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Operating Manual PacDrive Controller P600

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1. Bit Meaning Bit 0 overload shut down Bit 1 amplifier overtemperature shut down Bit 2 motor overtemperature shut down Bit 3 cooling error shut down Bit 4 control voltage error Bit 5 feedback error Bit 6 error in the commutation system Bit 7 overcurrent error Bit 8 overvoltage error Bit 9 undervoltage error Bit 10 power supply phase error Bit 11 excessive position deviation Bit 12 communication error Bit 13 overtravel limit is exceeded shut down Bit 14 Reserved Bit 15 manufacturer specific error see 1164 Table 8 4 SERCOS C1D error assignment according to SERCOS specifications 164 SERCOS C1D manufacturer specific error Diagnosis class see 8 1 Diagnosis Classes standard 1 Reaction manufacturer specific A manufacturer specific SERCOS error in diagnosis class 1 C1D has occurred The extended diagnosis contains a data word that provides information on the exact cause For information on what each bit means refer to the manual of the SERCOS device manufacturer 165 SERCOS C2D warning Diagnosis class see 8 1 Diagnosis Classes standard 6 Reaction manufacturer specific ASERCOS warning in diagnosis class 2 C2D has occurred The extended diagnosis contains a data word that provides information on the exact cause ELAU AG PacDrive Controller P600 Page 93 Page 94 The meaning of the data word has changed Incorrect interpretation of the error message Referto the oper
2. C Motor decelerates with max delay yet 124 Overload see 8 5 2 25 124 Power remains under control brakes do not en Off due to overload gage D Warning message to PacDrive control 125 I2t motor warning see 8 5 2 26 ler program can be used for controlled 125 1 2t motor warning synchronous standstill if no reaction oc curs then a state class 1 error may result E Message 133 Speed dependent power reduction see 8 5 2 34 133 Speed de pendent power reduction See also Servo amplifier time diagram bus err LED The bus err LED SERCOS onPacDrive components allows fast and easy detec tion when a fiberoptic cable is interrupted or the intensity setting for a transmitter in the SERCOS loop is incorrect The LED turns off when error free telegrams are received After booting the master starts to send telegrams continuously At this point all bus err LEDs of the SERCOS slave PacDrive Controller Servo amplifier and others must be OFF PacDrive Controller P600 ELAU AG NOTE ELAU AG The status of the bus err LED is undefined during the boot procedure The err LED indicates when the boot procedure is complete The err LED switches on when the BIOS starts and switches off when the operating system user configuration user parameters and the IEC program are loaded and the IEC program starts The boot procedure is now complete Operating principle When the fiberop
3. gt Prevent fall in mains voltage while drive is in control mode gt Switch off controller or final stage of servo amplifier when switching off the mains contactor parameter ControllerEnable or input enable at the servo amplifier 5 Short circuit or ground fault in DC circuit wiring gt Check wiring 140 Ramp down braking time out Diagnostic class see 8 1 Diagnosis Classes standard 2 Reaction see 8 2 Reactions B The maximum ramp down time was exceeded during control down ramping of mo tor When switching off ControllerEnable or HW_Enable or when an error occurs with Reaction B best possible stoppage or user driven stoppage the ramp down time is determined by the parameter StopTimeLim If the drive has not stopped at the end of the down ramp time the brake engages and the error message Ramp down time exceeded is emitted Following the expiry of the BrakeCoupling Time the drive is connected torque free For error with Reaction C Overload function the ramp down time is firmly set at 800ms If the drive is not still once the ramp down time has expired the error message Ramp down time exceeded with Reaction B is triggered In so doing the ramp down time StopTimeLim is restarted until the brake engages Once the BrakeCoupling Time is up the drive is connected torque free The load on the drive is too great to adhere to the set ramp down time gt Check parameter StopTimeLim If the diagnostic m
4. DiagExtCode Meaning Phase 4 Phase change after phase 4 Phase 4 xxx Internal error xxx during phase change after phase 4 Phase 5 Phase change after phase 5 Phase 5 xxx Internal error xxx during phase change after phase 5 Table 8 3 Possible values for DiagExtCode for diagnostic message 042 SERCOS phase change Phase lt Phase number gt lt internal error number gt An error has occurred during the phase change gt Check the message logger for other SERCOS diagnostic messages gt Note the description of these diagnostic messages Phase 1 lt internal error number gt SCL 055 motors are connected to the PacDrive controller The connection of the SCL 055 motors in the PacDrive PD 8 box is not correct gt Check the connection of the SCL 055 motors in the PacDrive PD 8 box It is not enough to place the jumpers on the desired terminations No nodes to be plug ged into the following SERCOS plug in position gt Observe also the information outlined in the SCL and PS 4 and PD 8 oper ating manuals 043 Detect SERCOS configuration The SERCOS configuration is being detected A scanis executed during this proc ess The ext diagnose in the message logger shows the following values Start gt Configuration scanning started Position gt The physical address of the instance in the SERCOS loop is shown e g in stance SLAVE1 position 3 End gt Configuration scanning stopped No slaves
5. gt Check the IEC program 321 Division by zero check Diagnosis class see 8 1 Diagnosis Classes standard 5 A division by zero was found in the IEC user program by the Check lib The message logger call hierarchy function can be used to backtrace the function block call or nesting A division by zero should executed in the IEC program gt Include division by 0 in the IEC program gt Check the number range 322 Exception by IEC task Diagnosis class see 8 1 Diagnosis Classes standard 5 If an IEC task detects a fatal error e g access error using pointer it triggers a diag nosis message The message logger call hierarchy function can be used to backtrace the function block call or nesting 323 String too long Diagnosis class see 8 1 Diagnosis Classes standard 5 The maximum string length 255 was found in the IEC user program by the Check lib The message logger call hierarchy function can be used to backtrace the function block call or nesting The maximum string length in the IEC user program was exceeded gt Check the IEC program 324 UPS internal failure Diagnosis class see 8 1 Diagnosis Classes standard 5 There is an internal error in the UPS The battery ofthe UPS is empty gt Charge the battery The power supply of the UPS is working but the ON OFF input of the UPS is set to OFF PacDrive Controller P600 ELAU AG gt If the voltage supply is correct then the ON
6. Diagnosis class Name Priority Fatal error High Error resulting in complete shutdown Error resulting in single shutdown Error resulting in complete stop Error resulting in single stop if error is triggered by an axis Warning Message Low Logger entry None Table 8 1 Diagnosis Classes and Reactions Priority oIsJ o lo 2r oI nw The following restrictions apply when overwriting an assignment Certain internal diagnosis codes servo amplifier with Reaction see 8 2 Reac tions A B and C may only be assigned with classes 1 2 and 3 Reactions A E associated with the Group 1xx MotorController type of di agnosis messages MC 4 PS 4 SCL cannot be changed Error class 8 is used by the system and may not be changed The 112 Communication error real time bus see 8 5 2 13 112 Communication error real time bus diagnosis message is not reported in the system because when an error occurs the motor controller MC 4 PS 4 SCL cannot report the diagnosis code to the controller e g C400 over the SERCOS bus In this case diagnosis code 506 Fatal SERCOS error MASTER see 8 5 6 7 506 Fatal SERCOS error MAS TER is reported NOTE Certain system reactions are permanently assigned to each diagnosis class Class 1 2 3 4 Entry in message logger x X X X Best standstill of all drives x X l Best standstill of the triggering drive X Error stop of
7. JV Feldbus Info VW Zus tzliche SERCOS Diagnose I Filter Typ 6 I Filter Typ 7 I Filter Typ 8 Figure 8 6 Set the filter in the message logger for additional SERCOS diagnosis However the filter settings should correspond to the basic settings in EPAS 4 V16 SP3 or higher General infor To better understand the outputs of the extended SERCOS diagnosis a brief intro mation on SER duction of the operating principle behind SERCOR communication in the PacDrive COS communi system is provided here cation SERCOS involves cyclical communication occurring in a ring shaped communication structure Controller PD_SyDi0008ML Figure 8 7 SERCOS communication ring Page 64 PacDrive Controller P600 ELAU AG ELAU AG Allreceived signals are immediately forwarded by the drives in the ring They interrupt the ring only when sending their own data telegrams The controller does not forward data telegrams but only evaluates them There are three type of telegrams in SERCOS communication MDT master data telegram Master AT drive data telegram Slave Controller Drive SERCOS Cycle Figure 8 8 SERCOS communication types of telegrams The most important telegram is the synchronization telegram MST which is sent by the controller at the beginning of each cycle This telegram synchronizes the individual drives and can send your telegrams at the correct time These telegrams are th
8. Page 160 Specifications regarding product in question lem NAME ces rennt ne nad er nenn nee Serial number 4 444sssnneennennnennenenne nennen nn an Software version unnsessssssennsennennnennennnnnnnnnnnnnnnnnnnnnnnnnenneennnenn nn Hardware code 44444444444404000000RnRnn nn Rn nenn nen nnnnnnnnnnnnnnnnnnnne Parameters included Yes No IEC Program included Yes No Information about machine on which the error occurred Machine manufacturer unnuunnssensennnnnnnnnennnn nennen nn nennen nennen Type ane er ene ee PEACE Poy eee rere Cer Enter ey nem HEINE ener a erry a wre ra rrr err Operating hours cceeeeeseeeceeeeeeeceeeaeeeaeee eeeeeeeeeeeseeeeneeeeeeeeeeeees Date of COMMISSIONING a eltern Manufacturer Type of machine control Additional information PacDrive Controller P600 ELAU AG Condition of error Causes is always available unknown during commissioning wiring error occurs sporadically mechan damage occurs after approx hours moisture in device occurs when shaken encoder defective depends on temperature contaminant in device ELAU AG Accompanying side effects problems in the mechanism power failure 24V controller failure motor failure broken cable insufficient ventilation Is there an air conditioner in the switch cabinet Y N Have there bee
9. gt No SERCOS slaves found 044 SERCOS firmware download A firmware download is being executed from the PacDrive controller toa SERCOSbus slave The ext diagnose in the message logger shows the following values DL start gt Firmware download started DIx OK gt Successful firmware download to slave x x is the RealTimeBusAdr 045 error by writing in file Error occurred when writing in a file Insufficient memory capacity PacDrive Controller P600 ELAU AG gt Check to see that memory capacity is sufficient parameter RamDiskFree Disk free gt Increase the RamDiskSize The default size was increased from V00 16 10 from 128KB to 1MB An attempt was made to write a trace file onto the RAM disk ram0 gt Increase RamDiskSize The default size was increased from V00 16 10 from 128KB to 1MB 046 FPGA firmware download After programming the FPGA C400 C600 and P600 or in the event of errors the diagnostic message is discharged The various causes are displayed by different external diagnostic codes The following is an overview of all ofthe external diagnostic codes what caused them and how to eliminate them DiagExtCode C6_xpxx esv e g C6_0301 esv or C6_xpxx xsv e g C6_0301 xsv The FPGA firmware was successfully programmed The DiagExtCode states the name of the programmed FPGA file gt DiagExtCode PinOut lt gt p e g PinOut lt gt 3 No C6_xpxx xsv file wi
10. 0 0 26 0 51 1 02 2 05 tis LED flashes slow SERCOS error an aus 0 1 02 2 05 t s LED permanent on fatal system emor an aus t s Figure 8 3 Display status of the err diagnosis LED of the SERCOS slave devices e g MC 4 Typical Errors On 1 device the err LED is constantly on On 1 device the err LED is constantly off Acknowledging diagnosis messages There are two possibilities when acknowledging the diagnostic messages EPAS 4 gt Online gt Reset diagnostic message Function DiagQuit PacDrive Controller P600 Page 53 Page 54 Position loss due to serious SERCOS bus error Property damage possible Due to the erroneous acknowledgement of diagnostic message 506 Serious SER COS error MASTER without restarting the controller loss of position of the axes and physical encoder SinCos incremental encoder from V00 15 00 is possible Only acknowledge diagnostic message if the re initialization or referencing of the system by the IEC program has been ensured The capability to acknowledge the diagnostic message can be switched off with the function DiagNoQuitSet Potentially use functions SysReset or PrgResetAndStart Please note that acknowledging a diagnostic message does not eliminate the cause of the error Acknowledgement serves to confirm that have seen the message By acknowledging the diagnostic message in the PacDrive system will be deleted If the cause for the diagnostic mes
11. 2 2 Notation Tor Safety Instructions aan need 9 2 3 Proper Use nuunssssssssensnnnnnnnnnsnnennennnnnnnnnnnnnnnnnnn sn ns aE TAR aA EE EEG EE AEE Eis Adai Eaa 9 2 4 Selection and Qualification of Employees 2222 22444444444444444400H Rennen an anne 10 2 5 R sidualTiSkS sisipe ee e ae a a E 10 3 System Overview 13 3 1 Drive Concepts of Packaging Machines uumrusunnnnssnnnnnnnnnnnnnnnnannnnennnn nn 13 3 2 Structure of the PacDrive Automation System uuesssersessennnnnnennnnennnnnnnnnnnnn nn 14 3 3 Components ccc cce cece cece cece eect ee eae ea ae eae eee eeaae eeeeeee cae eae saaaeaaaeeseegaeeeseeeseesaeeeaneaeeeenees 15 4 Indicators and control elements diagnosis 19 4 1 Indicators and control elements nes 19 4 1 1 CompactFlashTM card slot anssnonnnnnnnnnnnnnnrenrnnntrrrrrrrrrrrrrrnrrrnrnrnrrnnrnnnnnnnrrenreeereeneeet 21 4 1 2 Battery compartment vs 21 4 1 3 Switching the PacDrive controller P600 on off and resetting eeeeeereeees 22 4 2 UMNO agers saison cates aa a A E A 24 4 2 1 PacDrive controller minimal boot 22224222444440404000404n00 RR nnnn nenn Han nnnnen anna 24 4 2 2 Connection to PacDrive controller 22 uur0s044444aR HR naar 24 4 2 3 Example of a diagnostic message umunnsnnsssnnsnnnnannnnnnnnnnnnnnnnnnnnnnnnnannnnnnnnnnnnannn 25 5 Transport storage unpacking 26 6 Servicing 29 6 1 Spare POMS nun nen een 29 6 2 FRED G
12. 3 2 Page 14 Structure of the PacDrive Automation System The The PacDrive automation system provides the optimal solution for electronic packaging machines both in terms of technology and economy PacDrive consists of a high performance controller run on a PC or controller based architecture the PacDrive controller and the digital servo amplifiers which contain the power supply unit the final stages and the servo controller for the individual axes The PacDrive controller is the intelligent head of the system and is based on an in dustrial PC The PacDrive controller synchronizes and coordinates the motion func tions of the packaging machine Thanks to the use of an IEC 1131 3 soft PLC areas of application that had previously been unavailable to a classical PLC have been opened up to the PacDrive controller family The individual PLCs or motion tasks can thus be split up into various parallel tasks that can then be implemented with the pro gramming environment EPAS 4 as per the IEC 61131 3 standard Up to 99 servo axes can be connected to one PacDrive controller and supplied with motion data The circular digital real time bus SERCOS implements the secure data exchange with the MC 4 servo amplifiers With the use of fiber optic technology the data bus is in sensitive to electromagnetic disturbances and cyclically supplies the decentralized MC 4 servo amplifiers with new set points at a data rate of up to 16 MBaud All internal c
13. The CamTrack in the PositionSource parameter contains an invalid value The symbolic name of a logical encoder or an axis MC 4 or SCL was not specified in the PositionSource parameter gt Check the value in the PositionSource parameter 328 Invalid Destination Diagnosis class see 8 1 Diagnosis Classes standard 6 The CamTrack in the Destination parameter contains an invalid value ELAU AG PacDrive Controller P600 Page 109 Page 110 z The Destination parameter was specified either without the symbolic name of an output group or with none gt Check the value in the Destination parameter 329 Invalid BitNumber Diagnosis class see 8 1 Diagnosis Classes standard 6 The CamTrack in the Bitno parameter contains an invalid value x An invalid bit number was specified in the Bitno parameter gt Check the value in the Bitno parameter 330 Bad master parameter data Diagnosis class see 8 1 Diagnosis Classes standard 5 This diagnosis message will be triggered ifthe system is unable to process the master positioning job of an axis even though no errors were detected by the job parameter area checks e g error in the precalculation of generator data The error is shown in the extended diagnosis message as GT XXX MJIG YYY XXX indicates the generator type while YYY indicates the Master Jobld of the job that caused the problem Generator type 0 gt CAM 1 gt POS Internal calculation error gt Conta
14. gt Replace the device 150 Phase L1 failure Diagnosis class see 8 1 Diagnosis Classes standard 1 Reaction see 8 2 Reactions B The L1 phase of the mains connection to the device has failed or is too low Wiring error gt Check the connection of the phase gt Check the wiring of the mains contactor External fuse has activated gt Check fuses The mains contactor is defective gt Replace the mains contactor 151 Phase L2 failure Diagnosis class see 8 1 Diagnosis Classes standard 1 Reaction see 8 2 Reactions B The L2 phase of the mains connection to the device has failed or is too low Wiring error gt Check the connection of the phase gt Check the wiring of the mains contactor External fuse has activated gt Check fuses The mains contactor is defective gt Replace the mains contactor 152 Phase L3 failure Diagnosis class see 8 1 Diagnosis Classes standard 1 Reaction B The L3 phase of the mains connection to the device has failed or is too low Wiring error gt Check the connection of the phase gt Check the wiring of the mains contactor PacDrive Controller P600 ELAU AG External fuse has activated gt Check fuses The mains contactor is defective gt Replace the mains contactor 153 DC bus discharge failure Diagnosis class see 8 1 Diagnosis Classes standard 1 Reaction see 8 2 Reactions B DC bus was not discharged properl
15. important additional aspect to observe is the electromagnetic compatibility EMC with other system components The great edge steepness ofthe pulsed voltage generates very intense harmonic oscillations that extend into the high frequency range Observe the following EMC rules gt During installation select the HF grounding option with the lowest Ohm load e g an uncoated mounting plate on the switching cabinet Ensure electrical contact areas are as large as possible skin effect If neces sary remove any paint Lay the grounding in a star configuration from the central earthing point to the corresponding connections Looping the grounding is not permitted and can cause unnecessary influences Only use shielded cables Supply large area shielding bridges Connecting shields via the PIN contacts of connectors is not permitted You must observe the recommendations for circuits and switches Shorten the motor cable to a minimal length Do not lay any cable loops in the switching cabinet Electromagnetic fields System errors or system failure may occur Observe the following rules during installation to eliminate the results of excessive errors and failure as much as possible Page 30 When using electronic controls do not allow any kind of inductive load without the appropriate interference suppression Appropriate interference suppression is achieved during direct current operation by using recovery diodes and b
16. the voltage with a voltage meter before accessing the unit to be sure that the voltage is less than 50 volts Do not touch the electrical connection points of the components when the unit is switched on Before switching on the unit safely cover the live components to prevent contact The following provides protection against indirect contact DIN EN 50178 Section 5 3 2 Dangerous Movements There are various causes of dangerous movements Wiring or cabling faults Error in the application program Component fault or flaw Error in the measured value and signal transmitter Operation error Personal protection must be ensured by a higher level monitoring functions or meas ures in the plant You should not rely only on the internal monitoring system of the drive components Monitoring systems or measures must be applied according to the spe cific conditions and circumstances of the system in accordance with a hazard and error analysis of the machine manufacturer The applicable safety instructions for the sys tem must be incorporated in such measures PacDrive Controller P600 Page 11 PELV Protec tive Extra Low Voltage FELV Function al Extra Low Page 12 Voltage Dangerous Movements Risk of fatal injury serious bodily harm and or damage to property Prevent entry to a danger zone for example with protective fencing mesh guards protective coverings or light barriers Correctly size protective eq
17. 111284 ms A single telegram miss at the axis_2 drive was determined A second block follows the first block In this case the display of the multiple cycle error is involved since the telegram from the axis_2 drive was missed a second time fl EPAS4 MEL 2 IB x Meldungstext Erweterte SERCOS Diagnose Erweberte SERCOS Diagnose Erwekerte SERCOS Diagnose Erwekerte SERCOS Diagnose Erwekerte SERCOS Dianos Erwekerte aa Diagnose R 1 Erweterte SERCOS Diagnose nerr 2 Erwekerte SERCOS Diagnose M 111280ms Erwekerte SERCOS Diagnose 2 01 376 0x0010 A iss Erwekerte SERCOS Diagnose 2 01 376 Ox0010 F Erweterte SERCOS Diagnose 1 51 372 0x1000 S SERCOS Phasenwechsel 1 51 266 0x0002 mehrfacher SERCOS Zyklusfehler 1 43 356 Ox1000 SERCOS Phasenwechsel 1 42 912 0x1000 SERCOS Phasenwechsel 1 39 140 Ox1000 SERCOS Phasenwechsel 1 36 564 0x1000 ss SERCOS Phasenwechsel NULAND Figure 8 14 SERCOS interface example of a message logger when an error occurs multiple cycle error The multiple cycle error occurred directly in the next cycle cycle time 4 ms after the single cycle error and affected the axis_2 drive again The error counter for this drive PacDrive Controller P600 Page 69 Page 70 nerr 2 increased to 2 as did the error counter for simple cycle errors r 2 The error counter for the multiple cycle error R 2 also increases for the first time The only difference between the last diagnosis block and the first two
