Category Archives: Troubleshooting

FANUC Controls Alarms

FANUC CNC Troubleshooting – Frequently Asked Questions

MRO Electric stocks new and refurbished FANUC products, and also offers reliable FANUC repairs. Please call 800691-8511 or email sales@mroelectric.com for a quote.

What is the proper method to test a motor for a short?
The proper way to test a FANUC motor for a short is to first lock out the machine, remove the cable from the drive, and test all three motor phases to ground with a megohmmeter. This will test both the motor and the cable for problems.

Why am I getting errors when I connect to my FANUC drive’s RS-232 port?
There are a number of explanations for these errors. The RS-323 port is a high-fail component on a FANUC drive as it is very susceptible to electrical surges. However, the RS-232 cable is also another high-fail item. Ensure that you are using a cable that is known to be functional when communicating. Otherwise when you attempt to read-in or punch-out a cable, you will get an 086 alarm that is going to indicate that the cable is incorrect, or that the port has failed.

To test whether the cable or the port has failed, take a known good cable and insert it into the RS-232 port. Next, set your machine up to receive a file. The screen should being to flash “READ”. Next, transmit your file into the machine tool. If the machine continues to flash “READ” (or “LSK” on modern controls) but never receives the file, you have a defective communications port on either the memory board or the master board. These boards or your machine will need to be sent in for repair.

What is an Axis Communications Error?
An Axis Communications Error indicates a communications problem between the motor encoder and the CNC control. This can be caused by the motor encoder itself,  the cable going to the encoder, or the axis control card the cable is plugged into.

What is an Excess Error Alarm and why is it caused?
Generally, an Excess Error means that the machine has moved beyond its allowable tolerance. The CNC has told the servo drive to make a move, the servo drive moves the motor,  which in turn moves the encoder. As the machine moves, there will be some deviation. This deviation is known as the Excess. The parameters set how much deviation/excess should be allowed.

These errors can be caused by a variety of problems. For example, a dull tool can caused the axis to be pushed out of position which results in a deviation error. Debris build up can cause deviations while the machine is stopped. Additionally, a failed servo drive can also cause deviation errors.

What is FANUC Alarm 401?
Alarm 401 is a very generic alarm. It simply means that the servo’s did not obey. The CNC, which is in charge of the servos, tells the servo drives to turn on and remain on. If for whatever reason the servo drive turns itself off without the permission from the CNC, the CNC will generate a 401 alarm. This alarm will usually occur with other alarms, such as the 414 Alarm.

What is FANUC Alarm 414?
The 414 Alarm is an alarm issued by the CNC that says a problem has been found in either the servo drive or the feedback system. The alarm will show which axis is causing the problem. To identify the specifics of this alarm, you must go into the CNC diagnostics page. Diagnostics number 200 on the 16th row will indicate what is causing the problem.

What is the difference between a High-Current Alarm and an Over-Current alarm?
A high current is an abnormal current that can be caused by noise. When the system detects this, it will generally shut the machine down and generate a High-Current Alarm. This alarm is usually caused by defective servo drive or cooling contamination inside of the motor windings or cable.

An Over-Current Alarm indicates that too much current has flowed through the DC link. This is usually caused by a short in the system, an unplanned contact, a defective transistor module, or dull tooling attempting to make a cut. 

Why do I get a Soft Overtravel Alarm when I try to reference a newly installed motor?
When the CNC power down, it remembers its last known position. When you restart the machine, an incremental encoder will ask that the machine be re-positioned. When you try to do a re-reference of the machine tool, and it doesn’t agree with where the last known position was, the machine with automatically go into a default that indicates a Soft Overtravel Alarm. These alarms can occur as any point in the travel of the machine. To bypass this alarm, power the machine down and hold down the key with the letter “P” on it as well as the “Cancel” button (at the same time). Then power the machine up while you continue to hold down both of these buttons. If you do this, the machine will ignore all Soft Overtravels until the first zero referenced position has been done on that axis, and will clear the Soft Overtravel Alarms.

