value corrupted" 10000h _A:L01.03 _A:L01.01

_E:L01.16

110 17 "C-0-0050 too short for selected high speedcams" (C-0-0049)

10000h -- --

111 17 "Too many DEA cards for HS-waypointsactivated " (C-0-0049, A-0-0036

10000h A:C01.01 --

140 32 "3964R serial interface overrun" in prep. 10000h _A:C01.03 _E:C01.03

141 32 "3964R serial interface parity error" in prep. 10000h _A:C01.03 _E:C01.03

142 32 "3964R serial interface transmission error(frame)" - in preparation

10000h _A:C01.03 _E:C01.03

150 33 "Communication via the fieldbus is impossible" 10000h _A:C01.03 _E:C01.03

151 33 "Non-supported firmware version of theinterface board"

10000h _A:C01.03 --

152 15 "Process data are invalid (C-0-0129 / C-0-0128 / C-0-0127 / C-0-0126 / C-0-131 / C-0-0132 andDBs)"

10000h A:C01.01 --

153 15 "Parameter channel is not possible (see

C-0-0126 and C-0-0129)"

10000h A:C01.01 --

154 15 "Multiplex channel is not possible (seeC-0-0126 / C-0-0129 / C-0-0132)"

10000h A:C01.01

160 15 More than one register controller per axis notpossible

n = address -- --

161 15 Winding axis must be in speed synchronization(A-0-0003, A-0-0025)

n = address -- --

170 15 "C-0-0039/C-0-0040: Number of entries notequal"

10000h A:C01.01 --

171 15 "A-0-0008/C-0-0039: Activated analoguechannel not linked"


172-174

reserved

175 15 "A-0-0030: Process control P-Gain too high" n = address A:C01.01 --

176 15 "A-0-0025: Analogue channel for tensioncontrol not defined"


177 15 "A-0-0025: Analogue channel for tensioncontrol not activated"


178 15 Tension controlled axis must be speed synch.(A-0-0003, A-0-0025, A-0-0087)

n = address -- --

179 15 More than one tension controller per axis notpossible

n = address -- --

180 15 "Parameter A-0-0038 not correct" (in prep.) n = address A:C01.01 --

181 15 "C-0-0013: Non-permissible DEA address(see C-0-0002)"


182 15 "C-0-0013: Synchronization mode not n = address A:C01.01 --


31/72

SYNAX Diagnoses and Fault Numbers arranged as per Fault Number (Parameter C-0-0048) 3-3


permissible (A-0-0003)"

183 15 "C-0-0013: Adressed X-I/O not permissible(see C-0-0024/C-0-0033)"

10000h A:C01.01 --

184 15 "C-0-0013: Idle mode not permissible (seeA-0-0009)"


185 15 "C-0-0013: Set-up mode not permissible (seeA-0-0009)"


186 15 "C-0-0013: Special mode not permissible (seeA-0-0070)"


187 15 "C-0-0013: Non-permissible version ofPARA.EXE"

10000 h A:C01.01 --

188 15 "C-0-0013: Data integry violated" 10000 h A:C01.01 --

189 15 "C-0-0013: Non-permissible DEA address (e.g.ECODRIVE)"


190 15 "CLC link - other link master already active" 10000 h _A:C01.01 --

191 15 "CLC link not possible (CLC hardware)" 10000 h A:C01.01 --

192 15 "C-0-0013: PLC-interface not allowed on CLC-D and CLC-P01"

10000h A:C01.01 --

193 15 "No different feedbacks selectable(A-0-0003/A-0-0009/A-0-0070)"


194 15 "Phase synchr. & absolute format not possible(see A-0-0001/A-0-0003)"


195 15 "A-0-0003: Drive does not support selectedsync. mode"


196 15 "A-0-0070: Drive does not support selectedspecial mode"


197 15 "S-0-0103: Modulo value = 0 is invalid (seeA-0-0001)"


198 15 "Special mode only with CLC-P possible(A-0-0070/A-0-0071/A-0-0072/A-0-0073)


199 15 "Pattern control & modulo format notpermissible (see A-0-0001/A-0-0003)"