18. 17 19 10 19 003 Imeren nal master encoder DG 60 LWSR 5 000 incre Master encoder ments rotation Incremental master encoder DG 60 LWSR 10 000 incre Master encoder 17 19 10 19 006 ments rotation ME 08600 High voltage warning sticker 105 mm x 52 mm KT 10592 UPS Battery 3 V Lithium Renata CR2450N Maintenance interval 6 years 15 15 44 14 xxx DeviceNet Adapter one slave up to max 3 m cable length 15 15 44 15 xxx DeviceNet Adapter multi slave up to max 3 m cable length including adapter Table 6 4 Order numbers of accessories ELAU AG PacDrive Controller P600 Page 35 T Technical information 7 1 General Parameters Value Type code Product P600 up to 22 SERCOS nodes PacDrive P600 10 1 1 1 1 00 configuration SERCOS nodes MC 4 SCL iSH Order number P600 up to 22 SERCOS nodes 13 13 02 63 001 Processor CPU Intel Pentium M 1 6 GHz RAM 512 MB L2 Cache 1MB NVRAM 256 kB CompactFlashTM card X21 not required Real time clock RTC yes battery maintenance interval 5 years Watchdog yes max 60 V lt 2 A Diagnosis alphanumeric diagnostic display Status LEDs PC configuration HDD 40 GB DVD ROM 8x DVD 24 x CD ROM PS2 X16 Number 1 USB 2 0 X8 X9 Number 2 IEEE1394 FireWire X7 Number 1 DVI VGA X6 Number 1 PCI slots Number 2 Operating system Real tim
19. 1P_SubietMask 255 0 0 0 S Diagnose 4 IP Address 10 205 100 107 5 1P_Gateway 0 2 0 0 S versionen 6 Ehernet de 006033510107 Zi Memory amp Disks Z Tast mtch 630 1680 1 6 Tast5mkchi 16 1 1580 1 i System Fater Zus 1680 16 BJ EC Programm 10 ControtlarReset wahr TRUE Pr s u ComiUser Auto 2 Epas 4 Me SERCOS inerfece RTO 12 ComUserState Auto gt Search 3 mko H E Allgemeines 13 Retaininik bei Dokus 1 nach Dow Gy Systernintern t4 1OReset nach Download oder Prg Reset 2 hain Rese H E Ger te bersicht Bi Netzger t 4 lt PS4_1 gt a sj gt 4 Figure 8 5 Set TestSwitch1 parameter to 1 V00 16 30 VOO 16 40 The display filter settings in the message logger must continue to include the 5 entry additional SERCOS diagnosis 14 01 12 065 1401 10 510 14 01 01 673 14 01 00 904 14 00 57 032 14 00 40 948 14 00 47 302 14 00 30 581 MLADO 14 00 37 830 M LI AUg 2004 14 00 33 968 M L1 Aug 2004 14 00 25 804 M LI AUg 2004 14 00 24 323 M LI 2004 14000 15 992 Mi Lt Aug 2004 14 00 14 740 M L1 AUg 2004 1400 10 077 MiLt Aug 2004 14 00 02 793 ML1 Aug 2004 14 00 01 237 MLADO 13 59 52 408 PacDrive Controller P600 SERCOS Pr SERCOS Pr SERCOS P SERCOS Pr SERCOS Pe SERCOS Pr SERCOS PR SERCOS P SERCOS PR SERCOS Pr Page 63 Definierte Anzeigefilter OK ae IV Allgemeine Systemmeldungen Abbrechen JV Diagnosemeldungen JV IEC Prg Systembausteine Alle setzen
20. 203 Faulty parameter file 207 Hardware module does not exist 209 Last boot failed 300 Division error up to 312 Parameter relocation failed 700 CAN Layer2 driver error 701 CAN Layer2 init error 721 Module not ready 723 No Profibus config data 730 Bad master parameter data 731 Automatic bus deactivation 737 Double IEC address assigned 738 Config IO data gt permitted IO range PacDrive Controller P600 ELAU AG 8 5 8 5 1 ELAU AG 739 Double profibus address assigned 752 No CanOpen EDS file exists 753 Initialization CanOpen module failed 826 Error during PIC FW update 900 Software error Suspend task 901 Software error invalid opcode 902 Software error page fault 904 Software error class 1 Diagnostic messages Oxx Messages diagnosis messages 001 Diagnosis acknowledgement A diagnosis message was acknowledged The 001 diagnosis avcknowledgement message is always entered in the message logger even if the diagnosis class see 8 1 Diagnosis Classes of the message was set to 9 using the DiagConfigSet function 002 PacController boot started The PacDrive controller was restarted In V00 15 00 or higher the firmware version is shown in the ext diagnosis in the mes sage logger e g FW V00 15 00 003 PacController boot finished The startup procedure for the PacDrive controller is complete In V00 15 00 or higher the kernel version i
21. 4 is checked All SCLs that have been assigned a specific PS 4 power supply in the control configuration must be physically connected with that PS 4 If an assign ment error occurs the 516 SERCOS wrong device position diagnosis message will be displayed The message appears for the affected SCL The DiagExtCode displays the name of the PS 4 that actually should be assigned to the SCL The addresses of the integrated SCL servo drive have been incorrectly set via the rotary switch on the device gt Check the address settings on the SCL The addresses of the PS 4 power supply have been incorrectly set via the rotary switch on the device gt Check the address settings on the PS 4 The RealTimeBusAdr parameter in the control configuration contains incorrectly specified PS 4 and or SCL addresses gt Check the RealTimeBusAdr parameter in the control configuration 517 Multiple used RealTimeBusAdr Diagnosis class see 8 1 Diagnosis Classes standard 1 A SERCOS address RealTimeBusAdr has been assigned more than once in the control configuration A check is performed while preparing the SERCOS phase 1 The boot procedure of the SERCOS bus will be cancelled The DiagExtCode parameter and the ext diagnosis in the message logger display the address that have been as signed more than once A SERCOS address has been assigned more than once in the RealTimeBusA dre parameter in the control configuration gt Check the RealTimeB
22. Bi SCL lt SCL_1 gt fee SCL lt SCL_2 gt B MC 4 MC4_2 gt ll sf Figure 8 11 SERCOR interface parameter for scanning the bus To start this function the SERCOR must be in phase 0 and no communication errors may be present StartAddress and EndAddress can be used to specify the address range to be scanned ScanStatus can be used to monitor the current status of the scan Once the scan is complete the scanned status will appear Now the information on the physical ring configuration is available in the message logger The Instance column contains the SERCOS address of the drive SLAVExx while the Ext Diagnosis column contains the corresponding position PacDrive Controller P600 Page 67 E EPAS4 MEL 0 1000 End Eme 5 SERCOS Konfiguration 0x1000 al Phase 0 SERCOS Phasenwechsel 0x1000 SLAVES2 Poskion 2 Ermittle SERCOS Konfiguration 0x1000 SLAVESI Poskon 1 Ermittle SERCOS Konfiguration 0x1000 SLAVEIO Poskon S Ermittle SERCOS Konfiguration 0x1000 SLAVE2 Poskion 3 Ermittle SERCOS Konfiguration 0x1000 SLAVEI Poskon 4 Ermittle SERCOS Konfiguration 0x1000 RTB Phase 2 SERCOS Phasenwechsel 0x1000 RTB Phase 1 SERCOS Phasenwechsel 0x1000 RIB Phase 0 SERCOS Phasenwechsel 0x1000 RTB Phase 1 SERCOS Phasenwechsel 0x1000 RTB Start Ermittle SERCOS Konfiguration eNUF Aw Ow Figure 8 12 SERCOS interface result of the bus scan in the message logger If a slave has position 0 the position could not be determined Th
23. Ext diagnosis Displays the node addresses of the detected node that has not been configured Structure Nodeld xxx xxx decimal node address CanOpen node not configured gt Configure or switch off node 752 No CanOpen EDS file exists Diagnosis class see 8 1 Diagnosis Classes standard 4 Unable to load the COPMAX4 EDS CANopen description file on the flash disk of the controller Description file has not been transferred to the controller or has been deleted gt Transfer the description file to the controller via FTP 753 Initialisation CanOpen module failed Diagnosis class see 8 1 Diagnosis Classes standard 4 An error has occurred during the initialization phase of the CANopen module Meaning of ext diagnosis can_open Init driver of the can_open call failed CmsConfig Init driver of the CmsConfig call failed SetHostEndian Init driver of the SetHostEndien call failed InquiryStatus Init driver of the InquiryStatus call failed SSyncToHost Init driver of the SsyncToHost call failed Baudrate Init driver of the Baudrate call failed Termination Init driver of the Termination call failed PacDrive Controller P600 ELAU AG LsBusOnRea init driver of the LsBusOnReg call failed CalMaster Init driver of the CalMaster call failed dVersRed Init driver of the IdVersReq call failed LsSwitchBerrRea Init driver of the LsSwitchBerrReq call failed Software error gt Contact your ELAU repre
24. Mandatory Optional See description of the triggering node gt CopMatTriggerEmcy was called by another controller gt 755 CanOpen node guarding error Diagnosis class see 8 1 Diagnosis Classes standard 4 The CANopen master can monitor the individual CANopen slave nodes While moni toring the status of the nodes is queried in configurable intervals Guard Time Ifa response is not received within a specified time Guard Time Life Time Factor this diagnosis message will be triggered The CANopen slave also checks the time be tween monitoring queries Guard Time Life Time Factor after the first monitoring query is received No ext diagnosis is displayed in this case Meaning of the ext diagnosis of the CANopen master Structure Nxxx timeout N decimal CANopen node address The displayed node has not responded to a monitoring query within the specified time Guard Time Life Time Factor Structure Nxxx toogle bit N decimal CANopen node address The displayed node has responded to a query with an incorrect monitoring response The toggle bit has not been sent properly The correction of this error will not be displayed Structure NXXX e xx r Xx N decimal CANopen node address e expected status of hexadecimal CANopen status r received status of hexadecimal CANopen node address Status DISCONNECTED INITIALISINGO CONNECTED3 PREPARED4 OPERATIONAL5 PRE_OPERATIONAL 7f The displayed node has respond
25. OFF input must be ON in order to use the UPS 7 A UPS object is specified in the control configuration but no UPS is connected gt Connect the UPS or adjust the control configuration An internal UPS error has occurred gt Check the UPS Ext diagnosis PIC fail or State 5 An internal error in the PIC controller has occurred gt Contact your ELAU representative 325 File corrupt Diagnosis class see 8 1 Diagnosis Classes standard 5 A problem File not available or CRC error has occurred while reading the retain file The retain file will be read by the flash disk while the PacDrive controller boots if the Enable parameter of the UPS object is set to External 1 A UPS object is specified in the control configuration but no UPS is connected gt Connect the UPS or adjust the control configuration The UPS is not functioning properly gt Check the UPS 326 Unsupported function Diagnosis class see 8 1 Diagnosis Classes standard 5 A function has been called that is not supported by the PacDrive system More infor mation on the object type and the instance is displayed in the message logger The DiagExtCode also provides information on the error cause The PacDrive controller hardware does not support this function gt Check the hardware version in reference to the type plate and the MAx4Type dd parameter 327 Invalid PositionSource Diagnosis class see 8 1 Diagnosis Classes standard 6
26. PacDrive Controller P600 ELAU AG 10 5 Safety tests The following safety checks for the PacDrive controller are performed in production in accordance with EN 50178 EN 60204 1 Check for end to end connection of grounding conductor with 30 A Insulating resistance check with U 500 V DC Withstand voltage check with U 2500 V DC for a time period of 1 min 10 6 Hardware software compatibility list Software package version Hardware code V16 A x x 1743100320 or higher V22 A 0 x 1743100320 or higher Table 10 1 PacDrive Controller P600 hardware and software compatibility 10 7 Changes 06 2004 New edition of the operating manual 02 2007 Various error eliminations and additions Layout of document revised Diagnostic messages expanded PROFIBUS connector added Chapter on uninterruptible power supply added Chapter on hardware software compatibility list added The updated documentation application notes and the updating to the products are available on the ELAU Homepage NOTE ELAU AG PacDrive Controller P600 Page 159 11 Fault report form This error report is required without fail to enable efficient processing Send the error report to the responsible ELAU representative or to ELAU AG Customer Service Department Dillberg 12 97828 Marktheidenfeld Germany Fax 49 0 93 91 606 340 Return address Company City Date Department Name Tel
27. The current through the output stage of the servo amplifier in the DC bus of the network device is too high In contrast to the 120 Overload PowerOff of output stage see 8 5 2 21 120 Overload PowerOff of output stage and 146 DC bus overload see 8 5 2 47 146 DC bus overload diagnosis messages the power is switched off as soon as the max current is exceeded Servo amplifier wiring error The motor cable is not connected properly has a short circuit gt Check the wiring Servo amplifier The current controller parameters are incorrect gt Check the Curr_P_Gain Curr_ _Gain and CurrFilter current control parameters and parameterized with default values if necessary Servo amplifier hardware error The motor has a short circuit gt Replace the motor PS 4 power supply To many consumers e g ServoDrive SCL connected to the DC bus gt Use an additional PS 4 power supply and distribute the power supply of the consumers gt The existing arrangement of devices may be made adequate by adjusting one of the applications e g decreasing acceleration 108 Excess voltage Diagnosis class see 8 1 Diagnosis Classes standard 2 Reaction see 8 2 Reactions A The DC bus voltage is too high for 400 V AC devices greater than 860 V DC for 230 V AC devices greater than 430 V DC Wiring error Bleeder is not connected gt Connect bleeder The braking energy of the motor that is fed back into the DC bus is
28. This means it appears when an update is forced in the PIC bootloader but the necessary file is not on the flash disk C400 and C600 or on the hard disk P600 gt Transfer the firmware file to the flash disk C400 and C600 or to the hard disk P600 gt If this attempt also fails contact your ELAU customer service representative Ext diagnosis File not OK This message appears when the PIC update file is incorrect gt Transfer the correct firmware file to the flash disk C400 and C600 or to the hard disk P600 gt If this attempt also fails contact your ELAU customer service representative z Ext diagnosis Header not OK This message appears when the ELAU header in the file is not correct gt Transfer the correct firmware file to the flash disk C400 and C600 or to the hard disk P600 gt If this attempt also fails contact your ELAU customer service representative Ex Diagnosis HWIndex lt gt lt Index gt e g HWindex lt gt 5 Checking hardware dependencies The message appears if PIC update files are found that have an incorrect hardware code The index outputs the required HW index gt Use the PIC update file that matches the device hardware 827 Power Off due to hardware monitoring Diagnosis class see 8 1 Diagnosis Classes standard 3 MsgFilter Bit 1 Diagnosis Messages PacDrive Controller P600 Page 149 8 5 10 Page 150 The hardware provides an internal error logger that lo
29. Update the firmware in the PacDrive controller gt Using older library versions may also work 316 Faulty NvrRam CRC Diagnosis class see 8 1 Diagnosis Classes standard 6 The NvRam lost the data This means that the data in the message logger and the IEC variable values have been deleted PacDrive Controller P600 ELAU AG ELAU AG s Object in the message logger MAX4 The PacDrive controller has not been switched on for over 7 days control volt age gt Reboot the PacDrive controller The error should now be resolved Object in the message logger PN4 The internal or external battery on the PN 4 optional module is empty and the PacDrive controller has not been switched on in over 7 days control voltage gt Reboot the PacDrive controller The error should now be resolved Object in the message logger MAX4 Ext diagnosis in message logger Nvram damaged The NvRam on the PacDrive controller is defective gt Replace the PacDrive controller z Object in the message logger PN4 Ext diagnosis in message logger Nvram damaged The NvRam on the PN 4 optional module is defective gt Replace the PN 4 optional module Hardware error The buffer capacitor is defective gt Replace the PacDrive controller 317 Cycle time overrun Diagnosis class see 8 1 Diagnosis Classes standard 6 A cycle time error has been found This error is triggered when the cycle time exceeds one system clock tick def
30. Voltage DC 20 33 V input current liy 5 mA at Un 24 V polarized yes input filter TPO to TP15 100 us resolution TPO to TP15 10 us at a cycle time of 1 2 4 ms digital outputs X2 Number 16 IEC61131 2 Output voltage UL 3 V lt Uour lt UL Rated current I 250 mA per output Inrush current lemax lt 2 A for 1s Leakage current 0 signal lt 0 4 mA Transmission time 100 us Short circuit proof yes Supply outlet DC 24 V 15 25 3 A digital outputs X5 additional digital and analog I Os Number 2 Range Uour 10 10 V Resolution 12 Bit 5 mV Load gt 5 kOhm max offset lt 75 mV via field bus max 3 584 bytes digital analog inputs and max 3 584 bytes digital analog outputs max number of stations 126 PROFIBUS additional fast digital VOS additional Touchprobe inputs via PacNet max 128 inputs and 128 outputs via PacNet max 128 Touchprobe inputs Power supply Power supply unit DC 24 V 15 25 max 3 0 A without UPS and 4 5 A with UPS Dimensions and Power consumption max 85 W Uninterruptible power su internal optional maintenance interval 3 years pply UPS Dimensions see chapter Dimensions Dimensions packaging Width 180 mm Be Height 400 mm depth 300 mm Weight 5 6 kg Weight with packaging 6 2 kg Ambient conditions Protection class IP 20 Ambient temperature 5 55 C Operatin
31. a min imal boot SYS Connection to PacDrive controller TCP IP address conflicts in the network The PacDrive controller P600 works with three network addresses For the two inte grated systems real time system VxWorks and the Windows XP operating system the distribution is designed as follows PacDrive Controller P600 ELAU AG 4 2 3 ELAU AG Ethernet TCP IP PacDrive Controller P600 Ethernet r network card 10 201 100 136 Premal k PacDrive MS Windows XP Server EON AAO j Shared Memory network card TCP IP t Windows XP 172 17 0 2 real time system Shared Memory network card VxWorks PD_P600TCP_us0406 fh8 Figure 4 2 PacDrive Controller P600 internal distribution of the network addresses If the address range of the Windows XP Ethernet network card for the external com munication is the same address range as the two IP addresses for the communication with the real time system see illustration PacDrive Controller P600 internal distribu tion of the network addresses the controller internal network communication is disturbed In this case change the IP address of the real time system Refer to the programming manual for further information regarding the configuration of the Pac Drive controller P600 Example of a diagnostic message Diagnostic message 2121 braking resistor temperature too high is displayed Meaning of diagnostic messag
32. assigned twice if it is displayed twice it has been assigned three times and so forth A SERCOS slave address has been assigned more than once in the control configuration gt Find the double assigned address in the DiagExtCode parameter gt Check and adjust the RealTimeBusAdr parameter in the control configuration 501 SERCOS slave not found Diagnosis class see 8 1 Diagnosis Classes standard 1 PacDrive Controller P600 ELAU AG ELAU AG ASERCOS slave specified in the control configuration is not detected in the SERCOS bus SERCOS slave not present in the SERCOS bus gt Connect the SERCOS slave to the SERCOS bus or remove the SERCOS slave from the control configuration or parameterize it as avirtual device z SCL 055 motors are connected at the PacDrive controller The SCL 055 motors in the PacDrive PD 8 box are not connected properly gt Check the connection of tne SCL 055 motors in the PacDrive PD 8 box Simply placing jumpers on the desired terminals will not resolve the problem Slaves must not be inserted into the following SERCOS slot In addition follow the notes in the SCL and PS 4 and PD 8 operating in structions 502 Ring not closed Diagnosis class see 8 1 Diagnosis Classes standard 1 The SERCOS ring is not closed The result is a longer interruption gt 100 ms of the ring You can detect whether the interruption is still present using Light diode bus err see 8 3 bus err LED
33. at the incremental encoder input BT 4 ENC1 or incremental encoder module INC 4 PacDrive Controller P600 Page 141 Hardware encoder error Position loss of the master encoder Acknowledge the diagnosis message only after the re initialization or referencing of the system is secured by the IEC program use the SysReset or the Prg Wiring error Encoder cable at the encoder or the encoder input has been re moved or is defective gt Check the encoder cable and replace if necessary gt Check the ground connection shield The encoder encoder supply or encoder simulation is not ready gt Switch off the default monitoring with the parameter CheckOff gt If the encoder or encoder simulation is ready then activate the monitoring in the IEC program Encoder defective gt Replace the encoder 785 Hardware defect Diagnosis class see 8 1 Diagnosis Classes standard 4 A hardware defect exists Ext diagnosis PIIX Error gt Replace the controller Ext diagnosis EEPROM damag gt Replace the optional PN 4 module a Ext diagnosis EEPROM S xxxx gt Replace the optional PN 4 module Ext diagnosis RTC is damaged Unable to set the time of the RealTimeClock in the PN 4 option module This is due to a problem in a very early hardware version ofthe PN 4 This prob lem has been removed in hardware code 030033 or higher gt Replace the PN 4 module Ext Diagnosis Ref PowerFail In
34. connection of the SCL 055 motors in the PacDrive PD 8 box It is not enough to place the jumpers on the desired terminations No nodes to be plug ged into the following SERCOS plug in position Also observe the information outlined in the SCL and PS 4 and PD 8 oper ating manuals PacDrive Controller P600 Page 119 Page 120 507 Write cycle overflow Diagnosis class see 8 1 Diagnosis Classes default 4 The transfer of the target position to the SERCOS bus occurred too late The previous target positions may have been transferred twice This results in a velocity jump in the drives see RTBWriteResparameter gt SERCOS bus is overloaded Increase the CycleTime parameter in the control configuration The real time process is overloaded Reduce the number of objects with real time tasks e g virtual axes virtual en coders logical encoders sum encoders One or more SERCOS slaves have been switched off and therefore no longer supply data to the SERCOS bus Switch on SERCOS slave 508 SERCOS run up error Diagnosis class see 8 1 Diagnosis Classes default 1 A system error has occurred v Virtual SERCOS slaves are specified in the control configuration although the slaves are physically connected on the SERCOS bus Check the RealTimeBusAdr parameter of the SERCOS slaves in the control configuration There are more SERCOS slaves in the loop than specified in the control con figuration Check the nu
35. currently used controller hardware does not yet support BT 4 ENC1 bus terminals E Ext diagnosis FPGA Version An FPGA version was found on the controller C200 C400 C600 or P600 that is specified as a beta test version PacDrive Controller P600 ELAU AG ELAU AG The pinout of the FPGA firmware is the number represented by p in the zpxx of the FPGA firmware version The pinout of the controller can be read in the Con trollerType1 parameter and is indicated by the p for C200 under FPGA pyzpxx The highest bit indicated by z is a beta test version Install the released FPGA firmware file on the controller C200 C400 and C600 gt flash disk P600 gt hard disk Ext diagnosis BusAddr gt Max The PROFIBUS address is larger than the maximum permitted bus address Check the PROFIBUS configuration 788 Wiring error Diagnosis class see 8 1 Diagnosis Classes standard 5 There is a wiring error Ext diagnosis Overload The affected output is short circuited or overloaded Check the wiring of the output Ext diagnosis Openload The output is not connected or only slightly loaded Check the wiring of the output It may be useful to disable the diagnosis message Ext diagnosis PowerFail The external power supply of the digital outputs was not connected The supply of the digital outputs is checked if at least one bit is set to 1 in the DiagMask parameter of the output group object Check the power supp