I unplugged my motor, and now I am getting a 300APC Alarm. What is that?
A 300APC Alarm indicates that you are using an absolute pulse coder. The difference between an absolute pulse coder and a incremental pulse coder deals in the memory retention of the position. Using a CNC control with an incremental pulse coder, you must reference the machine every time you turn the machine back on.

With an absolute pulse coder, there is a battery backed memory that retains the position of the machine tool when it powers down. When the CNC machine turns back on, it asks the encoder its position, and the encoder then responds back with its current position. If it is within tolerance of where it was when it shut down, the CNC will continue to run the program. However, if you lose the memory retention due to an encoder cable being unplugged, you will end up with the 300 level APC alarms. These alarms simply signify that the machine must be re-referenced. The re-referencing procedure is determined by the machine tool builder – consult your machine tool builder manual for the proper operation.

Micromaster 420

Siemens Micromaster 420 Faults and Alarms

A blog we posted earlier this week about the Micromaster 420 troubleshooting referenced the Faults and Alarms list for the Micromaster series, so we decided that it would make sense to make the list of Micromaster 420 Faults and Alarms directly available. This is from the corresponding manual for the Micromaster 420 series, but it is buried within the manual which most people most likely don’t even have. Hopefully this helps with your troubleshooting.

View our 420 Micromaster Drives in stock. For more information or to request a quote, please call 800-691-8511 or email sales@mroelectric.com. We also provide pre-priced Micromaster 420 Repairs.

Continue reading Siemens Micromaster 420 Faults and Alarms

Siemens Simodrive Diagnostics and Troubleshooting

On the front of the Siemens Simodrive monitoring and NE modules there is a series of 6 LED lights that are used to diagnose issues with the drive. We have a diagram of the LED below along with the meaning of each light so that customers can properly diagnose their Siemens Simodrives.

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Modicon 140CPU65260: Beyond the User Manual / Firmware Information

Have a Modicon CPU down? Request a Quote on a Spare Today.

The Modicon Quantum 140CPU65260 is a Pentium Unity processor with 3072 kB of internal RAM and a clock frequency of 266 MHz. It has 2 local racks, and can have 6 optional modules: Ethernet, Modbus, Modbus Plus, Profibus DP, and Sy/Max. The module has 2 local signaling LEDs – 1 red for Ethernet collision and 1 green for Ethernet activity.

The 140CPU65260 firmware has a long history. The launch version was Unity Pro V2.0. Over time, 50+ changes have been made to a variety for firmware versions, correcting a number of bugs and issues. You should always update your module to the latest firmware revision. Firmware versions greater than V3.30 must be used with Copro version 5.8.

140CPU65260 firmware version V3.5 and all previous versions contain hardcoded backdoors that produce multiple vulnerabilities, allowing hackers (even remote ones) to view firmware, modify the module’s website, modify passwords, and download and run custom firmware.

Overall, the 140CPU65260 has a total of 4 communication ports. One Modbus (RS-232/RS-485), one Modbus Plus (RS-485), one USB, and one Ethernet. The CPU module requires a bus current of 2760 mA. This module also comes with a key switch. Its reference capacity for discrete (bits) is 62 kBytes and its reference capacity for registers (words) is also 64 kBytes. Its battery has a shelf life of 10 years and its service life is 12 mAh. The 140CPU65260 uses a 3V lithium battery.

The CPU module contains a number of built-in diagnostic capabilities. On powerup, it will check and diagnose any issues with RAM, RAM address, executive checksum, user logic, and the processor. While running, it will check all of these functions with the exception of the processor.