200 90 "Pattern control serial interface overrun" 10000h _A:M01.01 _E:M01.01

201 90 "Pattern control serial interface parity error" 10000h _A:M01.02 _E:M01.01

202 90 "Pattern control serial interface frame error" 10000h _A:M01.03 _E:M01.01

203 90 "Pattern control data buffer overrun" 10000h _A:M01.04 _E:M01.01

204 90 "Pattern data start byte faulty" 10000h _A:M01.05 _E:M01.01

205 90 "Pattern data undefined target position" 10000h _A:M01.06 _E:M01.01

206 90 "Pattern data error in number of axes" 10000h _A:M01.07 _E:M01.01

207 90 "Pattern data checksum error" 10000h _A:M01.08 _E:M01.01

208 90 "Pattern data not in order" 10000h _A:M01.09 _E:M01.01

209 90 "Pattern data positive pattern limit exceeded" n = address _A:M01.10 _E:M01.01

210 90 "Pattern data negative pattern limit exceeded " n = address _A:M01.11 _E:M01.01

211 90 "Pattern data limits between received targetpos. exceeded"

n = address _A:M01.12 _E:M01.01

220 15 "A-0-0025: Too many register controllersactivated"


221 15 "Port A (X27) multiple assigned(C-0-0011/C-0-0033/C-0-0104/Jumper)"

10000 h A:C01.01 --

222 15 "Port B (X28) multiple assigned(C-0-0011/C-0-0033/C-0-0104/Jumper)"

10000 h A:C01.01 --

223 15 "Cam and register control not possible(see A-0-0003/A-0-0025)"


224 15 "Register cont. and oscilloscope not possible n = address A:C01.01 --


32/72

3-4 Diagnoses and Fault Numbers arranged as per Fault Number (Parameter C-0-0048) SYNAX


(see A-0-0025/C-0-0107)"

225 15 "Cam/register/osci. not possible(see A-0-0003/A-0-0025/C-0-0107)"


226 15 "Drive does not support oscilloscope-function " n = address A:C01.01 --




230 21 "SERCOS transmission error (no driveresponds)"

1000h _A:C01.02A:C01.01

--

231 21 "SERCOS interface - transmission error duringinitialization"


232 15 "A-0-0009: Drive does not support selected setup mode


233 15 "Drive locked with password (S-0-0267)" n = address -- --

234 15 "Electr. gear ratio not possible (S -0-0236,S-0-0237)"

n = address -- --

235 15 "A-0-0107: Master drive gear not available

(P-0-0156/P-0-0157)"

n = address -- --

236 15 Register control only possible with modulo axis(A-0-0001, A-0-0025)

n = address -- --

237 15 "Register controlled axis withoutsynchronization (see A-0-0003)"

n = address -- --

240 15 "HS waypoints and I/O to DEA4.1 not possible(C-0-0013, C-0-0049, A-0-0036)"

n = address --

241 15 "HS waypoints and I/O to DEA28.1 not possible(C-0-0013, C-0-0049)"

10000h -- --

242 15 "C-0-0013: DEA 4.1 and DEA 8.1simultaneously not possible"

n = address -- --

243 15 "Drive does not support DEA8.1 card" n = address -- --

244 15 "Combination of used functions not possible(relative bits)"

n = address -- --

250 15 "Target axis must be phase sync or cam axis(A-0-0133)"

n = address -- --

251 15 "More than one group parameter per axis notpossible"

n = address -- --

3000 +y 98 Example: "motor overtemperature "drive error status class 1:copy of parameter S-0-0095(y = error number P-0-0009)

n = address _A:F#.10 _E:F#.14

4000 + x 95 "Operating system error" (x = error number) 10000h A:C01.01 --

Comments:

A:C01.01:CLC operating ready timing signal does not toggle ( = 0 or =1 static)

A:C01.01:CLC operating ready timing signal toggles

(CLC ready on DEA responds, if _A:C01.01 is on the DEA output _A:D#.16)


33/72

SYNAX Definition of the Error Messages 4-1


4 Definition of the Error Messages

(16) "CLC EPROM defective"

The EPROM test resulted in an error.