36. displays the pending register information at the time the error occurred Structure SXXrXXtXxX s Status register see Status r Receive Error Counter see Status parameter t Send Error Counter see Status parameter 705 CAN system error Diagnosis class see 8 1 Diagnosis Classes standard 4 An internal error in the CAN module has occurred The type of error is specified in more detail in the ext diagnosis Ext diagnosis msg lost XXxX The control firmware was unable to retrieve the command or status messages from the CAN module fast enough As a result the buffer has overflowed and XXX messages have been lost gt Contact your ELAU representative Ext diagnosis fmsg lost XXX The control firmware was unable to retrieve the layer2 messages from the CAN module fast enough As a result the buffer has overflowed and XXX messages have been lost gt Contact your ELAU representative Ext diagnosis module overload CPU on CAN module was unable to read the data from the CAN bus fast enough and messages have been lost as a result gt Contact your ELAU representative z Ext diagnosis module int lost CPU on CAN module was unable to read the CAN messages intended for CAL CANopen from the bus fast enough No messages for CAL CANopen have been defined for layer 2 Error is not permitted to occur with the CAN layer 2 module gt Contact your ELAU representative z Ext diagnosis mod queue out CPU on CA
37. general rules for design DIN EN 50178 Electronic equipment for use in power installations EMC Directive 89 336 EEC ELAU AG PacDrive Controller P600 Page 9 2 4 Selection and Qualification of Employees This description is aimed solely at technically qualified personnel who have detailed knowledge in the area of automation technology Only qualified personnel can recog nize the significance of the safety instructions and put them into practice correctly The description is intended primarily for designers and implementation engineers from the fields of mechanical and electrical engineering plus service engineers and start up engineers Work on electrical equipment Work on electrical equipment may only be carried out by qualified electricians or by trained staff under the instruction and supervision of a qualified electrician in accord ance with electrical regulations Qualified electricians are only those persons who can perform the following tasks as a result of their training knowledge and experience Evaluate the task assigned to them Identify possible dangers and Take appropriate safety measures 25 Residual risks Health risks arising fromELAU Components have been reduced by means of safety technology and design engineering However a residual risk does remain since ELAU Components work with electrical voltage and electrical currents Installation and Handling A WARNING Risk of injury risk dur
38. has failed gt Check the SERCOS slave 511 CPU time overflow Diagnosis class see 8 1 Diagnosis Classes default 2 The real time process is overloaded CycleLoad gt 95 The DiagExtCode parameter displays the measured load as Load xxx with xxx indicating the load in PacDrive Controller P600 Page 121 NOTE NOTE Page 122 After detecting the error the actual and target values for the encoders generators and axes will no longer be processed in the real time process As a result the target and actual values parameter of the axes will show invalid values Too many objects are specified in the control configuration gt Increase the CycleTime parameter of the SERCOS interface in the control con figuration 512 SERCOS wrong device type Diagnosis class see 8 1 Diagnosis Classes default 1 While starting up the SERCOS bus in phase 2 the type of the detected SERCOS slave MC 4 SCL PS 4 will be checked based on the slave specified in the control config uration If no match is found the SERCOS bus phase startup will be cancelled The SERCOS address and the detected type will be entered in the extended diagnosis Multiple address assignments may also exist If this is the case at least two SERCOS slaves have the same address The SERCOS slave address RealTimeBusAdr on the SERCOS slave MC 4 SCL PS 4 was not set correctly gt Check the address setting on the SERCOS slave that is displa
39. kB nostic messages Output Actuator power 8 servo axes SERCOS cycle time 1 ms 14 servo axes SERCOS cycle time 2 ms 22 servo axes SERCOS cycle time 4 ms max of 255 parallel motion profiles possible PLC output Time for 1000 Bit instructions 4 us unlimited number of PLC processes Type of PLC processes continuous periodic or event driven Cycle time fast task 250 us nominal I O response time 500 us read in data process set output Cam switch group Cam switch group max 256 cams dynamic switch group Outputs Memory or digital outputs Inputs external master encoder virtual master encoder axis position Processing time 250 us digital inputs X3 Number 20 IEC61131 2 Range U 0 Voltage DC 0 6 V Range U 1 Voltage DC 20 33 V es input current I 5 mA at Un 24 V polarized yes input filter 1 or 5 ms can be parameterized analog inputs X2 Number 2 Range Uw 10 10 V Resolution 12 Bit 5 mV Resistance 100 kOhm or Range lIn 0 20 mA Resolution 12 Bit 5 pA Resistance 500 Ohm Interrupt inputs X4 Number 4 IEC61131 2 Range U 0 Voltage DC 0 6 V Range U 1 Voltage DC 20 33 V input current In 5 mA at Un 24 V polarized yes input filter 0 1 or 1 ms can be parameterized ELAU AG PacDrive Controller P600 Page 37 Parameters Touchprobe inputs X4 Value Number 16 IEC61131 2 Range U 0 Voltage DC 0 6 V Range U 1
40. on the hard disk The CompactFlash card is only used as additional data storage for service purposes Note that no Compact Flash card may be used with the devices Do not insert any CF card into the slot except for service purposes If a Compact Flash card is inserted malfunctions may occur on the hard disk or the DVD Rom drive The real time system and the firmware are stored on the hard disk The Com pactFlash card is not required to operate the controller Battery compartment The PacDrive controller battery buffers controller data Bios NVRAM time etc As a general rule the battery should be replaced every 6 years After this period of time the battery must be replaced If the device with battery inserted is not used for an extended period of time you should check replace the battery You can measure the battery charge by removing the battery and measuring manually or by using the con venient PacDrive controller diagnostic system You can also note the diagnostic message 037 battery dead in your IEC program and if necessary display it by putting the message on an HMI panel From the time the diagnostic message is first issued you still have about 3 days to change the battery You can change the battery while PacDrive Controller P600 Page 21 Page 22 the controller is on or off There is no loss of data when it is performed with the controller on When the controller is switched off the time period allotted fo
41. rate Check the dimensioning of the bleeder gt Use additional bleeder modules BM 4 with 400V AC devices v 2xx Object managing diagnosis messages 200 Faulty logical address of parameter Diagnosis class see 8 1 Diagnosis Classes standard 4 An object or a parameter is being accessed that is not in the control configuration In the ext diagnosis in the message logger logical address is displayed An object or a parameter from the IEC program is being accessed that is not in the control configuration gt Check the program Please contact our application support department Subsequent errors from 209 last boot failed diagnosis message PacDrive Controller P600 Page 97 gt See diagnosis message 209 Last boot failed see 8 5 3 10 209 Last boot failed dd 2 The configuration file on the controller is incorrect gt Transfer the configuration file to the controller again 201 Faulty parameter type code Diagnosis class see 8 1 Diagnosis Classes standard 4 The type code of a parameter is incorrect Software error gt Contact your ELAU representative 202 Faulty configuration file Diagnosis class see 8 1 Diagnosis Classes standard 4 The configuration file is no longer readable In controller firmware version 00 16 30 or higher the name of the temporary configu ration file is displayed in the ext diagnosis in the message logger E There is no configuration file in the PacDrive controller
42. reports that power is available 032 Begin saving retainarea At shutdown via UPS monitoring saving retain area was started 033 Retainarea saved At shutdown via UPS monitoring saving retain area was terminated 034 IEC tasks terminated At shutdown via UPS monitoring the IEC tasks were terminated 035 UPS active system shutdown started At shutdown via UPS monitoring the O_OffValue output was set to UPS shutdown 036 Rebooting started At shutdown via UPS monitoring the power supply of the PacDrive controller was found to be OK A reboot of the PacDrive controller was initiated 037 Battery low The battery voltage has dropped below the permissible minimum value z The battery voltage is too low PacDrive Controller P600 ELAU AG ELAU AG gt Change the battery for the PacNet optional module PN 4 038 Power fail 7 There was a voltage drop at the NvRam and at the real time clock RTC The NvRam is deleted and the system time is not correct The system has been switched off for too long and the battery voltage is insuf ficient see 8 5 1 37 037 Battery low gt Retain range and reinitialize clock gt Change the battery for the PacNet optional module PN 4 Ext Diagnosis PowerFail0 7 There is no power supply to outputs 0 to 7 of bus terminal BT 4 DIO gt Check power supply at connector X6 of bus terminal BT 4 DIO Ext Diagnosis PowerFail 8 15 There is no power supply to outputs 8 t
43. res The module with bus address xx is suddenly not responding The transfer is disrupted gt Check the wiring of the module PacNet Warning An RX clock is missing gt Check the wiring of the module 8xx System diagnosis messages 800 Insufficient memory Diagnosis class see 8 1 Diagnosis Classes standard 2 The 800 diagnosis message is triggered as soon as the free main memory exceeds 512000 bytes The DiagExtCode parameter in the control configuration or message logger can be used to localize the problem Insufficient RAM for the project DiagExtCode free lt 512000 gt Reduce the control configuration decrease RamDiskSize reduce the number of tasks use a controller with more memory General Information on ScanDisk A function for checking the file system on the IDE disk has been integrated in the firmware This ScanDisk function is automatically called when the system boots Errors are automatically detected logged and corrected The consistency of the file system is repaired Defective incomplete file are removed A detailed protocol is saved in the message logger After ScanDisk repairs the file system a message 015 Filesystem lt ide0 gt repaired see 8 5 1 15 015 filesystem lt ide0 gt repaired will be triggered ScanDisk generates the following diagnosis messages DiagCode DiagMsg DiagExtCode 800 Insufficient memory 801 Error reading FAT 802 Error writing FAT FAT l
44. the commutation Motor turns when starting boot procedure the MC 4 servo amplifier gt Make sure that the motor is still when starting boot procedure the servo am plifier Wiring error encoder cable is not plugged in or defective gt Check the wiring 117 Reading error encoder EEPROM Diagnosis class see 8 1 Diagnosis Classes standard 1 Reaction see 8 2 Reactions A Unable to read the correct data from the encoder EEPROM Wiring error Encoder cable is not correct gt Check the wiring Hardware error Encoder is defective gt Change out the motor or the encoder 118 Error on serial interface to encoder Diagnosis class see 8 1 Diagnosis Classes standard 1 Reaction see 8 2 Reactions A The data transfer to the encoder is disrupted Wiring error Encoder cable is defective Check the encoder cable and replace if necessary Check the ground connection shield Check the jumpers in the encoder cable connector vY vV V u The encoder voltage is unavailable or incorrect gt Check the encoder voltage Hardware error Encoder is defective gt Change out the motor or the encoder 119 Short circuit or ground fault in output stage Diagnosis class see 8 1 Diagnosis Classes standard 1 Reaction see 8 2 Reactions A The motor and motor lines are checked for short circuits phase short circuit Wiring error Short circuit in motor cable gt Replace the motor cable PacD
45. the correct setting of the limit switch check the braking distance in both directions Transfer project with the EPAS 4 automation toolkit to the PacDrive controller Hazardous movements Risk of death serious injury or property damage Ensure that no one is in the danger zone Remove all tools loose parts and other working aids not belonging to the axis machine system from the area of movement Ensure machine is in operating state ELAU recommends waiting to engage the engine until after the function tests have been successfully performed Check devices and wiring again If you haven t already done it connect the mains voltage Carry out function test using a checklist for axis machine system functions Continue to put system into operation according to packaging machine manu facturer s operating instructions PacDrive Controller P600 Page 33 6 7 6 8 6 8 1 Page 34 Configuration programming The PacDrive system is adapted to your task using the EPAS 4 automation tool kit In EPAS 4 the system is configured and programmed in accordance with IEC 61131 3 ACAUTION Complex functionality of PacDrive system and the machine Property damage possible Program changes may only be carried out by trained personnel with in depth knowledge of the system In other words changes may only be carried out by your machine supplier or by ELAU employees ELAU AG is not liable for damages caused by
46. the mains connection to the device has failed If the warning persists for 10 s or longer the system issues the error message 152 Phase L3 failure see 8 5 2 53 152 Phase L3 failure ELAU AG PacDrive Controller P600 Page 91 Page 92 157 DC bus overload warning Diagnosis class see 8 1 Diagnosis Classes standard 6 Reaction see 8 2 Reactions D The load ofthe DC bus is at 80 This is displayed by the parameter DC_BusOver load An error message will be triggered if the load reaches 100 146 DC bus overload see 8 5 2 47 146 DC bus overload 158 24V power supply overload warning Diagnosis class see 8 1 Diagnosis Classes standard 6 Reaction see 8 2 Reactions D The load of the 24V power supply for the SCL ServoDrives is at 80 An error message will be triggered if the load reaches 100 147 24V power supply overload see 8 5 2 48 147 24V power supply overload 159 DC bus no discharged warning Diagnosis class see 8 1 Diagnosis Classes standard 6 Reaction see 8 2 Reactions D An attempt was made to discharge the DC bus but the mains voltage is still present If the DC bus voltage does not decrease to 25 V within 200 ms of this warning ap pearing the system issues the error message 153 DC bus discharge failure see 8 5 2 54 153 DC bus discharge failure is triggered Wiring error The mains contactor is not controlled correctly gt Check the wiring 160 Undervoltage power stage driver Di
47. too high and therefore results in voltage build up gt Brake at a slower rate gt Check the dimensioning of the bleeder gt Use additional brake resistance bleeder module BM 4 with 400V AC devices 7 The mains voltage is too high gt Check the mains supply Hardware error The servo amplifier is defective gt Replace the servo amplifier PacDrive Controller P600 Page 77 Page 78 109 Undervoltage Diagnostic class see 8 1 Diagnosis Classes standard 2 Reaction see 8 2 Reactions B The DC link voltage is too low For 400 V AC devices smaller than 480 V DC smaller V00 20 00 450 V DC For 230 V AC devices smaller than 240 V DC smaller V00 20 00 225 V DC Exception PS 4 smaller than 260 V DC The mains voltage is too low gt Check mains voltage see technical information Parallel connected DC links servo amplifier error gt Locate servo amplifier with error and eliminate error 110 Phase error power supply Diagnosis class see 8 1 Diagnosis Classes standard 2 Reaction see 8 2 Reactions B Failure of one or two phases in the mains connection of the servo amplifier The 131 Phase failure of power supply warning see 8 5 2 32 131 Phase failure of power supply Warning must have been pending 10 s in advance Wiring error Not all phases are connected properly the mains contactor is not wired properly gt Check the wiring External fuse has activated gt Check fus
48. 0 Article name gt PacDrive P600 10 1 1 1 1 1 00 3 Article number gt 13130263 001 HW 02X2100210 5 Hardware version Serial number gt 123456 0010 X24 SW 00 16 20 3 Software version P rod u ction date PD_P600_Typenschild_logis_us FH8 Figure 5 2 Logistic type plate of a PacDrive controller P600 Article name PacDrive P600 Uin1 1x 24V DC lin1 3 0A lin1 with UPS 4 0 A optional PD_P600_Typenschild_techn_us FH8 Figure 5 3 Technical type plate of a PacDrive controller P600 ELAU AG PacDrive Controller P600 Page 27 UPS inside 12 V 2000mAh Article number gt KT10646 53130050 new order 4 Article number sparepart and backfitting PD_P600_Typenschild_UPS_us FH8 Figure 5 4 Type plate for optional USV Page 28 PacDrive Controller P600 ELAU AG 6 1 6 2 NOTE ELAU AG Servicing Quick detection and elimination of errors helps keep production losses to a minimum when machines break down The PacDrive system diagnostic messages can be called up via the EPAS auto mation toolkit and enable targeted and effective troubleshooting In the event of a breakdown it is possible to smoothly replace defective components to guarantee that the fault is quickly eliminated and operation can be resumed These jobs may only be carried out by qualified maintenance personnel When returning a defective device to ELAU customer service we would ask that you complete the error report in th
49. 06 313 106 314 106 315 106 316 106 317 107 318 107 319 107 320 108 321 108 322 108 323 108 324 108 325 109 326 109 327 109 328 109 329 110 330 110 331 110 332 110 333 111 334 111 335 112 336 114 338 114 339 115 4 400 115 401 115 402 115 403 115 404 116 405 116 5 500 116 501 116 502 117 503 117 504 118 505 118 506 119 507 120 508 120 509 121 PacDrive Controller P600 Page 163 510 121 511 121 512 122 513 122 514 123 516 123 517 123 518 123 6 600 124 601 125 7 700 125 701 126 702 126 703 127 704 128 705 128 706 129 707 129 720 129 721 130 722 131 723 131 724 132 725 132 726 132 730 132 731 133 732 133 733 133 734 134 735 134 736 135 737 135 738 135 739 135 750 135 751 136 752 136 753 136 754 137 755 138 756 139 757 139 758 140 759 140 770 140 771 141 780 141 781 141 Page 164 782 141 785 142 786 143 787 143 788 145 789 146 8 800 146 801 147 802 147 803 147 804 147 805 147 806 147 807 147 808 147 809 148 810 148 811 148 812 148 813 148 814 148 815 148 816 148 817 148 818 148 819 148 820 148 821 148 822 148 823 148 824 149 825 149 826 149 827 149 9 900 150 901 150 902 150 903 151 904 151 a automation system structure 14 A Automation system system overview 15 PacDrive Controller P600 ELAU AG C Changes 159 Configuration 34 Contact addresses 154 Corporate information 2 D Diagnosis 19
50. 070 60 010 SM 070 60 020 or SM 100 50 030 is connected to the MC 4 50 A gt Use a larger motor e g SM 100 40 050 or a smaller servo amplifier e g MC 4 10 A 139 Error in DC precharge Diagnostic class see 8 1 Diagnosis Classes standard 2 Reaction see 8 2 Reactions A from MC 4 PS 4 V00 16 30 Reaction see 8 2 Reactions B in MC 4 PS 4 versions lt V00 16 30 The error message is issued when the mains voltage is present and the DC link voltage of 450V DC for 400V AC devices or of 225V DC for 230V AC devices has not been PacDrive Controller P600 ELAU AG ELAU AG achieved one second following switching on of the mains phases Starting with V00 22 00 the monitoring time for the PS 4 was reduced from 1s to 350ms The setting ofthe parameter PhaseCheck MC 4 or PhaseCheckMode PS 4 has no influence on this error monitoring This monitoring protects the internal precharged switching a The parameter DC_LowCheck is off The mains voltage is falling and the drive remains in control mode If DC_LowCheck is on then diagnostic message 109 under voltage see 8 5 2 10 109 Undervoltage is displayed This leads to a Reaction see 8 2 Re actions B and the drive does not remain in control mode z The mains voltage increases again drive is still in control mode when e g a load is pressing on the axis power consumption at shaft In so doing enough energy is used that the DC circuit cannot be charged
51. 1 5 mm 10 0 09 digital output 10 1 5 mm 11 0 10 digital output 11 1 5 mm 12 0 11 digital output 12 1 5 mm 13 0 12 digital output 13 1 5 mm 14 0 13 digital output 14 1 5 mm 15 0 14 digital output 15 1 5 mm 16 0 15 digital output 16 1 5 mm Table 7 3 Electrical connections C400 C600 P600 X2 PacDrive Controller P600 ELAU AG 10 20 10 20 ELAU AG X3 Digital inputs Pin Designation Meaning Max cross section 1 1 00 digital input 0 DC 20 30 V 1 5 mm 2 1 01 digital input 1 DC 20 30 V 1 5 mm 3 1 02 digital input 2 1 5 mm 4 1 03 digital input 3 1 5 mm 5 1 04 digital input 4 1 5 mm 6 1 05 digital input 5 1 5 mm 7 1 06 digital input 6 1 5 mm 8 1 07 digital input 7 1 5 mm 9 1 08 digital input 8 1 5 mm 10 1 09 digital input 9 1 5 mm 11 1 10 digital input 10 1 5 mm 12 1 11 digital input 11 1 5 mm 13 1 12 digital input 12 1 5 mm 14 1 13 digital input 13 1 5 mm 15 1 14 digital input 14 1 5 mm 16 1 15 digital input 15 1 5 mm 17 1 16 digital input 16 1 5 mm 18 1 17 digital input 17 1 5 mm 19 1 18 digital input 18 1 5 mm 20 1 19 digital input 19 1 5 mm Table 7 4 Electrical connections C400 C600 P600 X3 X4 Touchprobe and fast digital inputs Pin Designation Meaning Range Max cross 1 T 00 Touchprobe input 0 1 5 mm 2 T 01 Touchprobe input 1 1 5 mm 3 T 02 Touchprobe input 2 1 5 mm 4 T 03 Touchpr
52. 2 Reactions B The current motor speed is greater than the rated speed of the motor Error occurs when using motor SH 055 with a rated speed greater than 6000rpm gt Use firmware version no earlier than V00 22 00 in the servo amplifier MC 4 i Error occurs with CAM movement function e g MultiCam due to incorrect curves or profile data gt Check curve data and program PacDrive Controller P600 Page 81 NOTE Page 82 Jumps occurred in the master encoder gt Check master encoder The error occurs during a CAM movement function due to an incorrect position manipulation e g Setpos1 function gt Check program Hardware error Commutation error i e the motor encoder SinCos is not cali brated or leveled gt Contact ELAU customer service 123 Error inverter enable Diagnostic class see 8 1 Diagnosis Classes standard 2 Reaction see 8 2 Reactions A The input Inverter Enable reached LOW while the drive was in control mode If the drive is shut down by HW_Enable or ControllerEnable the controller is active until the drive stops and the brake then engages BrakeCouplingTime Wiring error gt Check wiring of Inverter Enable input Circuit error The input Inverter Enable was set to LOW gt Check addressing of Inverter Enable input 124 PowerOff due to overload Diagnosis class see 8 1 Diagnosis Classes standard 5 Reaction see 8 2 Reactions C Overload PowerOff