MRO Electric and Supply carries both new and refurbished Modicon 140CPU65260 Modules. For more information or to request a price quote, please email sales@mroelectric.com or call 800-691-8511.
140CPU65260
140CPU65260

 

A06B-6079-H208

FANUC A06B-6079-H208: Beyond the User Manual

The FANUC A06B-6079-H208 is a Servo Amplifier Module, SVM2-80/80. This module drives a servo motor of the 200V input series. It is a 2-Axis amplifier, and can be used with Type A or Type B interfaces. The module weighs approximately 7.0 Kg. Its external dimensions are 380 x 90 x 307 millimeters. It has a rated output current [Arms] of 18.7 and a nominal current limit [Ap] of 80.

One common alarm for the A06B-6079-H208 is Alarm 9. When this occurs, the M-Axis has an over current caused by a servo drive or motor fault. If you have an Alarm 9 with a dot, then that is an M-Axis IPM alarm, and you should replace or repair your A06B-6079-H208.

Below is the A06B-6079-H208 wiring diagram for ground cable connections:

A06B-6079-H208 Wiring Diagram
A06B-6079-H208 Wiring Diagram

The A06B-6079-H208 converts alternating current to direct current in the converter section, and exercises variable motor speed control by PWM control based on switching by the six transistors in the inverter section. Switching noise is generated by the 6 transistors turning off and on at high speeds. Each time a transistor turns on or off, noise current flows to ground through stray capacitance between the cable or motor and ground. The value of this noise current depends on the stray capacitance and transistor switching speed. The frequency band of the amplifier’s noise is about 30-40 MHz.

The presence of this noise means that cost-effective measures should be taken to reduce its level. Noise problems prevented prior to operation can help reduce costs over the lifetime of the installation. The following precautions should be taken when installing your A06B-6079-H208.
– Separate power lines and motor power lines from signal lines.
– Contain power lines and motor power lines in a metallic conduit.
– Perform appropriate grounding installation including grounding wire connections. This will also serve to prevent electrical shock due to leakage currents.
– Grounding wires should be as thick and as short as possible.

Noise can affect things like radio communication, refrigeration, telehones, fax machines, and essentially any electronics nearby.

MRO Electric stocks new and refurbished A06B-6079-H208 Servo Amplifiers. If you would like more information or to purchase a spare or replacement drive, please call 800-691-8511 or email sales@mroelectric.com.
A06B-6079-H208
A06B-6079-H208

Simodrive E/R Troubleshooting for 6SN1145-1BA02-0CA1

 

6SN1145-1BA02-0CA1
6SN1145-1BA02-0CA1

We often have people who are having issues with their current drive setup but can’t confirm that a specific drive in their system is the issue. They are all but sure, but understandably want to confirm the problem before buying a replacement from us, so we have a set of troubleshooting procedures issued from Siemens that we can send out so that people can confirm that they have a problem. Last week a customer was replacing a Siemens 6SN1145-1BA02-0CA1 module and wanted to troubleshoot their I/R module, so we’ve listed the troubleshooting procedures in the table below to help with  Simodrive E/R Troubleshooting.

For a full list of the Siemens Simodrives that we have available you can visit the section on our website here. To request a quote, please call us at 1-800-691-8511 or email sales@mroelectric.com

Continue reading Simodrive E/R Troubleshooting for 6SN1145-1BA02-0CA1

FANUC A06B-6093-H152: Beyond the User Manual

The FANUC A06B-6093-H152 is a Beta series servo amplifier. It is important when using this amplifier that the ground fault interrupter is mounted. Fit the factory power supply or machine with a ground fault interrupter that is designed for use with an inverter. This will guard again fire and electrical shock. Ensure that the motor and amplifier is an appropriate combination, and that valid parameters are specified. Specifying an invalid parameter can not only prevent normal operation, but can also damage the amplifier.

Before connecting the power supply wiring on your A06B-6093-H152 amplifier, check that the voltage supply is within the appropriate range. It is also important that appropriate countermeasures are taken against noise. Signal lines should be routed away from the power supply lines and the power lines.

If you encounter a failure on your A06B-6093-H152, first check the LED display for the alarm code to determine the cause and apply the appropriate countermeasure.