Remedy:

1. Make sure the EPROMs are correctly positioned.

2. Replace CLC and send it in to INDRAMAT customer service.

(17) "CLC SRAM defective"

The check of the memory modules (SRAM) resulted in an error.

Remedy:

1. Replace CLC and send in to INDRAMAT Customer Service.

(19) "CLC hardware defective"

The hardware test of the CLC resulted in an error.

Remedy:

1. Replace CLC and send in to INDRAMAT Customer Service.

(25) "CLC in test mode zero bit stream"

The test mode "zero bit stream" was selected in parameter "SERCOSinterface - configuration" (C-0-0038). The CLC then sends zero bitcurrent and prevents progression.

Remedy:

Correct C-0-0038 and enter intialization mode.

- - (26) "CLC in test mode continuous light"The test mode "continuous light" was selected in parameter "SERCOSinterface - configuration" (C-0-0038). The CLC then generates a steadylight and thus prevents progression.

Remedy:

Correct C-0-0038 and enter initialization mode.

C-0-0048: 16

C-0-0048: 17

C-0-0048: 19

C-0-0048: 25

C-0-0048: 26


34/72

4-2 Definition of the Error Messages SYNAX


01 (01) "SERCOS interface - ring break"

There is a break in the SERCOS interface fiber optic cable ring.

Remedy:

1. Switch machine off

2. Repair SERCOS interface ring

3. Switch machine on

02 (02) "SERCOS interface - no drives connected"

After powering up or progression into operating mode, the CLC attemptsto contact the drives via the SERCOS interface (LWL) ring. In this case,the attempt was not successful. The LWL ring is, however, closed.

Cause:

1. there is no drive in the LWL ring2. drive address(es) is (are) set to "0"

03 (03) Error on switching to phase 3 Example: "Parameter incomplete (-> S-0-0021)"

An error occurred when running up the LWL (fiber optic cable) ring priorto reaching an intermediate stage of communications phase 3. The drivediagnoses the error and signals this diagnosis to its parameter"diagnostic message" (S-0-0095). The CLC then reads this parameterand copies it into parameter "SYNAX - diagnostics text"(C-0-0047).

Note: "Error on switching to phase 3" is then in parameter "SYNAX -diagnostics text" (C-0-0047) instead of, e.g., "parameterincomplete" (-> S-0-0021)".

Remedy:

1. See drive command error C1/xx

04 (04) Error on switching into operating mode

Example: "Error master encoder"An error occurred when running up the LWL ring prior to reachingoperating mode. The drive affected diagnosis of the error and signals it toits parameter "diagnostic message" (S-0-0095). The CLC reads thisparameter and copies it into parameter "SYNAX - diagnostics text"(C-0-0047).

Remedy:

1. See drive command error C2/xx.

Note: "Error when switching into operating mode" will be inparameter "SYNAX - diagnostics text" (C-0-0047) instead of,e.g., "error master encoder".

C-0-0048: 01

C-0-0048: 02

C-0-0048: 03

C-0-0048: 04


35/72



05 (05) "SERCOS interface - double drive telegram failure"

The telegram of a drive has failed at least twice.

Cause:

1. LWL ring is defective

2. drive is defective

Remedy:

1. repair SERCOS interface ring or

2. replace the respective drive

06 (06) "Fiber optic ring not closed"

SYNAX checks, prior to phase progression, whether the LWL (fiber opticcable) ring is closed or not. This diagnosis can only take place during

phase progression. SYNAX waits until (without timeout) the LWL ring isclosed.

If the LWL ring has closed once, then a break is evaluated as a failure. Inthis case, the error message "SERCOS interface ring failure" (01) isgenerated.

Cause:

The LWL ring is not closed.

Remedy:

1. Drive controller not on, check power supply unit.

2. Check fiber optic cable ring, make necessary adjustments.

07 (07) "Drive addresses not correct (see C-0-0002, C-0-0086)"

The list of drive addresses in C-0-0002 does not agree with theaddresses of the drive that are in the ring.