53. 24 V or too low ON Normal operation control voltage in normal range Flashing UPS active w wd watchdog indicator Watchdog is a hardware module to monitor the controller OFF Normal operation ON Fatal error reset required reboot system In the event of a fatal error or activated watchdog only the real time system VxWorks of the PacDrive controller P600 must be restarted If the Windows XP operating system is still running smoothly a software reset of the real time system must be performed via Windows XP see also Switching on off and resetting the PacDrive controller A fatal error is a serious hardware problem or an unexpected software problem When a fatal error occurs the outputs are reset and the wd Watchdog relay outputs are opened err error indicator NOTE The error LED err displays errors The following table lists the possible display con ditions and their accompanying error descriptions OFF Normal operation Flashes slowly 1 7 Hz Error of class 1 2 3 4 or 5 active Flashes quickly 10 Hz PacDrive controller boot completed last boot failed See diagnostic mes sage 209 last boot failed PacDrive controller performed a minimal boot ON A serious error occurred during current boot The err LED is switched on following Power on Once the operating system user configuration user parameters and the IEC program have been loaded a
54. 6 A diagnosis message from the IEC program has been triggered with the Dia gMsgWrite function The error was triggered by the IEC program gt See description of your IEC program It is possible to display an additional error text with the DiagMsgWrite function 405 IEC diagnosis message class 7 Diagnosis class see 8 1 Diagnosis Classes standard 7 A diagnosis message from the IEC program has been triggered with the Dia gMsgWrite function The error was triggered by the IEC program gt See description of your IEC program Itis possible to display an additional error text with the DiagMsgWrite function 5xx SERCOS realtime diagnosis messages 500 SERCOS slave with duplicate address Diagnosis class see 8 1 Diagnosis Classes standard 1 While booting the SERCOS bus in phase 3 the addresses of the detected SERCOS slave are checked The system detects any multiple address assignments This func tion however must by supported by the SERCOS slaves ELAU slaves MC 4 SCL and PS 4 support this function in V00 15 00 or higher A SERCOS slave address has been assigned to the SERCOS slaves twice gt Check the rotary switch settings on the SERCOS slaves Meaning in versions below V00 15 00 A SERCOS slave address has been assigned more than once in the control configu ration The DiagExtCode parameter displays the address that has been assigned multiple times If the address is displayed once it has been
55. 600 Page 103 8 5 4 NOTE Page 104 3xx General diagnosis messages 300 Division error Diagnosis class see 8 1 Diagnosis Classes standard 4 A division by 0 should be executed in the IEC program The division by 0 is defined for REAL and LREAL and hence does not generate the 300 Division error diagnosis message The divisor was zero in an IEC division function gt Include division by 0 in the IEC program gt Check the number range 301 Coprocessor segment overflow Diagnosis class see 8 1 Diagnosis Classes standard 4 A system error has occurred An internal system error has occurred gt Please contact your ELAU representative 302 Stack error Diagnosis class see 8 1 Diagnosis Classes standard 4 A system error has occurred An internal system error has occurred gt Please contact your ELAU representative 303 General protection error Diagnosis class see 8 1 Diagnosis Classes standard 4 A system error has occurred An internal system error has occurred gt Please contact your ELAU representative 304 Coprocessor error Diagnosis class see 8 1 Diagnosis Classes standard 4 A system error has occurred An internal system error has occurred gt Please contact your ELAU representative PacDrive Controller P600 ELAU AG ELAU AG 305 Memory limit exceeded Diagnosis class see 8 1 Diagnosis Classes standard 4 A system error has occurred An internal system error h
56. AINS geese Naar Na Here E 29 6 3 EMC RUES sen een een 30 ELAU AG PacDrive Controller P600 Page 3 Table of Contents 6 4 6 5 6 6 6 7 6 8 6 8 1 6 8 2 6 8 3 7 1 7 2 7 3 7 4 10 10 1 10 2 10 3 Page 4 Device replacement uu4s44444444442RRnennnonnnonnnnnnnnnnnnnnnnennnnnnennneennennnennennn nn 31 CleaNiNgi ee ee een einen 32 870 8710 LEI C0 111 4 9 e Penner ORNTREROERTEUELEL Seer eon Ye rer eer ener er Perey Freres ee ere 32 Configuration programming unseren 34 Order NUMDETS sets esse 34 PacDrive controller P600 2 34 Cable eseis n E EEE E NEEE ENEE EEE 35 Pa tele 121210 1 gt sicaiongrnii riai aidi URENECUERNEHERTNEERCESRREN Ea Ei RSEN 35 Technical information 36 General san aea aE E ES TES EEEa E KNEE E Ea Si ai 36 Connection OVS VIEW neun ee 39 Electrical connections engere nee 39 DIMENSIONS srecen aeeie een en Aaaa 48 Diagnosis 49 Diagnosis Es Seren ei aS En a en 49 Reactions euere se er aani reset en 50 DUS er LED Sn ae ee a 50 Acknowledging diagnosis messages 2444444HHnnennnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn ern 53 Diagnostic messages SpPPRARREFRENIURERSEHPERLTEOREREFFEESPFRESESERPEIHRSEDEERFENELELFERRERFUERULEAPREEREESEFRECELFR 55 Oxx Messages diagnosis Messages uueeeeesssnnnennnnnnnnnnnnnnnnnnnnnnennnnnnnnnnnnnnnnnn ann 55 1xx Drives diagnosis messages cicissccdccantninssccnedinnccnemenss nngedenocienteadsuneddentmenumeonsead 73 2xx Object managing diag
57. C analog H sync c5 IN C GND X7 firewire 5 1 Designation Meaning Max cross at section 6 2 1 power 2 ground 3 TPB 4 TPB 5 TPA 6 TPA X8 9 universal serial bus usb pe a A Mi A x x9 section 44 1 VBUS ELAU AG PacDrive Controller P600 Page 43 NOTE Page 44 Designation data Meaning Max cross section 3 data 4 ground X10 Ethernet Pin Designation Meaning Max cross section 1 Txt OutputTransmitData 2 Tx OutputTransmitData 3 Rx InputReceiveData 4 PE 5 PE 6 Rx InputReceiveData 7 PE 8 PE Table 7 7 Electrical connections CA00 C600 P600 X10 Depending on the application you will need different cables to connect the PacDrive controller via the RJ 45 outlet Connecting PacDrive Controller lt gt Firm network with RJ 45 gt commercially available patch cable Connecting PacDrive controller lt gt Hub gt commercially available patch cable Connecting PacDrive Controller lt gt PC gt crossed RJ 45 network cable When in doubt ask your network administrator X11 Master encoder SinCos Pin Designation Meaning Max cross section 1 REFSIN Reference Signal Sinus 0 25 mm 2 SIN Sinus trace 0 25 mm 3 REFCOS Reference Signal Cosinus 0 25 mm 4 COS Cosinus trace 0 25 mm 5 9 V Supply voltage 0 25 mm 6 R
58. DataOut No sync encoder output has been configured or activated Check the PLC configuration Activate the sync encoder output if necessary parameter Enable diagnosis No Module No sync module or sync encoder input has been configured or activated Check the PLC configuration Activate the sync module or the sync encoder input if necessary Sync mod ule parameter Enable or sync encoder input parameter Enable diagnosis Sync Err The synchronization slaves are unable to synchronize with the synchronization master The Ethernet see parameter SyncQuality and or the CPU load see parameter AvailableLoad is too high Check the Ethernet connection Optimize the IEC project to reduce the CPU load diagnosis No Sync xxx The number of sequential synchronization telegrams xxx which were not re ceived exceeded the number specified in SlaveCycleErrorLimit The Ethernet see parameter SyncQuality and or the CPU load see parameter AvailableLoad is too high Check the Ethernet connection Optimize the IEC project to reduce the CPU load Increase the SlaveCycleErrorLimit diagnosis DataReady Err Either the sync encoder outputs are unable to configure the sync encoder in puts or a data error has occurred while the system is running Check parameter Diagcode of the sync modules to receive more detailed in formation about the source of the error diagnosis DataEnable Err Not all syn
59. E ELAU AG 2 EMC rules 30 Error report 160 G General safety instructions 7 H Homepage 2 154 Internet 154 L Leistungsmerkmale EPAS 4 16 MC 4 17 Performance features of SH motor 17 M Maintenance 29 Manuals 155 N Notation 7 O Operating manual 155 Order numbers 34 Overview 13 ELAU AG P Packaging machine 13 Pictograms 7 Programming manual 155 Proper use 9 R Reaktionen 50 Reference material 155 Repairs 29 Replacement parts 29 Risk classification 9 S Seminars 157 Service addresses 154 Storage 26 Symbols 7 T Trademark 2 Training courses 157 Transport 26 U Unpacking 26 W Warning instructions 7 PacDrive Controller P600
60. EPAS 4 will display the following message after the transfer is complete IEC program cannot be loaded gt If this happens reduce the number of data segments to two and transfer the project to the controller again after the conversion process is complete Cause of DOWNLOAD A subsequent error is involved in this case gt Refer to the previous error message e g 312 Parameter relocation failed see 8 5 4 13 312 Parameter relocation failed z There is no IEC program in the PacDrive controller or the IEC program is in compatible gt Transfer the IEC program again using EPAS 4 The IEC program code IEC data area or IEC retain area in the PacDrive con troller is too large gt See DiagExtCode gt Adjust project E The setting in EPAS 4 gt Project gt Options gt Conversion options in the item Number of Data Segments is less than 2 DiagExtCode ret xhhhhhhhh gt Increase the number of data segments 205 Impermissible parameter value Diagnosis class see 8 1 Diagnosis Classes standard 4 A parameter has an impermissible value The DiagExtCode parameter in the control configuration or message logger can be used to determine the logical address of the parameter that contains an impermissible value This allows assignment to the control configuration i Ext diagnosis BaudRate lt impermissible value gt M In V00 15 00 or higher the PacDrive controller supports the BaudRate SERCOS parameter 2 4 8 a
61. Limit object parameter PacDrive Controller P600 Page 83 Page 84 a The acceleration is too high gt Reduce acceleration The following error is a result of the 100 I2T Motor diagnosis message gt See diagnosis message 100 I2T Motor see 8 5 2 1 100 I2T Motor The mechanical system is sluggish or blocked gt Check the travel range Incorrect parameter settings gt Check the controller parameters and the J_Load The current feedforward is switched off gt Set the CurrFeedForw parameter to on TRUE Wiring error The wires in the motor or encoder cable are interchanged gt Check the cable connection cable Wiring error An incorrect encoder connector or motor connector is plugged in possibly from the neighboring actuator gt Check the encoder connecter and the motor connector gt Check the encoder cable and motor cable Wiring error Holding brake not released gt Check the holding brake No mains voltage gt Check the mains voltage at the servo amplifier An encoder with the incorrect resolution pulse oer revolution gt Check the encoder Hardware error The coupling to the position controller is loose gt Check the encoder coupling Hardware error Encoder signal jumps gt Check the travel range z The axis should be operated at regulated speeds gt Set the Pos_P_Gain parameter to 0 133 Speed dependent power reduction Diagnostic class see 8 1 D
62. N module was unable to read the CAN messages send for CAL CANopen fast enough No messages for CAL CANopen have been defined for layer 2 Error is not permitted to occur with the CAN layer 2 module gt Contact your ELAU representative PacDrive Controller P600 ELAU AG Meaning of ext diagnosis ELAU AG a Ext diagnosis mod error Event error ofthe CAN module not specified in more detail Default branch event error evaluation Should not occur gt Contact your ELAU representative 706 CAN layer2 errors below warning limit Diagnosis class see 8 1 Diagnosis Classes standard 8 The number of send or receive errors specified in the warning limit register has been exceeded Sending or receiving functioning again 707 CAN layer2 switched active Diagnosis class see 8 1 Diagnosis Classes standard 8 The number of send or receive errors 128 has been exceeded The CAN module is running again in active mode Sending or receiving functioning again The system displays the pending register information at the time the error occurred Structure SXXrXXtXxX s Status register see Status r Receive Error Counter see Status parameter t Send Error Counter see Status parameter 720 No module found Diagnostic class see 8 1 Diagnosis Classes standard 4 Module detection could not be found or it is not possible to update the field bus firm ware The firmware file on the flash disk or on the hard disk of the P600 i
63. OFIBUS_Stecker_0006 fh8 Figure 7 3 PROFIBUS connector Bus terminal resistors For the first and last bus nodes the terminal resistors must be switched on Otherwise data transmission will not function properly The shielding must be applied generously and on both sides PacDrive Controller P600 Page 47 first bus participant last bus participant Ol Ol on E on m off P off b bus closure bus closure from previous bus to next bus participant participant PROFIBUS_Busabschlusswiderstande_us fh8 Figure 7 4 Position of the bus terminal resistors 7 4 Dimensions PacDrive NM gt 1115232 S comi JX1 Zn ee De N 268 10 55 310 12 2 296 10 6 je ex E S a gE a m MII Made in Germany no 7 246 097 70276 35 1 38 246 0 9 ca 260 10 23 max depth incl connectors I 154 2 2 6 07 PDM_P600_Masszeichnung_us FH8 ca 235 9 25 Figure 7 5 Dimensions of PacDrive controller P600 Page 48 PacDrive Controller P600 ELAU AG 8 Diagnosis 8 1 Diagnosis Classes Different diagnosis classes are prioritized according to the consequences they have for the entire system At startup a specific diagnosis code is assigned to each diag nosis class An assignment can be DiagConfigSet overwritten with the user program DiagConfigSet function
64. Operating Manual PacDrive Controller P600 Article Nr 17130096 001 Edition 2007 02 Schneider ELAU PACKAGING SOLUTIONS Electric Corporate information All rights reserved ELAU AG even in the case of application for property rights No part of this documentation or the accompanying software and firmware may be reproduced transferred paraphrased saved to a storage medium or translated to another language or computer language without the written consent of ELAU AG Every imaginable measure was taken to guarantee the correctness of this product documentation However as improvements are continually being made to the hard ware and software ELAU AG cannot guarantee its completeness or correctness Trademark PacDrive is a registered trademark of ELAU AG All other trademarks named in this documentation are the sole property of their re spective manufacturer ELAU AG Dillberg 12 97828 Marktheidenfeld Germany Tel 49 0 9391 606 0 Fax 49 0 9391 606 300 e mail info elau de Internet www elau de Page 2 PacDrive Controller P600 ELAU AG Table of Contents 1 About this Manual 6 1 1 nlixtexe BTe 1 e 7 IOPRAFFUPREREHFFFFERFERSSCPELRGERHFERTFRSTREREESERFHEREITERNERTRFURTTEERFFEIGETPEFCRESR SERPRRCEARTER PRENTERRR 6 1 2 Symbols Characters and Notation 44nnssnnennnnnnnnn nn sneennennnennennnnnn 7 2 General Safety Instructions 8 2 1 PrINCIp lem E REDEN LES LEERE een 8
65. Page 73 Page 74 Delta tiom 45s 1 U current Current power Inn motor power in V00 11 00 or higher the lon Inn Characteristic curve is incorpo rated ta build up time trom dissipation time time of increase Figure 8 16 I2T motor build up time diagnosis message time of decrease Figure 8 17 12T motor dissipation time diagnosis message The holding brake is not released cable break power outside the 24 V 10 range gt Check the brake or wiring The lubrication system is defective gt Check lubrication Blunt tool gt Check replace the tool The motor is vibrating PacDrive Controller P600 ELAU AG ELAU AG Check the controller parameters The suspended axis is too heavy the weight distribution is incorrect Check drive sizing and weight distribution Drive accelerate the system at a slower speed The motor is de magnetized Replace the motor 101 Amplifier power off due to overtemperature Diagnostic class see 8 1 Diagnosis Classes standard 2 Reaction see 8 2 Reactions B The PacDrive servo amplifier cooling element is too hot vY vV V u v Ventilation is insufficient or ambient temperature is too high Check device fans and ventilation openings if available Check ventilation in switch cabinet Check function of air conditioner if available The final stage or the power rectifier is overloaded Check combination motor actuator C
66. R Diagnosis class see 8 1 Diagnosis Classes default 6 A check sum error on the SERCOS bus has been detected The data target and actual position of the last cycle will be used again Signal over the SERCOS fiberoptic conductor is incorrect gt Check the intensity setting in the PacDrive controller and PacDrive servo am plifier gt Check the fiberoptic conductor EMC problems gt Check the wiring SCL 055 motors are connected at the PacDrive controller The SCL 055 motors in the PacDrive PD 8 box are not connected properly PacDrive Controller P600 ELAU AG ELAU AG gt Check the connection of tne SCL 055 motors in the PacDrive PD 8 box Simply placing jumpers on the desired terminals will not resolve the problem Slaves must not be inserted into the following SERCOS slot In addition follow the notes in the SCL and PS 4 and PD 8 operating in structions 506 Fatal SERCOS error MASTER Diagnostic class see 8 1 Diagnosis Classes Default 1 An error was detected in two successive cycles when receiving data on the SERCOS bus The SERCOS bus was shut down For firmware versions earlier than V00 15 00 it is necessary to reset the PacDrive controller to start the SERCOS bus Position loss due to serious SERCOS bus error Property damage possible Due to the erroneous acknowledgement of diagnostic message 506 Serious SER COS error MASTER without restarting the controller loss of position of the
67. Replace the device 143 Encoder temperature warning Diagnostic class see 8 1 Diagnosis Classes standard 6 Reaction see 8 2 Reactions D The temperature inside the encoder is too high Ventilation is insufficient or ambient temperature is too high Check device fans and ventilation openings if available Check ventilation in switch cabinet Check function of air conditioner if available vY vV V u Hardware error The temperature sensor is defective gt Replace device 144 DC bus short circuit Diagnosis class see 8 1 Diagnosis Classes standard 1 Reaction see 8 2 Reactions A A short circuit has occurred in the DC bus PacDrive Controller P600 ELAU AG ELAU AG Wiring error The connection cables between PS 4 and PD 8 or PD 8 and PD 8 are not con nected properly or have a short circuit The motor cable has a short circuit gt Check the cable and replace if necessary 145 DC bus ground fault Diagnosis class see 8 1 Diagnosis Classes standard 1 Reaction see 8 2 Reactions A A ground fault has occurred Wiring error The connection cables between PS 4 and PD 8 or PD 8 and PD 8 are not con nected properly or have a ground fault The motor cable has a ground fault gt Check the cable and replace if necessary 146 DC bus overload Diagnostic class see 8 1 Diagnosis Classes standard 1 Reaction see 8 2 Reactions B The DC circuit is overloaded In this case unlike diagno
68. S485 Parameter channel 0 25 mm 7 RS485 Parameter channel 0 25 mm 8 SC_SEL Master encoder plugged in 0 25 mm bridge to GND 9 GND Supply voltage 0 25 mm Table 7 8 Electrical connections C400 C600 P600 X11 PacDrive Controller P600 ELAU AG X11 Master encoder incremental O Pin Designation Meaning Max cross 9 5 section 1 _UA track A 0 25 mm 2 UA track A 0 25 mm 3 _UB track B 0 25 mm 6 r 4 UB track B 0 25 mm Q 5 5V Supply voltage 0 25 mm 6 _UO track O 0 25 mm 7 UO track O 0 25 mm 8 0 25 mm 9 GND ground 0 25 mm Table 7 9 Electrical connections C400 C600 P600 X11 Plugging in unplugging the master encoder plug when switched on Damage to master encoder possible Only unplug or plug in master encoder when de energized Disconnect controller from the 24 V supply voltage X12 13 PacNet 1 8 Designation Meaning Max cross z 3 section 1 OutputTransmitData 8 1 2 TxD OutputTransmitData 3 RxD InputReceiveData 4 TxC OutputTransmitClock 5 TXC OutputTransmitClock 6 RxD InputReceiveData 7 RxC InputReceiveClock 8 RxC InputReceiveClock Table 7 10 Electrical connections C400 C600 P600 X12 X13 Use only approved PacNet cables at the PacNet connection to avoid malfunction NOTE X16 keyboard I Designation Meaning Max cross se
69. U AG is only six hours Then all functions can be used without restrictions until the evaluation phase of six hours has elapsed After this period of time runs out a high priority error is triggered that cannot be acknowledged After a few minutes about 5 min the SERCOS bus is shut down making any further use of the affected controller impos sible The number of license points on the compact flash card of the PacDrive controller is not sufficient gt Check the number of required licensing point based on the Licensing parameter in the control configuration 333 Fatal error receiving encoder data aV00 22 00 or higher Diagnosis class see 8 1 Diagnosis Classes standard 5 In the encoder network a fatal error occurred while distributing the encoder positions Ext diagnosis Dupl Obj Multiple initialization of object SYN_DIN SYN_DOUT Ext diagnosis Int Err xxx Internal error code gt Ext diagnosis SyncLost Synchronization was lost while the object SYN_DIN SYN_DOUT was active Ext diagnosis No Data xxx E The number of data sets xxx that was not received sequentially exceeds the limit specified in DataCycleErrorLimit gt a Ext diagnosis Send error Due to an internal error the system was unable to send a telegram for 5cycles gt 334 Error receiving encoder data warning aV00 22 00 or higher Diagnosis class see 8 1 Diagnosis Classes standard 6 An error h
70. a purely mechanical nature quickly reach their limits because modern packaging is always requiring less material and is becoming more flexible and smaller The required flexible linking of the function and motion sequences can only be ensured via intelligent software in the future PacDrive Engineering tools Automation Toolkit EPAS 4 for Configuration and Programming Motion Toolkit ECAM 4 for curve design and for the drive layout Engineering Interface ENI 4 PacDrive Project Converter for quick and uncomplicated conversion of projects for various types of PacDrive controllers PacDrive Diagnostics for easy determination of service data PacDrive PacDisk 4 for creating flash disks for PacDrive controllers PacDrive Netmanage for locating configuring and managing the PacDrive con trollers PacDrive Firmware Assistant for easy firmware swapping of a PacDrive controller ELAU AG PacDrive Controller P600 Page 15 Automation Toolkit EPAS 4 Motion Toolkit ECAM 4 comprehensive functionality Page 16 PacDrive SERCOS Firmware Assistant for easy firmware swapping of the SER COS slave devices MC 4 SCL PS 4 PacDrive Change Detection Tool for detecting project changes Due to the combination of comprehensive functions and fully developed tools the Au tomation Toolkit EPAS 4 is a good example of a powerful programming tool that is as easy to use as a Standard office program The primary advantage of the EPAS 4 is th
71. agnosis class see 8 1 Diagnosis Classes standard 1 Reaction see 8 2 Reactions A The supply voltage of the power stage driver is too low Hardware error Device is defective gt Replace the device 161 Overtemperature board warning Diagnosis class see 8 1 Diagnosis Classes standard 6 Reaction see 8 2 Reactions D The temperature of the board in the SCL housing is too high If the temperature con tinues to rise the message 142 Board PowerOff due to overtemperature see 8 5 2 43 142 Board PowerOff due to overtemperature will be triggered 162 Wiring error O_0 Diagnosis class see 8 1 Diagnosis Classes standard 5 Reaction see 8 2 Reactions B There is a wiring error at Pin 1 of the sensor actor connector of the SCL The output is short circuited or overloaded gt Check the wiring of the output PacDrive Controller P600 ELAU AG Hardware error The output function block is defective gt Replace the device 163 SERCOS C1D error Diagnosis class see 8 1 Diagnosis Classes standard 1 Reaction Manufacturer specific A SERCOS error in diagnosis class 1 C1D has occurred The extended diagnosis contains a data word that provides information on the exact cause The meaning of the data word has changed Incorrect interpretation of the error message Refer to the operating instructions of the SERCOS device The individual bits of this data word have the following meanings