Beta Series Servo Alarms
Beta Series Servo Alarms
FANUC Beta Servo Amplifier Alarm Codes
FANUC Beta Servo Amplifier Alarm Codes
MRO Electric stocks both new and refurbished FANUC A06B-6093-H152 Amplifiers. For more information or to request a quote, please email sales@mroelectric.com or call 800-691-8511.

Siemens 6SL3120-2TE21-8AA3: Beyond the User Manual

The Siemens 6SL3120-2TE21-8AA3 is a Sinamics S120 Double Motor Module with a 600V DC output and an 18A/18A frame size. For Sinamics S120 double motor modules, a DMC20, a TM54F, and a CUA32 each correspond to two DRive-CLiQ particiapants. This also applies to double motor modules when just one drive is configured. Mixed operation is not permissible on the 6SL3120-2TE21-8AA3.  When connecting the motor encoder via DRIVE-CLiQ, use motor connection X1: encoder at X202 and motor connection X2: encoder at X203.

The 6SL3120-2TE21-8AA3 must not be operated as a single drive if you are using FW2.1 or FW2.2 firmware releases. A combination of operating modes is not possible on a double motor module.

There are a number of local signaling LEDs on the 6SL3120-2TE21-8AA3. The Off LED means that the electronic power supply is missing or outside permissible tolerance range. If your green LED is off, then the component is ready for operation and cyclic DRIVE-CLiQ communication is taking place. If this LED is orange, then the DC link voltage is present. If it is red, then the DC link voltage is too high. If the orange LED on the module is active, then DRIVE-CLiQ communication is being established. The Red LED signals that the component has at least one fault. This LED is activated regardless of whether the corresponding messages have been configured. To clear this code, remedy and acknowledge the fault.

If you see a green or red flashing LED at 0.5 Hz then firmware is being downloaded. When this light goes to 2 Hz, then the firmware download is complete and the user should carry out a POWER ON and wait. If you see a green/orange or red/orange local signal on the  6SL3120-2TE21-8AA3, then component detection via LED is activate. Both of these options depend on the LED state when activated via P0124 = 1.

MRO Electric stocks both new and used 6SL3120-2TE21-8AA3 Double Motor Modules. For more information or to request a quote, please call 800-691-8511 or email sales@mroelectric.com.
6SL3120-2TE21-8AA3
6SL3120-2TE21-8AA3

Schneider Electric Magelis HMIs – Frequently Asked Questions Part II

MRO Electric carries new and refurbished Magelis HMIs. To request a quote, please call 800-691-8511 or email sales@mroelectric.com.
Magelis HMIs
Magelis HMIs

Why is the Magelis XBTRT511 is not giving me the correct floating point value reading on the alphanumeric display when communicating with a Momentum?
If you address the alphanumeric display as a %MW that is incorrect. To read a floating point value, you need to address the alphanumeric as a %MF.

Does the Magelis Panel PC, HMIPUC9D0E01, have line out to connect a speaker?
Yes, the Panel PC HMIPUC9D0E01 have a Line out to connect an external speaker.

Can I lose my alarms log in Vijeo Designer V4.5 when power cycling my Magelis XBT-GT?
Each alarm group can have 2 such alarm buffers: one for History alarm events (size defined by the “Num of History Alarms” property) and one for Log alarm events (size defined by the “Num of Log Alarms” property).
These alarm buffers are stored in the DRAM (Dynamic RAM: similar to the RAM of a PC) of the target. Therefore, if the target is turned off, the alarm buffers are wiped out. If you need them to be saved even when the target is turned off, you can enable the “Backup Alarm Group” property (at the global alarm level). This way, these alarm buffers will be stored in the DRAM and in the SRAM (Static RAM: doesn t get wiped out when the target is turned off) as well.
Since the size of these alarm buffers is limited (the maximum value for the “Num of History Alarms” and “Num of Log Alarms” properties is 10000), they won t always contain the whole history of alarm events on the target. To obtain that behavior, you can enable the “Save To File” property (at the alarm group level). This way, the alarm events will be saved into Excel files (on the CF card) and these Excel files will contain the whole history of alarm events for the corresponding alarm groups.