Cause:

1. The connected drive addresses do not correspond to the projecteddrive addresses (C-0-0002).

2. All projected drive addresses (C-0-0002) were deactivated (C-0-0086).

Remedy:

1. Correct the number of drives of the drive addresses set.

2. Correct the drive addresses set in C-0-0002.

3. Check the addresses set in C-0-0086 (generally an empty list!)

4. Switch into initialization mode.

5. Switch into operating mode.

C-0-0048: 05

C-0-0048: 06

C-0-0048: 07


36/72



08 (08) "Max. number of drives exceeded"

The application has brought about a state where even an increase in theSERCOS interface cycle time does not suffice to operate the number ofdrives with the functions which have been set.

Remedy:

1. Reduce the number of drives or

2. reduce the functions of the drive, i.e., no setup mode, no tensioncontrol, no idle, fewer analogue channels, fewer process controllers,etc.).

09 (09) "Emergency reaction ’Phase 0’ - mode change notpossible"

A serious SERCOS interface error has previously occurred in operatingmode. The CLC has generated the emergency reaction of switching

SERCOS to phase 0. Any further SYNAX mode progressions are notpossible.

A progression is now only possible by switching the CLC off and on.

Cause:

1. SERCOS interface - ring interrupt

2. SERCOS interface - double drive telegram failure (e.g., due to loosefiber optic cable connection, a too tight bend radius or a fiber opticcable that is too long and so on.)

Remedy:

See error 01 or error 05

CLC must be turned off and on!

12 (12) "CLC Parameter exceeds min./max. value (see C-0-0068)"

The value of a parameter exceeds its defined min./max. input value. Theaffected parameters will be entered into the "list of invalid A and Cparameters" (C-0-0068).

Remedy:

1. Read out parameter C-0-0068

2. Correct the input value of the respective parameter.

13 (13) "CLC battery defective"

The battery on the CLC is dead.

CAUTION

Caution! Data could be lost!

⇒Replace the battery immediately.

C-0-0048: 08

C-0-0048: 09

C-0-0048: 12

C-0-0048: 13


37/72



Remedy:

1. Secure parameters.

2. Have a replacement battery ready.

3. Switch unit off.

4. Pull out the CLC card.

5. Remove old battery.

6. Insert new battery no more than one minute later.

14 (14) "CLC checksum error (see C-0-0068)"

The CLC checks the validity of all A/C parameters by means of achecksum. Every parameter that is challenged durng this sum is enteredin the "list of invalid A and C parameters" (C-0-0068).

Cause:

1. New CLC, parameters were not yet inscribed.

2. Parameter loss (e.g., due to battery power loss).

Remedy:

1. Load the parameter.

2. Write into the challenged parameter, e.g., via a terminal.

15 General procedure with this CLC display

A list of errors indicating faulty parametrization is a series of subdisplaysto this display.

In this case, it is necessary to alter one or more parameters. To do sorequires connecting a user interface, e.g., a CLC terminal.

The diagnostics parameters C-0-0046 through C-0-0048 specify thoseparameters which must be changed.

15 (15) "CLC Parameter not correct (see C-0-0068)"

A number of parameters are acknowledged as invalid during theplausibility check. The relevant parameters are entered into the "list ofinvalid A and C parameters" (C-0-0068).

Remedy:

1. Read out parameter C-0-0068.

2. Correct the input value of the relevant parameter.

15 (152) "Process data are invalid (C-0-0129 / C-0-0128 / C-0-0127 /C-0-0126 / C-0-0131 / C-0-0132 and DBs)"

The configuration of the fieldbus via the CLC-D has triggered theplausibility monitor.

The parameters which configure the fieldbus and/or the data modulehave inconsistent values.

C-0-0048: 14

C-0-0048: 15

C-0-0048: 152


38/72



Cause:

1. A write-protected object is configured in "Fieldbus: object list ofprocess data output" (C-0-0128).

2. An object was an unallowable length is configured in "Fieldbus: objectlist of process data input" (C-0-0127) or "Fieldbus: object list ofprocess data output" (C-0-0128). This can occur in the case of anunsuitable "Fieldbus: length of process data channel" (C-0-0126).