72. all drives x Error stop of the triggering drive Inform IEC program DiagMsgRead function xX X Activate ERROR LED x X x X X X x x Configurable x x x x x Ix Ix Ix x Ix Ix x Ix Update diagnosis parameters of PacDrive controller ELAU AG PacDrive Controller P600 Page 49 8 2 8 3 Page 50 Update diagnosis parameters of servo drive x X IX X X IX IX Table 8 2 Diagnosis classes and system reactions Best standstill If Enable ControllerEnable and HW_Enable is removed then DrivePeakC is the best way to stop the drive If used for this purpose DrivePeakC can be controlled with LimCurrent Error stop If ControllerStop is active use StopDec to stop the drive Reactions Errors in the servo amplifier diagnosis group have an additional reaction Reaction Meaning Diagnosis example A Motor immediately loses all torque 119 Short circuit or ground fault in output brakes engage immediately stage see 8 5 2 20 119 Short circuit or ground fault in output stage B Best automatic standstill Motor deceler 112 Communication error real time ates with maximum delay brakes en bus see 8 5 2 13 112 Communication gage when n lt nmin 10 revolutions min error real time bus or StopTimeLim default 400 ms is reached drive will lose all torque when StopTimeLim BrakeCouplingTime is reached default 500 ms
73. and the RingStatus parameter If the interruption is eliminated and the SERCOS bus is at least in Phase 2 then the error source can be defined using the SERCOS Firmware Assistant in the data view System diagnosis gt SERCOS configuration and SERCOS Topology Signal over the SERCOS fiberoptic conductor is incorrect gt Check Intensity setting in the PacDrive controller and PacDrive servo amplifier gt Check wiring see parameter RingStatus z A device in the SERCOS ring is switched off or was reset gt Check the power supply 24 V of the device gt Switch on the device SCL 055 motors are connected at the PacDrive controller The SCL 055 motors are not connected properly in the PacDrive PD 8 box gt Check the connection of the SCL 055 motors in the PacDrive PD 8 box Simply placing jumpers on the desired terminals will not resolve the problem Slaves must not be inserted into the following SERCOS slot Please refer to the notes provided in the SCL and PS 4 and PD 8 operating instructions 503 Error in parameter channel Diagnosis class see 8 1 Diagnosis Classes standard 4 A transfer error has occurred in the SERCOS bus during operation Additional infor mation will be stored in DiagExtCode DiagExtCode Meaning ST Err xxx Service transfer error ST Timeout Timeout during service transfer PacDrive Controller P600 Page 117 Page 118 DiagExtCode Meaning ST Any Other service t
74. ars Once this period has gone by the battery pack must be replaced NOTE ELAU AG PacDrive Controller P600 Page 153 10 Appendix 10 1 Addresses ELAU AG Customer Service Department Street address P O Box 1255 Dillberg 12 97821 Marktheidenfeld Germany 97828 Marktheidenfeld Germany Tel 49 0 9391 606 142 Fax 49 0 9391 606 340 e mail info elau de Internet www elau de ELAU AG Dillberg 12 97828 Marktheidenfeld Germany Tel 49 0 9391 606 O Fax 09391 606 300 e mail info elau de Internet www elau de ELAU Inc 165 E Commerce Drive Schaumburg IL 60173 USA e mail info elau com Internet www elau com Tel 1 847490 4270 Fax 1 847 490 4206 ELAU Systems Italia S r l Via Tosarelli 300 40050 Villanova di Castenaso BO Italy Tel 39 051 7818 70 Fax 39 051 7818 69 e mail info elau it Internet www elau it Additional contact addresses can be found on the ELAU homepage www elau de NOTE Page 154 PacDrive Controller P600 ELAU AG 10 2 ELAU AG Additional Literature You can obtain the following manuals and instructions about the PacDrive system from ELAU Programming manual Item no 17 13 00 61 00x DE EN PacDrive MC 4 Operating Manual Item no 17 13 00 62 00x DE EN IT FR CAN L2 Operating Manual Item no 17 13 00 66 00x DE EN PROFIBUS DP Operating Manual Item no 17 13 00 67 00x DE EN SM Motor Operating Manual Item
75. as occurred gt Please contact your ELAU representative 306 Arithmetic overflow Diagnosis class see 8 1 Diagnosis Classes standard 4 A system error has occurred An internal system error has occurred gt Please contact your ELAU representative 307 Double execution error Diagnosis class see 8 1 Diagnosis Classes standard 4 A system error has occurred An internal system error has occurred gt Please contact your ELAU representative 308 Invalid task state segment Diagnosis class see 8 1 Diagnosis Classes standard 4 A system error has occurred E An internal system error has occurred gt Please contact your ELAU representative 309 No memory segment Diagnosis class see 8 1 Diagnosis Classes standard 4 A system error has occurred An internal system error has occurred gt Please contact your ELAU representative 310 Faulty memory segment adjustment Diagnosis class see 8 1 Diagnosis Classes standard 4 A system error has occurred An internal system error has occurred gt Please contact your ELAU representative 311 Coprocessor division error Diagnosis class see 8 1 Diagnosis Classes standard 4 A system error has occurred PacDrive Controller P600 Page 105 Page 106 An internal system error has occurred gt Please contact your ELAU representative 312 Parameter relocation failed Diagnosis class see 8 1 Diagnosis Classes standard 4 A system error has occurr
76. as occurred in the encoder network while distributing the encoder positions Ext diagnosis No Data xxx A number xxx of data sets was not received sequentially If the number xxx of data sets that was not received sequentially exceeds the limit specified in DataCycleErrorLimit the 333 Fatal error receiving encoder data see 8 5 4 34 333 Fatal error receiving encoder data diagnosis message will be triggered PacDrive Controller P600 Page 111 Page 112 335 Fatal synchronization error 00 22 00 and higher Diagnosis class see 8 1 Diagnosis Classes standard 5 Filter type 2 Diagnosis messages A server error in the encoder network occurred while synchronizing the controller sys tem clocks Ext diagnosis Sync Init Object SYN_M or SYN_S Synchronization master or synchronization slave failed The IP address SlavelPAddress of the sync module is assigned twice gt Check the SlavelPAddress parameter of the sync module in the synchronization master controller configuration Ext diagnosis SercosPhase xxx The SERCOS ring is not in phase 4 gt SERCOS bus in phase 4 booted Ext diagnosis Dupl MasterID The set MasterlD is already being used by another synchronization master in the same network gt Change the MasterlD Ext Diagnosis ProtVer xxx The protocol version of the synchronization master does not match the protocol version of the synchronization slave gt Use compatible
77. as sent a CanOpen emergency message reset see 8 5 8 30 754 CanOpen emergency message to the bus Meaning of ext diagnosis shows the node address the error code and the error register Structure Nxxx Cxxxx Rxx N node address decimal CANopen node address C error code hexadecimal CANopen error code R error register hexadecimal CANopen error register PacDrive Controller P600 ELAU AG ELAU AG 018 CanOpen node guarding error resolved A CANopen node has sent a CANopen emergency message reset to the bus A CANopen node has reported the disappearance of a monitoring error Meaning of ext diagnosis shows the node address the error code and the error register Structure Nxxx Cxxxx Rxx N node address decimal CANopen node address C error code hexadecimal CANopen error code R error register hexadecimal CANopen error register 019 CanOpen node specific error info A CANopen node has sent an emergency message to the bus This diagnosis mes sage is always sent with the 754 CanOpen emergency message see 8 5 8 30 754 CanOpen emergency message diagnosis message It contains manufacturer specific error data This data consists of 5 byte values Meaning of ext diagnosis Structure b1 b2 b3 b4 b5 b1 b5 hexadecimal date 020 IEC cycle check changed The CycleCheckSet function was used to enable disable the cycle check TRUE or FALSE is displayed in DiagExtCode 021 IEC cycle check values are changed The CycleCheckSe
78. at all components are well matched to each other Benefits for the user Quick familiarization and simple to operate A tool for design and service Six standard IEC languages Simple programming using powerful libraries EPAS 4 based on CoDeSys from 3S Change detection for FDA conformity Engineering Interface ENI for multi user processing The bridge between the mechanical package and the ECAM 4 software is unique on the market for its design and functionality Complex mechanical motion sequences can be conveniently designed using the powerful tool and servo drives can be quickly and safely laid out in the sizing calculator using many practical aids which is a boon for the mechanical engineer ELAU users are excited about the multi axis motion ECAM 4 design toolkit All of the VDI 2143 profiles and polynomials of the 5th order can be integrated in any number of motion segments This preserves the mechanical package and allows swash free transport The ECAM 4 engineering toolkit was specially designed for motion control applications in electronic packaging machines With ECAM 4 you can now easily edit even the most complex motion profiles using the motion designer and you can quickly and safely lay out servo drives using the sizing calculator Exhaustive online help is available to support you when you are working with ECAM 4 The PacDrive controller family The PacDrive controller microprocessor based control hardware with the VxWorks
79. ating Manual Item no 17 13 00 98 00x DE EN IT FR PacDrive Controller C600 Operating Manual Item no 17 13 00 99 00x DE EN IT FR PacDrive PC Panel PCP Operating Manual Item no 17 13 01 02 00x DE SH Motor Operating Manual Item no 17 13 01 05 00x DE EN Intelligent Servo Module iSH Operating Manual Item no 17 13 01 13 00x DE EN Power Supply PS 5 and Distribution Box DB 5 Operating Manual Item no 17 13 01 15 00x DE EN Item no 000 DEutsch 001 ENglish 002 ITalian 003 FRench PacDrive Controller P600 ELAU AG 10 3 Product Training Courses We also offer a number of training courses about our products Our seminar leaders with several years of experience will help you take advantage of the extensive possibilities offered by the PacDrive system Go to the ELAU homepage for more information and our current seminar schedule www elau de NOTE ELAU AG PacDrive Controller P600 Page 157 10 4 Page 158 Manufacturer s declaration ELAU v Herstellererkl rung Declaration by the manufacturer D claration du constructeur ELN 117 02 02 04 Page 1 1 Product PacDrive Controller MAx 4 C200 C400 C600 P600 The manufacturer guarantees that the product delivered was manufactured in accordance with the applied harmonized stand ards specifications Applied harmonized standards EN 60204 1 11 1998 Safety of machines electrica
80. ating instructions of the SERCOS device The individual bits of this data word have the following meanings Bit Meaning Bit 0 overload warning Bit 1 amplifier overtemperature warning Bit 2 motor overtemperature warning Bit 3 cooling error warning Bit 4 reserved Bit 5 positioning velocity nLimit Bit 6 reserved Bit 7 reserved Bit 8 reserved Bit 9 Undervoltage warning bus voltage Bit 10 Reserved Bit 11 excessive velocity deviation Bit 12 Reserved Bit 13 Target position outside of travel range Bit 14 Reserved Bit 15 Manufacturer specific error see 6166 Table 8 5 SERCOS C2D warning assignment according to SERCOS specitications 166 SERCOS C2D manufacturer specific warning Diagnosis class see 8 1 Diagnosis Classes standard 6 Reaction manufacturer specific A manufacturer specific SERCOS warning in diagnosis class 2 C2D has occurred The extended diagnosis contains a data word that provides information on the exact cause For information on what each bit means refer to the manual of the SERCOS device manufacturer 167 SERCOS C3D operation status Diagnosis class see 8 1 Diagnosis Classes standard 9 A SERCOS C3D operation status of diagnosis class 3 C3D has changed The ex tended diagnosis contains a data word that provides information on the exact cause The meaning of the data word has changed Incorrect interpretation of the error message Refer
81. ault value for a system clock tick is 250 us or 1 ms with the C200 The DiagExtCode shows the current cycle time cycle time from the task configuration in ms 318 Calculated profile deleted Diagnosis class see 8 1 Diagnosis Classes standard 5 An attempt was made to calculate a profile e g CamMasterStart that was just deleted with the ProfilDelete The DiagExtCode displays the profile in hexadecimal form e g Prof 1001000 i Program error The profile to be calculated was deleted too early or the wrong profile was deleted gt Check the program 319 TPEdge not valid at 4ms Diagnosis class see 8 1 Diagnosis Classes standard 2 The touchprobe measurement is not valid at the specified CycleTime of 4 ms A cycle time of 4 ms is specified in the control configuration and the PacDrive controller hardware does not support the touchprobe measurement correctly for this cycle time gt Set the cycle time to 1 or 2 if possible PacDrive Controller P600 Page 107 Page 108 gt Update the PacDrive controller hardware Contact your ELAU representative 320 Bad array access check Diagnosis class see 8 1 Diagnosis Classes standard 5 An array access error in the IEC user program was found by the Check lib The mes sage logger call hierarchy function can be used to backtrace the function block call or nesting 7 While accessing an array the area limits of that array were breached in the IEC user program
82. ave bodily harm or major damage to property if the safety regulations are not followed CAUTION Indicates a potentially dangerous situation that could result in property damage if the safety regu lations are not followed 2 3 Proper Use The ELAU Components are intended to be installed in a machine or assembled with other components to form a machine or system You may only use them in accordance with the installation and operating conditions described in the documentation You must use the accessories and add ons components cables lines connectors etc specified in the documentation You must not use any third party devices or compo nents that are not expressly approved by ELAU For proper use you must also observe the operating manuals and other documentation see appendix and comply with the inspection and maintenance instructions Operating conditions at the installation location must be checked and maintained in accordance with the required technical specifications performance data and ambient conditions Start up is prohibited until it is guaranteed that the usable machine or system in which the motor is installed meets all requirements of EC Directive 98 37 EC machinery directive In addition the following standards directives and regulations are to be observed DIN EN 60204 Safety of machinery Electrical equipment of machines DIN EN 292 Part 1 and Part 2 Safety of machinery General terms
83. axes and physical encoder SinCos incremental encoder from V00 15 00 is possible Only acknowledge diagnostic message if the re initialization or referencing of the system by the IEC program has been ensured The capability to acknowledge the diagnostic message can be switched off with the function DiagNoQuitSet Potentially use functions SysReset or PrgResetAndStart DiagExtCode RFr or RFIr see 8 5 1 51 052 Extended SERCOS diagnosis MASTER Break in control voltage 24V DC has occurred Diagnostic message 134 Ex ternal 24V power supply too low see 8 5 2 35 134 External 24V power supply too low may still be entered in the message logger if it was still possible to transfer it via the SERCOS bus gt Check control voltage also refer to device s technical information DiagExtCode RFr see 8 5 1 51 052 Extended SERCOS diagnosis MAS TER during phase start up There are SERCOS slaves MC 4 with a firmware version earlier than V00 15 00 in the ring that are not addressed as real devices The result is a serious error during phase start up of the SERCOS bus interrupting the phase start up gt For SERCOS slaves MC 4 with a firmware version earlier than V00 15 00 that are not being addressed as real devices the SERCOS address must be set to 0 SCL 055 motors are connected to the PacDrive controller The connection of the SCL 055 motors in the PacDrive PD 8 box is not correct gt Check the
84. bold 1BufSelect AXIS_BUF_SELECTION Buffer Auswahl Program code is written in a different font Information symbol After this symbol you will find instructions and useful tips on using the components Warning symbol Safety instructions are provided at relevant points They are featured with the preceding symbol This symbol is followed by information about the content of the section and serves as an orientation aid PacDrive Controller P600 Page 7 2 General Safety Instructions This section contains general requirements for safe work Each person who uses ELAU Componentsor works on ELAU Componentsmust read and follow these general safety notes If activities involve residual risks a specific note is made at the appropriate points The note details the potential danger and describes preventative measures to avoid it 2 1 Principle The ELAU Components are state of the art and conform to recognized technical safe ty regulations However using this product could result in risk of life and limb and of damage to property if The ELAU Componentsis not used properly Work on the ELAU Componentsis carried out by unqualified or untrained staff You change or modify the ELAU Componentsinappropriately You fail to test the protective measures implemented after installation start up or maintenance You do not observe the safety notes and safety regulations Operate the ELAU Components only whe
85. c encoder outputs and sync encoder inputs are ready to exchange data Check parameter Diagcode of the sync modules to receive more detailed in formation about the source of the error PacDrive Controller P600 Page 113 Page 114 Ext diagnosis Wrong IP Add The SlavelPAddress parameter is not set gt Contact your ELAU representative Ext diagnosis Err xxx Internal error code gt Contact your ELAU representative 336 Synchronization error warning aV00 22 00 or higher Diagnosis class see 8 1 Diagnosis Classes standard 6 A fatal error has occurred in the encoder network while synchronizing the controller system clocks Ext diagnosis No Sync xxx More than half of the synchronization telegrams xxx specified in SlaveCycleEr rorLimit have not been received sequentially If more than half of the synchro nisation telegrams specified in the SlaveCycleErrorLimit have not been received sequentially the335 Fatal synchronization error see 8 5 4 36 335 Fatal syn chronization error diagnosis message will be triggered gt 337 Insufficient system memory to create DynlECData aV00 22 00 or higher Diagnosis class see 8 1 Diagnosis Classes standard 4 Filter type 1 general system messages The dynamic memory area which was specified with the DynIECDataSize parameter could not be reserved due to insufficient memory RAM During IEC program start a check will be performed to determine if t
86. ct your ELAU representative 331 Licensing Diagnosis class see 8 1 Diagnosis Classes standard 5 This diagnosis message will be triggered by the license server of the PacDrive con troller e g C600 if a function block is used without a sufficient number of points The 331 Licensing error can be acknowledged will be triggered first so as to notify the user that the remaining run time of the system is only six hours Then all functions can be used without restrictions until the evaluation phase of six hours has elapsed When this time period has elapsed a high priority error see 8 5 4 33 332 Licensing that cannot be acknowledged is triggered After a few minutes about 5 min the SERCOS bus is shut down making any further use of the affected controller impossible The number of license points on the compact flash card of the PacDrive controller is not sufficient gt Check the number of required licensing points based on the Licensing parameter in the control configuration 332 Licensing Diagnosis class see 8 1 Diagnosis Classes standard 5 This diagnosis message will be triggered by the license server of the PacDrive con troller e g C600 if a function block is used without a sufficient number of points The 331 Licensing see 8 5 4 32 331 Licensing error message can be acknowledged will be triggered first so as to notify the user that the remaining run time of the system PacDrive Controller P600 ELAU AG ELA
87. ction 1 DATA KB data keyboard 2 DATA MS data mouse 3 GND KB ground 4 VCC KB power 5 V 5 CLK KB clock keyboard ELAU AG PacDrive Controller P600 Page 45 Page 46 Ka Es ZU E CLKMS clock mouse Max cross section 7 11 Electrical connections P600 X16 X17 Com 1 RS 232 Designation Meaning Max cross section 1 Data Carrier Detect 2 RxD Receive Data 0 25 mm 3 TxD Transmit Data 0 25 mm 4 DTR Data Terminal Ready 0 25 mm 5 GND Signal Ground 0 25 mm 6 DSR Data Set Ready Clear To 0 25 mm Send 7 RTS Request To Send 0 25 mm 8 CTS Clear To Send 0 25 mm 9 RI Ring Indicator 0 25 mm Table 7 12 Electrical connections C400 C600 P600 X17 X18 Com 2 RS485 Pin Designation Meaning Max cross section 1 5 VM Supply voltage 0 25 mm 2 TxD RS485 Transmit 0 25 mm 3 TxD RS485 Transmit 0 25 mm 4 RxD RS485 Receive 0 25 mm 5 RxD RS485 Receive 0 25 mm 6 GNDR GND receive RS485 0 25 mm 7 reserved 0 25 mm 8 GNDM Supply voltage 0 25 mm 9 GNDR GND receive RS485 0 25 mm Table 7 13 Electrical connections C400 C600 P600 X18 X19 CAN Pin Designation Meaning Max cross section 1 reserved 0 25 mm 2 CAN_L bus line low 0 25 mm 3 GND ground 0 25 mm 4 reserved 0 25 mm 5 reserved 0 25 mm 6 reserv
88. ction Risk of death or serious injury Please ensure that only devices electrical components or lines that have suffi cient safe electrical separation from the connected circuits in accordance with the standards EN 50178 1998 edition Electronic equipment for use in power sta tions are connected to the signal voltage connectors of this component Ensure that the existing electrical separation is maintained throughout the entire circuit When using ELAU components in systems that do not have safe separation as a pro tective measure against direct or indirect contact of dangerous voltages all connec tions and contacts e g PacDrive controller Sub D connector serial interface that do not meet protection class IP2X require a permanent cover The cover or the device connection of the connected device must be designed so that it can only be removed using a tool The protective measure must be adhered to for all connected devices PacDrive Controller P600 ELAU AG 3 1 ELAU AG System Overview Drive Concepts of Packaging Machines Modern machine design in the packaging industry is characterized by the demand for high dynamics flexibility modularity and profitability Packaging machines were tra ditionally equipped with a main drive and an upright shaft that coupled all other moving organs in the machine with complex motion functions usually via mechanical compo nents With such packaging machines it is extremel