Is there a RS-485 cable to connect a M221 to a Magelis XBTN401?
No. There is no cable you must make your own the pin out is as follows;

4——–4
5——–5
7——–7
8——–8

No other pins can be used because the M221 can also be configured for RS-232. (can not use a straight through Ethernet cable).

What is the meaning of “PLC Returned error code 02H” for Magelis Targets HMIGTO ?The error “PLC Returned error code 02H”, means that you are trying to access an address in the slave device which is not defined or inaccessible or there can be issue with communication card , cable, or communication settings done inside IOmanager communication equipment channels must be checked. Mostly the issue observed is related to register mismatch between target and slave device. Correcting this will resolve the issues.

What is the the number of candela per square meter for the Magelis XBTGTO?
HMIGTO 3.5″ = 450
HMIGTO 5.7″ = 500
HMIGTO 7″ = 350
HMIGTO 7.5″ = 400
HMIGTO 10.4″ = 450
HMIGTO 12.1″ = 450

Can a Magelis HMI communicate to a M241 SL2 using SoMachine protocol?
The M241 can communicate to an HMI via SL2. The default communication settings for SL2 does not match the settings for the COM of the HMI (baud rate and parity are different). If the settings are adapted, the communication works fine.
Below is the RS485 pinout:

HMI to M241 SL2
Pin 4 to D1
Pin 5 to D0

Can the Magelis HMIPPF7A2701 be mounted at a 45 degree angle?
The unit can be mounted at a 45 degree angle as long as the ambient air temperature does not exceed 85F and that there is enough air flow surrounding the unit.

Why does Magelis HMI tell me to change my password when I log in?
In Vijeo Designer, there is a feature called Password Management. If this is enabled, and password expiry is enabled, your password will expiry in two cases:
1) At first login and
2) After the defined time has elapsed.

You will need to change your password in the runtime with the user manager part or redownload the application again.

Can I have two Magelis HMI to the same serial port of a M238?
No you cannot, there are two possibilities to realize configuration of a M238 + 2 XBTGTs.
You can connect an HMI to the SL1 of the M238 and the second HMI can be connected to SL2.

Why is there only some data logged in my Magelis HMI?
Vijeo Designer Runtime is designed to optimize storage for data logging by only creating a record when the value of the variable changes. If the value of the variable remains static, a new record will not be created (other than the initial record). Each record made is for a unique value. Vijeo Designer cannot send emails via SMTP2Go on the Magelis but is successful via simulation

When this situation occurs, it is likely the network settings on the HMI are incorrect. Ensure that the IP, Subnet Mask, Default Gateway, and DNS server are all set up correctly. Typically you can compare your PC’s settings vs the HMI’s settings to find the differences (if they are on the same network).

Can the TM2 expansion modules be used on the Magelis STU and STO?
No, if you want an HMI that can use the TM2 modules you will need to go to the HMISCU series.

Is there a Magelis HMI that can withstand 80psi of pressure?
The HMIGTO xx15 series has been tested to withstand 10 bar of high pressure washing machinery. (10bar = 145 psi)

Magelis HMIs – Frequently Asked Questions Part I

MRO Electric carries new and refurbished Magelis HMIs. To request a quote, please call 800-691-8511 or email sales@mroelectric.com.
Magelis HMIs
Magelis HMIs

Is it possible to download to a Magelis HMISCU with SoMachine using the IP address connection mode?
SoMachine V4.1 SP1.2 does not support this feature. It is only possible to download using the Node name connection mode.

What methods are there to put a Magelis back to factory settings?
Use the Vijeo Designer Runtime Installer found in the Start menu under Schneider Electric\ Vijeo-Designer to re-install the Runtime.

What are the Magelis XBTGT7340 DIO output specifications?
The Run, System Alarm and Event Buzzer outputs are rated for 24VDC and 50ma.