3. An object configured in "Fieldbus: object list of process data input"(C-0-0127) or "Fieldbus: object list of process data output" (C-0-0128)is not parametrized in the relevant data module. For example, in thecase of an activated multiplex channel the base objects relegated tothe data modules must have as many elements as his parametrized in"Fieldbus - multiplex size" (C-0-0131).

Remedy:

1. Check all parameters for the configuration of the fieldbuses and thedata modules and correct, if necessary.

15 (153) "Parameter channel is not possible (see C-0-0126 andC-0-0129)"

A configuration of the fieldbus via the CLC-D has actuated the plausibilitymonitor.

Cause:

1. The parameter channel is parametrized in "Fieldbus - control word"(C-0-0129). It requires six words of the process data channel. The"Fieldbus: length of process data channel" (C-0-0126), however, is

smaller than six words.

Remedy:

1. Set C-0-0126 to at least six words or delete parameter channel inC-0-0129.

15 (154) "Multiplex channel is not possible (seeC-0-0126/C-0-0129/C-0-0132) "

A configuration of the fieldbus via the CLC-D has actuated the plausibilitymonitor.

Cause:

1. The multiplex channel is parametrized in "Fieldbus - control word"(C-0-0129). The "Fieldbus - start address of multiplex channel"(C-0-0132), however, lies outside of the process data channel (see"Fieldbus: length of process data channel (C-0-0126)).

Remedy:

1. Coordinate C-0-0126 or delete the multiplex channel in C-0-0129.

C-0-0048: 153

C-0-0048: 154


39/72



15 (160) "More than one register controller per axis not possible"

More than one register controller is working the specified axis.

Remedy:

1. Deactivate register controller (A-0-0025)

2. Correct register controlled axes (A-0-0087)

15 (161) "Winding axis must be in speed synchronization (A-0-0003,A-0-0025)"

The winding function (see "process control - control word", A-0-0025) forthe specified axis (see C-0-0046) is activated.

This winding axis must be speed synchronous.

Remedy:

1. Deactivate the winding ("process control - control word", A-0-0025)

2. Parametrize the winding axis as a speed synchronous axis("synchronization mode", A-0-0003)

15 (170) "C-0-0039/C-0-0040: Number of entries not equal"

The parameters

"analogue channels - select source parameters" (C-0-0039) and

"analogue channels - select target parameters" (C-0-0040)

are of unequal length.

Remedy:

1. Correct the input value of the parameter.

15 (171) "A-0-0008/C-0-0039: Activated analogue channel not linked"

An analogue input activated in parameter "analogue channels - analogueinput control word" (A-0-0008) is not linked to parameter "analoguechannels - select source parameters" (C-0-0039).

Remedy:1. Deactivate the channel in "analogue channels - analogue input control

word" (A-0-0008) or

2. Change "analogue channels - select source parameters" (C-0-0039).

15 (175) "A-0-0030: Process control P-gain too high"

An error in calculation would result from the value set in "processcontroller 1 - proportional gain" (A-0-0030) (value too big).

Remedy:

1. Reduce parameter "process controller 1 - proportional gain"(A-0-0030).

C-0-0048: 160

C-0-0048: 161

C-0-0048: 170

C-0-0048: 171

C-0-0048: 175


40/72



15 (176) "A-0-0025: Analogue channel for tension control notdefined"

A tension controller has been set in the relevant axis (for address see"SYNAX - error source" (C-0-0046)).

Via parameter "analogue channels - select target parameters"(C-0-0040) the actual value for the tension controller "process actualvalue" (A-0-0027) must be allocated to an analogue input.

Remedy:

1. Define an analogue input for the parameter "process actual value"(A-0-0027) or

2. Deactivate the tension control in "process control - control word"(A-0-0025).

15 (177) "A-0-0025: Analogue channel for the tension control not

activated"A tension controller has been set in the relevant axis (for address see"SYNAX - error source" (C-0-0046)).

An a

Documents

INDRAMAT SYNCHRONIZATION OF MACHINE AXES SY05_WAR1.pdf