89. determined that torque was exceeded Overload function You can switch the diagnosis message off using the OverloadErrorOff function and switch it back on default using the OverloadErrorOn function An overload will occur if the overload function is active gt 125 1 2t motor warning Diagnosis class see 8 1 Diagnosis Classes standard 6 Reaction see 8 2 Reactions D The motor is overloading The integrator I2tparameter has already increased to 80 A 100 I2T Motor see 8 5 2 1 100 I2T Motor error may result 126 Amplifier overtemperature warning Diagnosis class see 8 1 Diagnosis Classes standard 6 Reaction see 8 2 Reactions D PacDrive Controller P600 ELAU AG ELAU AG The cooling element of the MC 4 SCL PS 4 is too hot A 101 Amplifier power off due to overtemperature see 8 5 2 2 101 Amplifier power off due to overtempera ture error may result 127 Overtemperature motor warning Diagnosis class see 8 1 Diagnosis Classes standard 6 Reaction see 8 2 Reactions D The internal motor temperature temperature switch in the motor is too high approx 130 C Ifthe internal motor temperature temperature switch in the motor is too high for 2 seconds or longer an error will occur 102 Motor PowerOff due to overtemperature see 8 5 2 3 102 Motor PowerOff due to overtemperature 128 Cooling error warning Diagnosis class see 8 1 Diagnosis Classes standard 6 Reaction se
90. dule Via FTP copy the correct FPGA firmware to the flash disk of the controller and restart the controller Ext diagnosis FPGA prg fail Unable to program the FPGA The firmware is not compatible with the module Via FTP copy the correct FPGA firmware to the flash disk of the controller and restart the controller Ext diagnosis no FPGAfl open Unable to open the FPGA firmware file The flash disk may be defective Replace the flash disk Ext diagnosis def FPGA head The header in the firmware file is not correct Via FTP copy the correct FPGA firmware to the flash disk of the controller and restart the controller Ext diagnosis wr FPGA size The size of the FPGA file is incorrect Via FTP copy the correct FPGA firmware to the flash disk of the controller and restart the controller Ext diagnosis no FPGAfile An FPGA firmware file was not found on the flash disk Via FTP copy the correct FPGA firmware to the flash disk of the controller and restart the controller Ext diagnosis RTC is damaged Unable to set the time of the RealTimeClock in the PN 4 optional module The diagnosis message cannot be acknowledged This is due to a problem in a very early hardware version of the PN 4 To correct the error the PN 4 module must be replaced The problem has been corrected in hardware code 030033 and higher Workaround PacDrive Controller P600 ELAU AG NOTE ELAU AG The DiagNoQuitReset IEC funct
91. e Class 2 error Diagnostic code 121 The meaning of the diagnostic code is more thoroughly explained in the online help section of the EPAS 4 automation toolkit 121 braking resistor temperature too high Diagnostic class see 8 1 Diagnosis Classes standard 2 Reaction see 8 2 Reactions B The braking resistor is overloaded The drive has incorrect dimensions gt Check drive sizing Hardware error The braking resistor or addressing is defective gt Contact ELAU customer service A complete list of the diagnostic messages can be found in the chapter entitled Diag nostic messages see 8 Diagnosis PacDrive Controller P600 Page 25 Page 26 Transport storage unpacking Transport Avoid heavy shocks and or vibrations Check each device for transport damage and inform the shipping company imme diately if necessary Storage Store the devices in a clean dry room The air temperature should be between 25 C and 70 C Temperature variations must not exceed 30 K per hour Unpacking Check that delivery is complete Check all devices for transport damage Type plate The type plates contain all important information PacDrive Controller P600 ELAU AG PSOO z gt e x e w a m technical type plate UPS type plate optional Windows XP license label logistic type plate PD_P600_Typenschild_us fh8 Figure 5 1 Type plates on PacDrive controller P60
92. e system supports the user with its comprehensive diagnostic sys tem The diagnostic messages can be read out with the EPAS 4 automation toolkit The PacDrive system contains a powerful message logger in which additional diagnostic information is recorded The diagnostic messages are generally displayed on the machine via a control pan el In the event of an error read the diagnostic message and contact your machine manufacturer Detailed diagnostic information can be found in the online help section of the EPAS 4 automation toolkit Indicators and control elements 20 00 oo ao Figure 4 1 PacDrive controller P600 control unit If the cover of the PacDrive controller is closed you will see four vertically arranged indicators pow control voltage indicator wd watchdog indicator err error indicator bus err SERCOS real time bus error indicator The LEDs signify various operating states or errors In addition to the LED displays further information about the operating status of the PacDrive controller is given on the 4 line LCD display Line 1 firmware version currently in use Line 2 current IP number of the PacDrive controller PacDrive Controller P600 Page 19 The horizontally arranged buttons on the PacDrive controller currently have no func tion pow control voltage display The pow LED indicates the state of the control voltage OFF No control voltage
93. e 2 Diagnosis messages In the power supply PS 4 the Excess current warning will be triggered in hardware code xx3xxx if a DC bus current of more than 50A is present for at least ims The error message 107 Excess current see 8 5 2 8 107 Excess current will be generated if the DC bus current reaches 55A Too many consumers e g ServoDriveSCL is connected to the DC bus gt Use an additional PS 4 power supply and distribute the power supply of the consumers gt The existing arrangement of devices may be made adequate by adjusting one of the applications e g decreasing acceleration 175 Bleeder overload Diagnosis class see 8 1 Diagnosis Classes standard 9 Reaction see 8 2 Reactions E Filter type 2 Diagnosis messages If a Bleeder I2t of 86 is reached with MC 4 and PS 4 the Bleeder overload mes sage may be triggered This message is assigned by default to diagnosis class 9 and therefore is not visible If you want to respond to the diagnosis message you can reconfigure the diagnosis class e g diagnosis class 7 or 8 At 100 Bleeder I2t the bleeder will be deactivated without further notification as before Only if the DC bus voltage increases to 860V the error message as previ ously 108 Excess voltage see 8 5 2 9 108 Excess voltage is generated The braking energy of the motor that is fed back into the DC bus is too high and therefore results in voltage build up gt Brake at a slower
94. e 8 2 Reactions D The internal temperature of the device is too high With SCL the internal power supply may also be overloaded A 103 PowerOff due to cooling error see 8 5 2 4 103 Pow erOff due to cooling error error may result 129 Overload PowerOff of output stage warning Diagnosis class see 8 1 Diagnosis Classes standard 6 Reaction see 8 2 Reactions D The output stage is overloaded A 120 Overload PowerOff of output stage see 8 5 2 21 120 Overload PowerOff of output stage error may result 130 Bleeder temperature rising Diagnosis class see 8 1 Diagnosis Classes standard 6 Reaction see 8 2 Reactions D The bleeder is overloading A 121 Bleeder temperature too high see 8 5 2 22 112 Bleeder temperature too high error may result 131 Phase failure of power supply Warning Diagnosis class see 8 1 Diagnosis Classes standard 6 Reaction see 8 2 Reactions D Failure of one or two phases in the mains connection of the servo amplifier If the warning persists for 10 s or longer a 110 Phase failure power supply see 8 5 2 11 110 Phase error power supply error will occur 132 Following error Diagnosis class see 8 1 Diagnosis Classes standard 6 Reaction see 8 2 Reactions D A position following error in the position controller of the servo amplifier has occurred that is greater than the FollowingLimit parameter The following error monitoring is too strict gt Increase the Following
95. e appendix Spare Parts To ensure that the equipment functions constantly and is always ready to go it is im portant to have a supply of the most important components on hand Incompatible replacement device System may not be working properly following component replacement Devices may only be replaced by devices with the same hardware configuration and software version Indicate the following information on the spare part order Item name e g C600 10 1 1 1 00 Item no e g 13130262 Hardware code e g HW 02200100 Software version e g SW 00 16 20 This information can be found on the type plate of the equipment see also Transport storage unpacking in the PLC configuration of the PacDrive system Repairs Please ensure that you complete the error report in the appendix when sending back defective components You can also copy the error report and send it by fax To avoid damage in transport and to guarantee that the repair process goes smoothly follow the method outlined in the chapter entitled Device Replacement PacDrive Controller P600 Page 29 6 3 EMC Rules The mains voltage is stored by rectification in the DC circuit of the servo amplifier to control and regulate the motors This stored power is supplied to the motor by precise on and off switching using six semi conductor switches The steep rise and fall in volt age puts considerable demands on the isolating stability of the motor winding An
96. e operating system VxWorks RT Applications operating system Windows XP Programming Programming language IEC 61131 3 CFC can also be used Instruction list IL Ladder diagram LD Function block diagram FBD languages Sequential function chart SFC Structured text ST Continuous function chart CFC serial interfaces Interfaces COM1 RS232 X17 COM2 RS485 X18 Network connection Ethernet 10 100 Base T X10 Field bus connection PROFIBUS DP Master Slave 12 MBaud X20 or CAN 2 0A or CANopen X19 DeviceNet Slave Ethernet IP Adapter EtherNet IP Scanner projected optional hardware module required 2 cable adapter required Page 36 PacDrive Controller P600 ELAU AG Parameters Real time bus interface Value SERCOS interface 16 MBaud X14 X15 PacNet interface 2 PacNet interfaces X12 X13 Master encoder interface 1 SinCos master encoder or 1 incremental master encoder X11 HMI interface User display devices RS485 Modbus or PROFIBUS DP HMI software tools OPC server for PacDrive controller P600 Windows XP or for an additional PC Windows NT 2000 XP or Windows CE Diagnostic interface for remote maintenance Web server or modem Communication protocols http ftp SMTP email integrated trace recorder soft 8 channels ware oscilloscope resolution 1 ms integrated data logger for diag 27
97. e second type of telegrams the drive telegrams DT They send the current positions and status information of the drives to the controller The times at which the DTs are sent are determined during the phase startup and are then sent to the MST At the end of the cycle the controller also sends its master data telegram MDT after the DTs This telegram contains a range for each drive that includes its target position and controller information During those times in which no telegrams are transferred the controller sends a con tinuous dummy signal that is forwarded by the drives For the controller there are primarily three different ways to diagnose communication errors the letters in parentheses are used by ext diagnose for identification pur poses Error in synchronization telegram If functioning properly the synchronization telegram MST sent at the beginning of a cycle is received by the master only a little later again As a result the means by which this telegram is received can be controlled This minimal delay is caused by the signal runtime in the ring The controller specifically checks whether the telegram arrives before e MST early or after I MST late the expected reception window which results in a simple SERCOR cycle error If an MST is not received in the appropriate time window over PacDrive Controller P600 Page 65 two sequential cycles an MST miss M MST miss will be detected and display
98. ection 4 8 DC 24 V Supply voltage 15 25 2 DC OV Supply voltage 1 5 mm 3 UL for digital outputs DC 24 V 1 5 mm 15 25 4 LO for digital inputs outputs 1 5 mm 5 DC 24 V 15 25 1 5 mm 6 DCOV Supply voltage 1 5 mm 7 WD Watchdog relay 1 5 mm 8 WD Watchdog relay 1 5 mm Table 7 2 Electrical connections C400 C600 P600 X1 ELAU AG PacDrive Controller P600 Page 39 Page 40 X1 1 24V X1 5 24V X1 2 0V X1 6 OV X1 3 UL X1 4 OVL X1 input connection of power supply simplified supply voltage internal supply voltage for digital outputs inputs PD_C4_600_P600_X1_us fh8 Figure 7 1 Electrical connections C400 C600 P600 X1 input connection Switching off the control voltage Data loss possible Use a UPS Only switch off the control voltage of the PacDrive controller after the Windows XP operating system has been properly shut down and the axes of the system are in a safe position Refer also to the EPAS 4 online help function Sys Shutdown X2 Digital outputs Pin Designation Meaning Max cross section 1 0 00 digital output 1 1 5 mm 2 0 01 digital output 2 1 5 mm 3 0 02 digital output 3 1 5 mm 4 0 03 digital output 4 1 5 mm 5 0 04 digital output 5 1 5 mm 6 0 05 digital output 6 1 5 mm 7 0 06 digital output 7 1 5 mm 8 0 07 digital output 8 1 5 mm 9 0 08 digital output 9
99. ed The IEC program does not match the active configuration gt Transfer the project again 313 Excessive cycle time overrun Diagnosis class see 8 1 Diagnosis Classes standard 4 The fatal cycle error of an IEC task is reported when the 10x cycle time see task configuration is exceeded The task then receives the status of error This situation can be solved only by resetting the controller Online gt Reset PacDrive controller The cycle time monitoring of the IEC task refers to the load parameter that is displayed in the IEC task expansion object in the controller configuration The processing time of a parameter or system functional block that is being called is taking too long gt Check the program e g access to SERCOS Parameter or WaitTime function 7 The time interval in the task configuration is too short gt Increase the time interval in the task configuration 314 Program file defective only in versions below 00 07 00 Diagnosis class see 8 1 Diagnosis Classes standard 4 A system error has occurred The check sum of the program is incorrect gt Transfer the program again 315 Library function not implemented Diagnosis class see 8 1 Diagnosis Classes standard 4 The program used an interface library that is not supported or not fully supported by the current PacDrive controller For the name of the function see DiagExtCode Firmware in the PacDrive controller is obsolete gt
100. ed via a multiple SERCOS cycle error Receive error of drive telegrams The controller also monitors the receipt of drive telegrams If one of the drive telegrams is not received in a cycle or an error occurs with the CRC monitoring of the telegram then a receive error r Receive Error will be indicated and displayed via a simple SERCOR cycle error If receive errors occur with multiple telegrams in a cycle they remain a simple SERCOR cycle error Only after receive errors are signalled in two sequential cycles this can also be dif ferent telegrams will a receive miss R receive miss be detected and a multiple SERCOR cycle error will be triggered Signal faults The dummy signal that is continuously sent out by the controller also allows commu nication faults in the SERCOR ring to be determined apart from the telegrams If the edges of the signal move beyond a specified window it means that there is a receive distortion d Receive Distortion which is displayed with a simple SERCOS cycle error If no edges arrive within a specific time period it means there is a fiberoptic break F Fiberoptic Break which is displayed with a multiple SERCOS cycle error Unfortunately the controller cannot detect errors during the master data telegram Another important point in evaluating the diagnosis information is the physical se quence in the SERCOR ring This is in no way dependent on the telegram sequence during a com
101. ed 0 25 mm 7 CAN_H bus line high 0 25 mm 8 reserved 0 25 mm 9 EXVCC ext supply trans 0 25 mm Table 7 14 Electrical connections C400 C600 P600 X19 PacDrive Controller P600 ELAU AG An adapter is required to connect to DeviceNet see order numbers NOTE An adapter is required to connect to DeviceNet see order numbers in accessories X20 profibus db O Pin Designation Meaning Max cross 9 5 section 1 PE Shielding 0 25 mm 2 reserved 0 25 mm 3 RxD TxD P Data P 0 25 mm 6 4 4 CNTR P Control signal P 0 25 mm 5 DGND Signal ground 0 25 mm 6 VP Supply voltage 0 25 mm 7 reserved 0 25 mm 8 RxD TxD N data N 0 25 mm 9 reserved 0 25 mm Table 7 15 Electrical connections C400 C600 P600 X20 Connector A PROFIBUS connector must be used to connect to the 9 pole PROFIBUS outlet because the bus terminal resistors are in this connector The possible PROFIBUS connectors with different cable outlets are illustrated below EST 49 m oO oj D im io oO ooo 000 i pe B L B Wess PR
102. ed con troller it is perfectly suitable for peripheral set up It is available with single or multi turn encoders and configures itself with the aid of the electronic type plate in the iSH itself PacDrive Controller P600 Page 17 The highlights compact design 3 5 times peak torque Integrated SERCOS interface High resolution single or multi turn encoder Protection class IP 65 simple wiring superior reliability PacDrive PS 5 The power supply unit PacDrive PS 5 features compact and autonomous design for control cabinet installation as well as state of the art technology All PacDrive iSHs are supplied using just one connecting cable via the quick to install PacDrive PS 5 Which means that the PS 5 fits seamlessly into the extremely flexible modular drive concept The highlights Integrated mains filter and bleeder Intermediate circuit power for up to 16 iSH depending on the application Integrated SERCOS interface fully diagnosable due to integrated controller simple to assemble PacDrive DB 5 PacDrive DB 5 is the link between PS 5 and iSH Depending on the number of drives anywhere from 1 to 4 iSH motors can be connected When operating more than 4 drives simply expand the system using one or more DB 5s The highlight 1 4 connections for iSH motors or easily expandable with more DB 5s Page 18 PacDrive Controller P600 ELAU AG 4 NOTE 4 1 ELAU AG Indicators and control elements diagnosis The PacDriv
103. ed to a query with an incorrect monitoring response An unexpected status was received CANopen node has not processed the reset or a configuration has not been sent gt Electrical bus connection faulty or incorrect PacDrive Controller P600 ELAU AG ELAU AG gt Check the wiring 756 CanOpen DPM access timeout Diagnosis class see 8 1 Diagnosis Classes standard 4 Unable to read one or more input application objects Meaning of ext diagnosis Displays the size of the non readable application object Software error module overload gt Contact your ELAU representative 757 CanOpen config error Diagnosis class see 8 1 Diagnosis Classes standard 4 An error has occurred while configuring the individual CANopen slaves Meaning of the ext diagnosis Controller MAx 4 Structure xxxxSyyzzvvNcc Upper case characters appear directly Lower case characters have the following meanings Character Meaning XXXX Cop Index in hex display yy Cop Sublndex in hex display zz Meaning of Cop Index is displayed as follows MT Map entry for send PDO MR Map entry for receive PDO T send PDO R receive PDO Index has nothing to do with PDO vw Number of the respective PDOs in hex display cc Node number in hex display CANopen node not reachable via Sdo access e g node still in startup phase node not available mapping of application object not permitted application ob ject no
104. en detected The MDT data may now be incorrect due to this fault In this case the data of the last cycle is reused Temporary faults can have the following causes Signal distortion Loss of more than 10 signal edges fibreoptic b reak Failure of the master synchronous telegram MST Failure of the master data telegram MDT Signal over the SERCOS fiberoptic conductor is incorrect gt Check the intensity setting in the PacDrive controller and on the servo amplifier gt Check the fiberoptic conductor a EMC problems gt Check the wiring SCL 055 motors are connected at the PacDrive controller The SCL 055 motors in the PacDrive PD 8 box are not connected properly gt Check the connection of tne SCL 055 motors in the PacDrive PD 8 box Simply placing jumpers on the desired terminals will not resolve the problem Slaves must not be inserted into the following SERCOS slot PacDrive Controller P600 Page 95 Page 96 In addition follow the notes in the SCL and PS 4 and PD 8 operating in structions 170 DrvEncPosition reading error Diagnosis class see 8 1 Diagnosis Classes standard 2 Reaction see 8 2 Reactions B The error message is triggered when an error occurs as the position is being read from or written to the electronic type plate of the motor Writing to the position occurs by using the function DrvEncSetPosition dd This diagnosis message replaces the diagnosis message 141 Reading erro
105. en set properly in the controller gt Check the interrupt settings based on the operating instructions for the option modules 780 Frequence gt 1MHZ Diagnosis class see 8 1 Diagnosis Classes standard 5 The incremental speed to be output was too high Incremental speed too hign Position loss at the incremental encoder output Amplified incremental encoder inputs or systems lose position reference Carry out the referencing of the amplified incremental encoder inputs or systems again Note the causes and troubleshooting measures listed below The speed of the encoder to be simulated is too high gt Reduce the speed of the encoder The resolution and or FeedConstant parameters have not been entered cor rectly gt Check the parameters 781 No connection to encoder Diagnosis class see 8 1 Diagnosis Classes standard 5 The jumper in the encoder cable connecter to the controller was not detected This monitoring function is active in the MAx 4 optional INC 4 optional module when connecting an incremental encoder The monitoring function for the SinCos encoder is active on the Cx00 and P600 controller Wiring error Encoder cable to the controller removed gt Plug in the encoder cable Wiring error Encoder cable is defective gt Check the encoder cable and replace if necessary 782 Track error Diagnosis class see 8 1 Diagnosis Classes standard 5 A hardware encoder error occurred
106. en triggered with the Dia gMsgWrite function The error was triggered by the IEC program gt See description of your IEC program It is possible to display an additional error text with the DiagMsgWrite function 401 IEC diagnosis message class 3 Diagnosis class see 8 1 Diagnosis Classes standard 3 A diagnosis message from the IEC program has been triggered with the Dia gMsgWrite function E The error was triggered by the IEC program gt See description of your IEC program Itis possible to display an additional error text with the DiagMsgWrite function 402 IEC diagnosis message class 4 Diagnosis class see 8 1 Diagnosis Classes standard 4 A diagnosis message from the IEC program has been triggered with the Dia gMsgWrite function The error was triggered by the IEC program gt See description of your IEC program It is possible to display an additional error text with the DiagMsgWrite function 403 IEC diagnosis message class 5 Diagnosis class see 8 1 Diagnosis Classes standard 5 A diagnosis message from the IEC program has been triggered with the Dia gMsgWrite function PacDrive Controller P600 Page 115 8 5 6 Page 116 The error was triggered by the IEC program gt See description of your IEC program Itis possible to display an additional error text with the DiagMsgWrite function 404 IEC diagnosis message class 6 Diagnosis class see 8 1 Diagnosis Classes standard