What is the MTBF for the Magelis HMISTU855?
-LCD and touch panel of STU655/855 is 50,000 hours
-HMISTU655/855 is 2,087,918 hours without LCD screen

Can the MBX Driver V7.0 be installed on a Magelis iPC Smart box with a primary 1GB CF card?
No there is not enough available space on the primary CF card. MBX Driver requires Microsoft .NET Framework 2.0 which requires about 150MB of available space on the primary CF card.

Can I use a VESA mount on the Magelis iDisplay MPCYT90NAN00N?
Yes. The iDisplay MPCYT90NAN00N can be mounted using a 100mm VESA mount.

Why can’t my Magelis HMI Communicate over Ethernet?
One common mistake people make is plugging the Ethernet cable into the RJ45 COM port of the HMI. First thing to check is to see if your Ethernet cable is actually plugged into the Ethernet port (it is labelled accordingly).

Is there a replacement keypad membrane for the Magelis XBTR410?
No. There are no replacement keypad membrane for the XBTR410.

Does the Magelis HMISCU support 3rd party drivers?
The HMISCUs only support Schneider Electric protocols. It does not support any 3rd party protocols. It was a Marketing decision to not include 3rd party drivers.

Does the Magelis HMISTO have e-mail functionality?
Only the HMISTO531 and HMISTO532.

Can I delay the Startup on the Magelis HMIGTO?
A Startup delay can be added from the Target Properties under Startup Options.

What is the fusing recommendation for the Magelis HMISCU?
We recommend using a slow-blow, 2A type T fuse. Type T and Class refer to different characteristics.
Type T is a time-delay slow blowing fuse. They are available in a wide variety of form factors and amperages. They typically have a fast over current link for surge spikes and a slower over current link for longer overload conditions.

Which Magelis HMI models support DH485?
The following HMI series support the DH485 protocol:
XBTGT
HMIGTO
HMISTU
HMISTO
XBTGK
HMISCU
HMIG3U

Is a Magelis HMISCU capable of logging data?
A HMISCU is capable of logging data onto an USB memory stick. Only the Vijeo Designer part of the controller will be able to do data logging. The SoMachine Logic Builder part cannot do data logging.

What is the communication cable to connect a Magelis XBTN401 to a Twido TWDNAC485D MiniDin port?
The cable part number is XBTZ968.

What software is used to program Magelis HMIGXU series ?
Vijeo Designer Basic V1.0 and higher is used to program the Magelis HMIGXU series.

Can the keypad on the Magelis XBTGK’s be replaced?
No, the keypad or membrane on the Magelis XBTGK’s are not field replaceable. There are no replacement parts for these and it will most likely have to be sent in for a repair.

What are the MTBF’s of the Magelis HMIGTU series?
See attached for the MTBF’s for the Magelis HMIGTU ranges.

Is the Magelis HMIGTO work with neoprene gloves?
The Magelis HMIGTOs use a resistive touchscreen. The touch is activated when pressure is apply to the screen and can be used with neoprene gloves.

Can the Magelis HMI be mounted vertically?
No, the Magelis series of HMIs programmed with Vijeo Designer cannot be mounted vertically. The reason for this is because Vijeo Designer software assumes that the (0,0) coordinate is the top left corner of the screen.

Are the Magelis HMIGTO series ATEX Certified?
Yes, the Magelis HMIGTO’s are ATEX certified and the models are listed below.
– HMIGTO1300
– HMIGTO1310
– HMIGTO2300
– HMIGTO2310
– HMIGTO2315
– HMIGTO3510
– HMIGTO4310
– HMIGTO5310
– HMIGTO5315
– HMIGTO6310
– HMIGTO6315

Magelis HMISTU boots to the message Runtime Unsupported : The hardware platform does not match the target type defined in the application. Is there a way to recover from this?
This usually can affect the following parts: HMISTU655/855, and HMIS5T. The HMISTU targets do not have a way to recover the Runtime. It is recommended that the unit be sent in for repair, or purchase a replacement unit.