107. er the re initialization or referencing of the system is secured by the IEC program use the SysReset or the Prg Wiring error Incorrect bus topology gt Check terminals transmission lines EMC faults gt Check the wiring and EMC protection Ext diagnosis asynchronous A synchronization error has occurred The TouchProbes on the BT 4 DIO1 are not working gt Check the jumper cable that connects the controller to the optional PN 4 module in the controller Ext diagnosis clock miss A communication error has occurred in PacNet This may be due to a variety of Causes PacNet loop not closed PacNet terminating plug is missing A module connected to PacNet failed no power gt Check the PacNet loop and all the modules in the loop 734 Bus short circuit detected Diagnosis class see 8 1 Diagnosis Classes standard 4 The number of bus short circuits specifed by count was detected Slave fault gt Check the slave device 7 EMC problem gt Check the wiring s Wiring error Cable is defective gt Check the wiring 735 Reject bus telegrams Diagnosis class see 8 1 Diagnosis Classes standard 4 The number of telegrams specified in count was rejected One or more telegrams could not be transmitted to the bus This occurs for example when there are no further slaves in the bus which is confirmed by the telegram Wiring error Cable is defective gt Check the wirin
108. es 111 Excessive following error Diagnostic class see 8 1 Diagnosis Classes standard 2 Reaction see 8 2 Reactions B A very large following error has occurred more than 8 times the value of the Follo wingLimit This error normally only occurs in conjunction with the CAM movement functions e g MultiCam gt Check curve data The axis should be RPM regulated gt Set parameter Pos_P_Gain to 0 112 Communication error real time bus Diagnosis class see 8 1 Diagnosis Classes default 2 Reaction see 8 2 Reactions B The servo amplifier did not receive a valid telegram over the real time bus SER COS The diagnosis message is not reported in the system because when an error occurs the motor controller MC 4 PS 4 SCL cannot report the diagnosis code to the controller e g C400 over the SERCOS bus In this case the 506 Fatal SERCOS PacDrive Controller P600 ELAU AG ELAU AG error MASTER see 8 5 6 7 506 Fatal SERCOS error MASTER diagnosis code is reported The intensity of the fiber optic signal from the preceding device is too low or too high gt Set the intensity according to specifications Hardware error Fibreoptic conductor is defective signal is too weak as a result of deterioration gt Increasing the intensity may solve the problem gt Replace the fiberoptic conductor Hardware error Defective PacDrive controller servo amplifier gt Replace PacDrive contr
109. essage occurs in conjunction with the Overload Functions keep in mind that in this case the ramp down time is firmly set to 800ms and is thus triggered independently from StopTimeLim In this case you need a more powerful motor servo amplifier combination Encoder in the motor defective or commutation not OK PacDrive Controller P600 Page 87 Page 88 gt Replace motor 141 EncoderPosition Reading Error Diagnostic class see 8 1 Diagnosis Classes standard 5 Reaction see 8 2 Reactions D An error occurred when reading the calibration position from the motor encoder The diagnostic message will be replaced as of MotorController Firmware 00 20 00 by the diagnostic message 170 Reading error DrvEncPosition see 8 5 2 71 170 DrvEncPosition reading error The function DrvEncSetPosition was called up but could not be properly proc essed gt Call up function DrvEncSetPosition again Encoder in motor defective gt Replace motor 142 Board PowerOff due to overtemperature Diagnosis class see 8 1 Diagnosis Classes standard 2 Reaction see 8 2 Reactions B The temperature of the board inside the SCL housing is too high z Ventilation is inadequate or the ambient temperature is too high gt Check the switching cabinet ventililation system gt If installed make sure the air conditioning unit if available is functioning prop erly Hardware error The temperature sensor is defective gt
110. essage only after the re initialization or referencing of the system is secured by the IEC program If necessary use the SysReset or the PrgResetAndStart function Wiring error The encoder cable is not plugged in correctly or is defective gt Check the encoder cable and replace if necessary Hardware error The SinCos encoder is defective gt Replace the encoder Hardware error The SinCos encoder interface in the controller is defective gt Replace the controller 7xx field buses and expansion module diagnosis messages 700 CAN layer2 driver error Diagnosis class see 8 1 Diagnosis Classes standard 4 Unable to start the driver for the CANopen module No CAN module in the PacDrive controller gt Order and install the CAN module Incorrect I O address or interrupt setting PacDrive Controller P600 Page 125 Page 126 v Check the I O address Check the interrupt setting v Hardware error CAN module defective gt Replace the CAN module Hardware error Controller is defective gt Replace the controller 701 CAN layer init error Diagnosis class see 8 1 Diagnosis Classes standard 4 Initialization has failed CAN module overloaded unable to process command messages fast enougn gt Hardware error CAN module defective Replace the module va 702 CAN layer2 single error detected Diagnosis class see 8 1 Diagnosis Classes standard 4 A send or receive e
111. estarting VxWorks via the Tool PacDrive Settings reset Restarting Windows XP and VxWorks Shut down Windows XP properly with the option restart or shut down on off Interrupt power supply This activates the controller s supply via the UPS and shuts down Windows XP on off PacDrive Controller P600 ELAU AG ELAU AG The system is not in a secure position Proper shutdown of the system cannot be guaranteed Destruction of system or damage to parts of system possible Put system in a secure position Restarting Windows XP and VxWorks f necessary program the IEC application to put the system into a secure position before shutting down control via IEC Event Task and Shutdown Event Procedure for switching the PacDrive controller on off and resetting it on off button Button used to switch the PacDrive controller on off gt Press button when the PacDrive Controller P600 is switched off completely wired and connected to the power supply Device switches on Press button when system is running The controller switches the device off If necessary put the system in a secure position before switching it off vs vs If only the VxWorks real time system is to be restarted use the Software Tool Pac Drive Settings or tne Automation Toolkit EPAS 4 to perform a reset If Windows XP does not run smoothly anymore first check to see whether a proper shutdown of Windows XP is still possible and perfor
112. g PacDrive Controller P600 ELAU AG ELAU AG 736 No I O data exchange with slave Diagnosis class see 8 1 Diagnosis Classes standard 4 Slave with bus address preceded by S1 is not exchanging cyclical I O data Slave is not configured correctly gt Check the configuration based on the documentation for the slave 737 Double IEC address assigned Diagnosis class see 8 1 Diagnosis Classes standard 4 The IEC start address for the input or output area was assigned more than once DiagExtCode Slxxx Slyyy The slaves with the Profibus addresses xxx and yyy have been specified with the same start address for the IEC input data O Slxxx Slyyy The slaves with the Profibus addresses xxx and yyy have been specified with the same start address for the IEC output data Slaves are not configured correctly gt Check the configuration gt Adjust the addresses manually or select Addresses automatic in the properties dialog box of the Profibus master object in the control configuration 738 Conf I O data gt permissible IO area Diagnosis class see 8 1 Diagnosis Classes standard 4 The maximum IO data size has been exceeded DiagExtCode D xxx gt yyy The maximum input data size of yyy bytes has been exceeded by the configured data size of xxx bytes O D xxx gt yyy The maximum output data size of yyy bytes has been exceeded by the configured data size of xxx bytes Slaves are not configured correc
113. g purposes Structure lt last error entry gt lt error group gt lt cause of error gt VoltageError TempError EnvError V3 3 lt Vmin V5 lt Vmin V 12 lt Vmin V 12 lt Vmin Vin lt Vshutd VAccu lt Vshutd Vin_jit lt Vshutd capacitance LTC error Vin gt Vmax VAccu gt Vmax V3 3 gt Vmax V5 gt Vmax V 12 gt Vmax V 12 gt Vmax VcpuCore lt Vmin VcpulO lt Vmin VM2 5 lt Vmin VM3 3 lt Vmin VM5 lt Vmin VM 12 lt Vmin VM 12 lt Vmin VcpuCore gt Vmax VcpulO gt Vmax VM2 5 gt Vmax VM3 3 gt Vmax VM5 gt Vmax PacDrive Controller P600 Page 71 Cause of error TempError Cause of error EnvError Example of message text Page 72 VM 12 gt Vmax VM 12 gt Vmax Vin lt Vmin VAccu lt Vmin TAccu lt Tmin TLM75 lt Tmin TCPU lt Tmin TM1 lt Tmin TM2 lt Tmin TAccu gt Tshutd TLM75 gt Tshutd TCPU gt Tshutd TM1 gt Tshutd TM2 gt Tshutd TAccu gt Tmax TLM75 gt Tmax TCPU gt Tmax TM1 gt Tmax TM2 gt Tmax I2C bus failed LM75 failed fan1stop shutd fan1istop off fan2stop shutd fan2stop off fan3stop shutd fan3stop off 1 TempError TLM75 gt Tshutd gt The error was in the last error entry created It is a temperature error in which the LM75 sensor detected a temperature that is too high The shutdown lim
114. g temperature without UPS Insulation class 5 40 C Operating temperature with UPS relative humidity 25 70 C Storage and transport without UPS 25 50 C Storage and transport with UPS Degree of pollu tion 2 no thawing 5 85 climatic category 3K3 EN 60 721 Approval Approval CE UL cUL Table 7 1 Technical information PacDrive controller P600 Page 38 PacDrive Controller P600 ELAU AG 7 2 Connection overview O gg 0 l PCI slot PCI slot X16 keyboard I y control voltage X1 watchdog X6 DVI digital video interface X17 COM1 serial interface RS232 SEER 3 ED digital outputs X2 optional S X7 firewire X8 USB x9 USB X18 COM2 serial interface RS485 X10 ethernet X11 master encoder SinCos optional X19 CAN CANopen digital inputs X3 touchprobe and X4 fast inputs X12 pacnet 0 X13 pacnet 1 X14 motion bus SERCOS IN analog 7 in outputs a 8 6 X20 profibus dp oao o X15 motion bus SERCOS O OUT I DVD ROM HDD max stud torque 0 8 Nm shield connection PD_Anschluss bersicht_P600_us FH8 1 3 Electrical connections X1 Control voltage and watchdog 1 5 Designation Meaning Max cross E s
115. g you can proceed in one of two ways either import the user project again using a PC on which the automation toolkit EPAS 4 is installed or remove the controller s already used CompactFlash card in need of repair and insert it into the new controller Ensure that the card is functional gt Store the PacDrive controller in need ofrepair in a suitable package for transport gt Put the system into operation again Cleaning When correctly installed the devices are largely maintenance free Dust and contam inants predominantly due to cool air currents can be removed by disconnecting the devices from the mains dismantling them and blowing them out with dry compressed air maximum 1 bar Commissioning We strongly recommend using ELAU staff for the initial start up This is not only for reasons of warranty but at the same time the equipment will be checked the optimal configuration recorded and operating staff can be instructed Procedure for initial start up gt Remove packaging Check devices for sound condition Only put undamaged devices into operation Check delivery for completeness Check for correct assignment of optional plug in positions Check data against type plates Yv v Vv Refer also to chapter entitled Device Replacement see 6 4 Device replacement gt Observe requirements of installation site gt Observe requirements of the protection class and the EMC regulations gt Install de
116. gs all the causes for error de pendent controller deactivations The next time the controller is started up the error logger is analyzed and the cause of the error can be output in the message logger In addition a more specific message is displayed 055 Debug message cause by hardware monitor see 8 5 1 54 055 Hardware Monitoring Debug Message that can be enabled by the MsgFilter Parameter through the EPAS 4 message logger This message is intended to be a debug message and outputs the exact cause of the de activation i The DiagExtCode defines the error further high or low voltage high or low tem perature fan error temperature sensor error Voltage lt Min Voltage gt Max Temp lt Min Temp gt Max Fan error LM75 error gt Contact your ELAU representative 9xx Software diagnosis messages 900 Software error suspend Task Diagnosis class see 8 1 Diagnosis Classes standard 4 This error should not occur while the PacDrive system is running gt Contact your ELAU representative 901 Software error invalid opcode Diagnosis class see 8 1 Diagnosis Classes standard 4 This error should not occur while the PacDrive system is running gt Contact your ELAU representative 902 Software error page fault Diagnostic class see 8 1 Diagnosis Classes standard 4 This error should not occur during operation of the PacDrive system An firmware version older than lt V00 10 00 was played onto a PacDr
117. guration that does not exist in the real system The DiagExtCode parameter in the control configuration or message logger can be used to determine the type of the hardware module z A non existent analog input or physical encoder was entered into the control configuration gt Check the control configuration 7 Hardware error The hardware module was not detected or is defective gt Replace the PacDrive controller or optional module 208 Too many real axes in config Diagnosis class see 8 1 Diagnosis Classes standard 4 The number of axes in the control configuration is too large Page 100 PacDrive Controller P600 ELAU AG NOTE NOTE ELAU AG In V00 15 00 or higher the diagnosis message is replaced by the 518 Too many real SERCOS Slaves see 8 5 6 18 518 Too many real SERCOS Slaves diagnosis mes sage e The number of axes for the CycleTime is too large gt Check the CycleTime The PacDrive controller has a limited number of axes gt Check the PacDrive controller type by referring to the type plate 209 Last boot failed Diagnosis class see 8 1 Diagnosis Classes standard 4 A drop in the control voltage of the PacDrive controller a reset of the PacDrive con troller or a fatal error occurred in the last boot procedure Use DiagExtCode to localize the problem While booting the PacDrive controller logs the individual phases in the NvRam If this results in a fatal error err LED continually ON t
118. hange data Data Enable Sync encoder outputs distribute encoder data to the sync encoder in puts 059 UPS active IEC control task running 060 control task active on changing state Filter type 13 extended system messages The control task can react to certain events in a fast task The UPS uses this tool to delay the shutdown of the PacDrive controller and thus enables the execution of ap plication specific activities before the system shuts down When changing UPS state machine in the following cases an event is triggered that starts the control task UPS State 3 UPS active no power UPS State 4 UPS active system shutdown started UPS State 6 UPS active system temperature too high The 060 control task active on changing state diagnosis message is displayed ifa control task that has been started by UPS is still active on the following UPS state changes UPS State 3 gt UPS State 4 UPS State 3 gt UPS State 6 UPS State 6 gt UPS State 4 1xx Drives diagnosis messages 100 I2T Motor Diagnosis class see 8 1 Diagnosis Classes standard 2 Reaction see 8 2 Reactions B The motor is overloaded or the power supplied to the motor is too high The integrator 12t parameter has increased to 100 The motor I2t monitoring is performed with the help of an integrator that is derived from the following equations l current Inm Delta t 45s 2 1 PacDrive Controller P600
119. heck calculation of motor and actuator Hardware error The temperature sensor is defective Replace device 102 Motor PowerOff due to overtemperature Diagnosis class see 8 1 Diagnosis Classes standard 2 Reaction see 8 2 Reactions B The internal motor temperature temperature switch in the motor is at least 2 seconds too high approx 130 C gt v vV V u Wiring error The temperature switch in the motor coil is not connected properly Check the wiring Wiring error The shielding of the motor cable is not attached properly Check the shielded terminal on the bottom of the MC 4 servo amplifier and the terminal boxes of the SM motor The holding brake is not released Release the brake The motor is overloaded Drive the system at a slower speed Check the drive sizing Use a larger motor for this application Commutation error i e the encoder is not aligned leveled Align level the encoder Hardware error The temperature switch in the motor coil is defective PacDrive Controller P600 Page 75 Page 76 gt Replace the motor 103 PowerOff due to cooling error Diagnostic class see 8 1 Diagnosis Classes standard 2 Reaction see 8 2 Reactions B The internal temperature of the device is too high 7 Insufficient ventilation or ambient temperature too high gt Check device fans and ventilation slots if available gt Check ventilation in switch cabinet 7 Hardware error The tem
120. hen the next boot will use the default configuration and diagnosis message 209 will be triggered If the PacDrive controller is started in minimal boot mode the configuration and the control configuration parameters will be set to their default values TCP IP address is set to its default value A configured modem is not available Subsequent errors will result when loading the IEC program e g diagnosis messages 200 and 206 The third startup will occur in normal boot mode If this does not happen the default configuration will used for the next startup and the process will be repeated DiagExtCode Meaning 1 Boot procedure begins before kernel initialization 2 Kernel initialization complete FTP server priority adjusted Time Slicing switched on System clock No Tick per second defined 3 Init logger and NvRam complete interrupts blocked 31 Before ScanDisk 4 Diag created messages sent before ObjectContr new 10 Begin Constructor ObjVerObjektContr Tasklock active 11 Config and Par file read 12 Config file evaluated generate before objects 13 generate after objects 14 set after CycleTime 15 after init of Moni Max LogGeb VirtGeb PhyGeb construction of RTP before filling in indication table PacDrive Controller P600 Page 101 NOTE Page 102 DiagExtCode Meaning 16 set after parameter 17 after Sercos startup 18 after runt
121. here is at least 4MB of available memory after the dynamic memory area is reserved also see the Memoryfreeparameter The dynamic memory area to be reserved is too high gt Reduce the DynIECDataSize parameter 338 UPS accu error Diagnosis class see 8 1 Diagnosis Classes standard 5 The battery is not sufficiently charged Ext diagnosis State 2 z The PacDrive controller has been switched off for too long gt Switch on the PacDrive controller The battery will be charged automatically when the PacDrive controller is on The UPS has been operating in the battery mode State 3 for an extended period gt Check the supply voltage Switch on the PacDrive controller if it is off The battery will be charged automatically when the PacDrive controller is on v PacDrive Controller P600 ELAU AG 8 5 5 ELAU AG The battery capacity is insufficient due to aging gt Contact your ELAU representative 339 UPS active system temperature too high Diagnosis class see 8 1 Diagnosis Classes standard 5 The temperature in the PacDrive controller is too high Ext diagnosis State 6 Ambient temperature too high gt For further details please refer to the technical data on the PacDrive controller see operating instructions 4xx IEC Task diagnosis messages 400 IEC diagnosis message class 2 Diagnosis class see 8 1 Diagnosis Classes standard 2 A diagnosis message from the IEC program has be
122. hield 1 5 mm 16 AO 1 analog output 1 1 5 mm 17 A GND AO 1 analog ground 1 5 mm 18 PE shield 1 5 mm Table 7 6 Electrical connections C400 C600 P600 X5 X5 input connection of analog inputs simplified R3 X5 1Al 0 b gt channel 1 R4 gt X5 3 Al O gt IL 7 jt R1 X5 2 J 0 1 1 N and ESE ae ee R5 X5 10Al 1 1 1 D C channel 2 R6 gt X5 12Al 1 D j2 R2 X5 11J 1 1 D AGND X5 5 gt 12V R1 R2 500R od oy R3 R8 1k R8 X5 6 gt h X59 gt j PE shield PD_C4_600_X5 Anain_us fh8 Figure 7 2 Electrical connections C400 C600 P600 X5 input connection PacDrive Controller P600 ELAU AG X6 DVI 17 ra Pin Designation Meaning Max cross a section ku Jen 1 RX2 data2 En 2 rx data2 Be ve 3 GND GND data2 4 shield 4 N C reserved 5 N C reserved 6 DDC Clock DDC clock 7 DDC DAT DDC data 8 N C Analog V sync 9 RX1 data1 10 RX1 data1 11 GND GND data1 3 shield 12 N C reserved 13 N C reserved 14 5V 5 V power 15 GND ground 16 IHOT hot plug det 17 RXO data0 18 RXO data0 19 GND GND data0 5 shield 20 N C reserved 21 N C reserved 22 GND GND clock shield 23 RXC clock 24 RXC clock C1 N C analog red C2 N C analog green c3 N C analog blue C4 N
123. iagnosis Classes standard 7 Reaction see 8 2 Reactions E Starting at a motor speed of lt 75 rpm 112 5 rpm for SRO58 150 rpm for SM070 the maximum motor current is restricted to 70 of the top current of the servo amplifier e g MC 4 This is a security measure to protect the final stage of the servo amplifier when reaching the stop position The message will only be generated from V00 11 00 ifthe target current is actually restricted to 70 of the top current PacDrive Controller P600 ELAU AG ELAU AG In older versions the message is generated if the restriction is activated even ifthe target current is less than 70 of the top current The axis has reached the stop position gt Check traversing range of the axis 134 External 24V power supply too low Diagnosis class see 8 1 Diagnosis Classes standard 7 Reaction see 8 2 Reactions E The control voltage 24 V DC is too low Control voltage too low gt Check the control voltage see the technical data on the device 135 Undervoltage warning Diagnostic class see 8 1 Diagnosis Classes standard 6 Reaction see 8 2 Reactions D An attempt has been made to start the drive but the DC link voltage is too low For 400 V AC devices smaller than 480 V DC smaller V00 20 00 450V DC For 230 V AC devices smaller than 240 V DC smaller V00 20 00 225V DC Exception PS 4 smaller than 260 V DC As of V00 20 00 the diagnostic message is also gene
124. ime system start 19 after RTP start before IEC program load 20 after IEC program load 5 after ObjectContr new 6 after axis release before WatchDogEin RAM lt 32MB Insufficient RAM in the PacDrive controller Procedure Read out and evaluate EPAS 4 connection with TCP IP default address or serial message logger important DiagExtCode The DiagExtCode can be used to read which phase of the boot procedure was executed correctly the last time If the PacDrive controller is booted using the minimal configuration settings LED blinks quickly then the program parameter and configuration will always be available for download in the download box when you log in with the EPAS 4 V00 07 00 or higher This does not indicate different versions of the files on the PacDrive controller Since the PacDrive controller was booted in the default configuration the 206 Faulty type code of LogAdr see 8 5 3 7 206 Faulty ObjType of LogAdr diagnosis message will be triggered when downloading the IEC program since the program will use pa rameters that are not available The SysReset function was called although the boot procedure of the PacDrive controller is not yet complete Use the GetPacDriveBootState function to make sure that the PacDrive con toller has stopped the boot procedure before you use the SysReset function DiagExtCode 19 Program error i e the IEC program file is incorrect Overwrite the IEC program on the PacDrive controller b
125. ing handling Risk of bodily harm from crushing shearing cutting and hitting Observe the general construction and safety regulations for handling and instal lation Use suitable installation and transport equipment correctly and use special tools if necessary Prevent clamping and crushing by taking appropriate precautions Wear suitable protective clothing for example safety goggles safety boots pro tective gloves Do not stand under suspended loads Touching electrical parts Touching parts with a voltage greater than 50 volts can be hazardous When electrical units are in operation certain parts are inevitably charged with a dangerous voltage Page 10 PacDrive Controller P600 ELAU AG ELAU AG High voltage Risk of fatal injury Observe the general construction and safety regulations for working on high cur rent electrical systems After installation check the fixed connection of the ground conductor to all elec trical units to ensure that connection complies with the connection diagram Generally and also for brief measurements and inspections operation is only allowed using a fixed connection from the ground conductor to all electrical com ponents Disconnect the unit from the power supply before working on electrical parts with a voltage greater than 50 volts Prevent the unit from being switched back on Wait at least 5 minutes after shutting down before accessing the components Check
126. ion can be used to make the diagnosis mes sage acknowledgeable Example DiagNoQuitReset 721 722 No cyclic telegram Diagnosis class see 8 1 Diagnosis Classes standard 4 The exchange of cyclical data was interrupted No error is displayed when the connection between the PROFIBUS DP Slave und PROFIBUS DP master is interrupted if the response monitoring in the slave was shut off by the master This means that diagnosis code 722 is not triggered The master interrupts the sending of cyclical data gt Check the master Cable fault gt Check the wiring The slave address has been assigned twice in the network gt Check the configuration 723 No profibus configuration data Diagnosis class see 8 1 Diagnosis Classes standard 4 This diagnosis message only occurs in the bootphase of the PacDrive controller or with bus enable No configuration file was found on the flash disk ofthe PacDrive controller A DiagExtCode may be generated Database Unable to delete the SyCon configuration database on the Profibus card software bad load No configuration file was found on the flash disk of the controller bad sldata The slave data of the configuration file is incorrect Should occur to gether with the 730 Bad master parameter data see 8 5 8 16 730 Bad master parameter data diagnosis message If not the incorrect configuration will result in the Profibus card resetting bad madata The master bus da
127. is is only possible in drive version V00 15 00 or higher Evaluation After a SERCOS cycle error occurs entries can be found in the message logger in a way similar to the figure below E EPAS4 MEL Erwekerte SERCOS Diagnose Erweterte SERCOS Diagnose Erwekerte SERCOS Diagnose Erwererte SERCOS Diagnose Erwekerte SERCOS Diagnose 0 111352ms Erwererte SERCOS Diagnose r 2 Erwekerte SERCOS Diagnose R 1 Erweterte SERCOS Diagnose nerr 2 Erwekerte SERCOS Diagnose M 111288ms Erwererte SERCOS Diagnose r Erwekerte SERCOS Diagnose nerr 1 Erwerterte SERCOS Diagnose 5 111234ms Erwekerte SERCOS Diagnose 1 51 372 Phase 0 SERCOS Phasenwechsel 1 51 288 Rr mehrfacher SERCOS Zyklusfehler 1 43 356 Fhase 4 SERCOS Phasenwechsel 1 42 912 Phase 3 SERCOS Phasenwechsel 1 39 140 Fhase 2 SERCOS Phasenwechsel 1 36 564 Phase 1 SERCOS Phasenwechsel NO FOO WO Figure 8 13 SERCOS interface example of a message logger when an error occurs The usual error message for a multiple cycle error appears at the beginning of line number 6 After line number 6 the first block of the extended SERCOS diagnosis appears line numbers 8 10 An info mark S 111284ms appears at the beginning of this diagnosis block here line number 7 and allows the block to be assigned a specific error message In this case a distinction is made between the three diagnosis situations S single SERCOS cycle error SingleCycleError M multiple SERCOS cycle error MultiCycleErr
128. is that the error counters of all the connected drives are displayed when switching to phase 0 even for those that did not have an error axis_1 and axis_3 The time span between the multiple cycle error and the last switch to phase O can vary greatly and depends on a number of different factors However the values of 10 20 cycles are typical E EPAS4 MEL 2 01 360 0x0010 r 15 Erweiterte SERCOS Diagnose 2 01 376 Ox0010 Rel Erweberte SERCOS Diagnose 2 01 376 0x0010 nerr 0 Erwekerte SERCOS Diagnose 2 01 376 Ox0010 nerr 18 Erwekerte SERCOS Diagnose 2 01 376 0x0010 nevr 0 Erwekerte SERCOS Diagnose 2 01 376 0x0010 0 111352ms Erweterte SERCOS Diagnose TOT S76 5 4 2 01 376 Ox0010 R 1 Erweterte SERCOS Diagnose 2 01 376 Ox0010 nerre2 Erwekerte SERCOS Diagnose 2 01 376 0x0010 M l11208ms Erwekerte SERCOS Diagnose 2 01 376 Ox0010 rel Erwekerte SERCOS Diagnose 2 01 376 0x0010 MC_ nerr 1 Erwekerte SERCOS Diagnose 2 01 376 0x0010 S 111284ms Erwerkerte SERCOS Diagnose 1 51 372 0x1000 Phase 0 SERCOS Phasenwechsel 1 51 266 0x0002 Rr mehrfacher SERCOS Zyklusfehler 1 43 356 Ox1000 Phase 4 SERCOS Phasenwechsel 1 42 912 0x1000 Phase 3 SERCOS Phasenwechsel 1 39 140 Ox1000 Phase 2 SERCOS Phasenwechsel 1 36 564 0x1000 Phase SERCOS Phasenwechsel XUV TU y J Wadi NULYO D Figure 8 15 SERCOS interface example of a message logger when an error occurs switch to phase 0 053 UPS active overtemperature Diagnosis class Default 8 Diagnosi
129. it was exceed ed and so the system shut down after the timer ran out 056 Shutdown due to supply voltage outage Diagnosis class standard 8 MsgFilter Bit 1 Diagnosis Messages The hardware provides an internal error logger that logs all the causes for error de pendent controller deactivations The next time the controller is started up the error logger is analyzed and the cause of the error can be output in the message logger If the reason for the shutdown was a supply voltage outage message 056 Shutdown due to supply voltage outage is output In addition a more specific message is output 055 Hardware monitoring debug mes sage that can be enabled by the MsgFilter parameter through the EPAS 4 message logger This message is intended to be a debug message and outputs the exact cause of the deactivation 057 Online change Filter type 13 extended system messages An online change was performed PacDrive Controller P600 ELAU AG 8 5 2 ELAU AG 058 Controller synchronization aV00 22 00 or higher General status information on controller synchronization Encoder Network Ext diagnosis Meaning Conf slave The synchronization slave is configured by the synchronization master Start Sync The synchronization process started Sync OK The synchronization slaves are not synchronized with the synchroniza tion master Data Ready Sync encoder inputs are configured by the sync encoder output and ready to exc
130. ive con troller and the project on the flash disk of the PacDrive controller was created for firmware gt 00 10 00 The error occurs while booting and is entered under object MAX4 in the message logger gt Retransmit project from EPAS 4 It is entered under object IECPRG in the message logger A serious error has been detected in the IEC task named under instance in the message logger PacDrive Controller P600 ELAU AG Possible errors include e g not observing the array limits erroneous handling of pointers or the address operator ADR gt Record erroneous program spot and correct user program 903 Software error class 2 Diagnostic class see 8 1 Diagnosis Classes standard 2 This error should not occur during operation of the PacDrive system gt Get in touch with your ELAU contact person 904 Software error class 1 Diagnostic class see 8 1 Diagnosis Classes standard 1 This error should not occur during operation of the PacDrive system gt Get in touch with your ELAU contact person ELAU AG PacDrive Controller P600 Page 151 9 1 Page 152 Uninterruptible Power Supply UPS The PacDrive controllers C400 C600 and P600 can be fitted with an internal battery pack for an uninterruptible power supply This is continually being charged via the power supply of the controller while in operation The function of the battery pack is to maintain the power supply to the controller in the event of a power failu
131. l equipment EN 50081 2 3 1994 Electromagnetic compatibility Generic emission standard EN 61000 6 2 3 2000 Generic standards Immunity for industrial environments Manufacturer ELAU AG Dillberg 12 97828 Marktheidenfeld Germa ny Stellung im Betrieb Position Vorstand Chairman Directeur qor Pott 1 9 04 Gunter Locherer Datum Date Unterschrift Sig nature product PacDrive Controller MAx 4 C200 C400 C600 P600 The manufacturer guarantees that the product delivered has been manufactured in accordance with the applied harmonized stand ards specifications Applied harmonized standards EN 60204 1 11 1998 Safety of machines electrical equipment EN 50081 2 3 1994 generic standard for noisy emis sion EN 61000 6 2 3 2000 generic standard interference re sistant Manufacturer ELAU AG Dillberg 12 97828 Marktheidenfeld Germany Product PacDrive Controller Le constructeur d clare que le produit livr a t fabriqu en conformit avec les normes et sp cifications harmonis es men tionn es ci dessous Normes harmonis es utilis es EN 60204 1 11 1998 S curit des machines Equipe ment lectrique EN 50081 2 3 1994 Norme g n rique sur l mission de perturbations EN 61000 6 2 3 2000 Norme g n rique sur limmunit aux perturbations Constructeur ELAU AG Dillberg 12 97828 Marktheidenfeld Germa ny
132. lly executed at the next startup Controllers C400 C600 and P600 approx 1 minute bus terminal Controller C200 approx 3 5 minutes bus terminal After the update all BT 4 DIO1 bus terminals must be switched off and on A standard reset on the controller is sufficient The update will only be executed if the bus terminal has a lower firmware version 050 No reaction from Windows Windows did not react within the WinWatchDogtime A control task can be used to react to this event 051 Controller type The PacDrive controller was restarted rebooted Shortly before the start procedure ends the controller type will be saved as a diagnosis message in the message logger Example Max4 FPGA 130f C PU 58 1 AX 8 RAM 32 NRAM 32 DiskS 16 The controller type might not be displayed in its entirety since the message text has a limited number of characters 052 Extended SERCOS diagnosis MASTER As it is very difficult to get an exact SERCOS diagnosis and localize communication errors especially when complex errors occur in pure SCL systems the first stage for extended diagnosis functions was implemented in V00 16 30 This stage is not a definitive solution and may change in the next firmware version Operating principle If a communication error occurs the controller will at specified times record the error counter in the SERCOR memory and the pending error events error interrupts in the SERCOS registers At first these time
133. ltage Windows XP and the real time system can only be properly shut down with an appropriate unit PacDrive Controller P600 Page 23 4 2 4 2 1 4 2 2 Page 24 PacDrive controller boot procedure First Windows XP is started In the meantime Windows starts the real time system The real time system then takes over control via the CPU distribution As a result Windows will only be executed as a low priority task in the framework of the real time system Windows XP in safe mode If the Windows XP operating system starts in safe mode the controller s real time system is not started Diagnosis PacDrive controller minimal boot If a serious boot error occurs as a result of an application error the user can perform a minimal boot The PacDrive controller automatically performs a minimal boot if avoltage interruption of the control voltage occurs when starting the controller while the err indicator is illuminated areset of the PacDrive controller is issued a serious error occurs memory call up cannot be performed During a minimal boot the application data PLC configuration and IEC program are not loaded Perform a minimal boot as follows Boot the PacController by pressing the reset button The PacController starts and the err error indicator lights up Press the reset button again while the pre set IP address is displayed After the boot the PacDrive controller will flash quickly 10 Hz signaling
134. ly of the digital outputs Check the DiagMask parameter Ext Diagnosis PowerFail BT 4 ENC1 The power supply of the encoder is too low Parameter EncPowerSupply Intern FALSE Short circuit of the power supply pin 5 and 9 to the connected encoder or de fective bus terminal BT 4 ENC1 Parameter EncPowerSupply Extern TRUE The is no or not enough power at the X5 plug connector or there is a short circuit of the power supply pin 5 and 9 of the connected encoder Check the power supply of the encoder Check the encoder cable Ext Diagnosis PowerFail BT 4 ENC1 A SinCos encoder physical encoder was entered in the PLC configuration but no SinCos encoder is recognized at connector X2 or X3 of BT 4 ENC1 Plug the SinCos encoder cable into the BT 4 ENC1 X2 or X3 connections Check the encoder cable Ext diagnosis type not supp The connected encoder type is not supported by the system Connect an encoder supported by the system PacDrive Controller P600 Page 145 8 5 9 Page 146 s Ext diagnosis out lt gt out Power is supplied externally to the connectors X2 X3 or X4 pin 5 and 9 of the bus terminal BT 4 ENC1 The connector for the incremental encoder output may have been plugged into an encoder input gt Check the assignment of the encoder connectors 789 Single bus error Diagnosis class see 8 1 Diagnosis Classes standard 6 A single bus error has occurred Ext diagnosis M xx n
135. m a restart as follows Windows restart via Start gt Turn off computer gt Restart In the event of a drop in supply voltage power failure etc the power supply of the controller is automatically activated via the UPS system The controller is shut down after a predefined period of time This possibility makes it absolutely necessary that via the IEC application the system be put into a secure position Because the incidence of this type of situation cannot be predicted and thus the possibility of manually driving into a safe position is not an option reset button Button used to reset the PacDrive controller When the reset button is activated only the PacController controller is rebooted Any MC 4 servo amplifiers connected have their own reset buttons Activate the reset button only if neither system Windows XP or VxWorks is running smoothly The system is not in a secure position Proper shutdown of the system cannot be guaranteed Destruction of system or damage to parts of system possible Manually put system into a secure position When the reset button is pressed the PacDrive controller is rebooted VxWorks real time system and Windows XP operating system PacDrive Controller P600 and UPS The PacDrive controller is ready for use of an internal UPS optional ELAU strongly recommends using a UPS system because data loss cannot be ruled out in the event of a power failure or interruption of the supply vo
136. mber of SERCOS slaves in the control configuration Check and RealTimeBusAdr parameter in the control configuration Remove the SERCO slave from the loop or set the address on the device to Zero SCL 055 motors are connected at the PacDrive controller The SCL 055 motors in the PacDrive PD 8 box are not connected properly Check the connection of the SCL 055 motors in the PacDrive PD 8 box Simply placing jumpers on the desired terminals will not resolve the problem Slaves must not be inserted into the following SERCOS slot Please refer to the notes provided in the SCL and PS 4 and P D 8 operating instructions Ext diagnosis no telegram If the connection is poor a loop interruption may not have been detected yet However the transfer quality on the BUS may be so bad that no telegrams can be transmitted As a result any startup from phase 0 will be cancelled without a diagnosis message The message logger then shows that the change from phase 0 to phase 1 was cancelled with internal error code 483 Check the intensity setting for the SERCOS interface Check the SERCOS bus wiring Check the setting of the MaxPhysicalSlavesparameter PacDrive Controller P600 ELAU AG ELAU AG Ext diagnosis SemDPM Timeout A synchronization error occurred during phase start up gt Contact your ELAU representative 509 Unsupported FW version Diagnosis class see 8 1 Diagnosis Classes default 4 The firmware version of the SERCOS
137. munication cycle The telegram sequence during a cycle corresponds to the sequence of the drives in the PLC configuration under EPAS 4 However the telegrams are grouped by drive type in the following order PS4 MC4 SCL EB Hi SERCOS Imerfaca RTS Sp Alpe men DD Srztemintem Garate Ceorsicnt Pr gt SERCOS Cycle ort 4 P34 Algemeines ured Status wo vater Free u Fr Figure 8 9 SERCOR interface telegram sequence The physical sequence corresponds to the sequence in which the slaves are con nected to the fiberoptic ring Note here that the physical sequence of the PS4 and connected SCL is reversed In this case the last connected SCL is the first slave and the PS4 is the last The above example could appear as follows Page 66 PacDrive Controller P600 ELAU AG ELAU AG Figure 8 10 SERCOR interface physical sequence PD_SyDi0011ML Any confusion concerning the physical sequence can be cleared up by using EPAS 4 The Scan function in the System internals group under the SERCOS interface object is available for this purpose W Steuerumgskonfiguration Hg SERCOS interface RTB gt io T Allgemeines p lsystemintem phaseset 0 4 ee MC 4 MCS_1 gt 4 nein j FALSE 5 ScanStatus a Netzger t 4 lt PS4 gt 6 Start ddress g ie Allgemeines und Statu 7 Endaddess H H x Ringotatus P S Su SolkIstwerte RealTimeCydeztter I h Controller MaxReallimeCydetter gt GS Systemintern
138. n it is in flawless technical condition Observe regulations act in a safety conscious and danger conscious manner and observe the information and instructions in this manual For the ELAU Components to run perfectly and safely it must be transported stored installed and assembled correctly and maintained carefully If circumstances occur which reduce safety or cause changes in the operating per formance of the ELAU Components switch it off immediately and contact the respon sible service staff In addition to this description you must also observe the following The regulative warning and instruction signs as well as the warning instructions on the ELAU Components the connected components and all signs in the switch ing cabinet The operating instructions of the other components The generally applicable local and national safety and accident prevention regu lations Applicable laws and regulations Page 8 PacDrive Controller P600 ELAU AG 2 2 Notation for Safety Instructions Risk categories The safety notes in this manual are divided into various categories The table below shows which risks and possible consequences the symbol pictogram and the signal words refer to Pictogram Signal word Definition DANGER Indicates a situation involving direct danger which will result in death or grave bodily harm ifthe safety regulations are not followed WARNING Indicates a possible situation which can result in gr
139. n similar errors in the same axis previously How often ooo ee eee eee eeeee eee ee Did the errors always occur on certain days or at certain times of day PacDrive Controller P600 Page 161 Index 050 62 051 62 052 62 053 70 054 70 055 71 0 056 72 057 72 ws 058 73 003 55 004 55 005 55 1 006 55 100 73 007 55 101 75 008 56 102 75 009 56 103 76 010 56 104 76 011 56 105 76 012 56 106 76 013 56 107 77 014 56 108 77 015 56 109 78 016 56 110 78 017 56 11178 018 57 11278 019 57 113 79 020 57 11479 021 57 11579 022 57 116 80 023 57 117 80 024 58 118 80 025 58 119 80 026 58 120 81 027 58 121 25 81 028 58 122 81 029 58 123 82 030 58 124 82 031 58 125 82 032 58 126 82 033 58 127 83 034 58 128 83 035 58 129 83 036 58 130 83 037 58 131 83 038 59 132 83 039 59 133 84 040 59 134 85 041 59 135 85 042 59 136 85 043 60 137 85 044 60 138 86 045 60 139 86 046 61 140 87 047 61 141 88 048 61 142 88 Page 162 PacDrive Controller P600 ELAU AG 143 88 144 88 145 89 146 89 147 89 148 89 149 90 150 90 151 90 152 90 153 91 154 91 155 91 156 91 157 92 158 92 159 92 160 92 161 92 162 92 163 93 164 93 165 93 166 94 167 94 168 95 169 95 170 96 171 96 174 97 175 97 2 200 97 201 98 202 98 203 98 204 98 205 99 206 100 207 100 208 100 209 101 210 103 211 103 3 300 104 301 104 302 104 303 104 304 104 305 105 ELAU AG 306 105 307 105 308 105 309 105 310 105 311 105 312 1
140. n the ControllerType1 parameter and is indicated by the p in FPGA pyxxx gt Install a valid c2_xpxx bin FPGA firmware file with a matching pinout on the flash disk of the C200 While installing a firmware version on the C200 controller the firmware assistant au tomatically copies the c2_xpxx bin to the flash disk of the C200 Ext diagnosis FPGA Pinout No c2_xpxx bin file with matching pinout was found on the flash disk of the C200 xpxx is the FPGA firmware version The C200 controller cannot be used The pinout of the C200 controller must match the pinout of the FPGA firmware The pinout of the FPGA firmware is the number represented by p in the xpxx of the FPGA firmware version The pinout of the controller can be read in the Con trollerType1 parameter and is indicated by the p in FPGA pyxxxx gt Install a valid c2_xpxx bin FPGA firmware file with a matching pinout on the flash disk of the C200 While installing a firmware version on the C200 controller the firmware assistant au tomatically copies the c2_xpxx bin to the flash disk of the C200 Ext diagnosis FPGA not supp The current firmware on the controller C400 C600 or P600 does not match the hardware of the controller gt Install a matching firmware version on the controller with the Firmware Assis tant Example Firmware versions below 00 16 40 e g 00 16 32 do not support HW versions with the FPGA pinout 3 e g FPGA version 0316 The
141. nd 16 MBaud values are supported in general Only specific values are supported depending on the type of PacDrive controller Max 4 CXX PXX Each value is dynamically checked when written Incorrect PacDrive Controller P600 Page 99 values are not transferred Diagnosis message 205 Impermissible parameter value is triggered gt Enter a valid BaudRate value I 0Bxx0004 i e a value is entered that is either too small or too large for ac celeration gt Enter a valid acceleration value I 03xx0025 i e the J_Load in the control configuration is too large gt Enter a valid J_Load value i I 01010004 i e the IP_Gateway in the control configuration does not match the IP_SubNetMask gt Only use standard IP address names 206 Faulty ObjType of LogAdr Diagnosis class see 8 1 Diagnosis Classes standard 4 No object with the type code exists The DiagExtCode parameter in the control con figuration or message logger can be used to determine the logical address of the parameter that contains an impermissible value This allows assignment to the control configuration Subsequent error of diagnosis message 209 Last boot failed see 8 5 3 10 209 Last boot failed gt See 209 Last boot failed diagnosis message Software error gt Contact your ELAU representative 207 Hardware module does not exist Diagnosis class see 8 1 Diagnosis Classes standard 4 A hardware module was entered into the control confi
142. nd the IEC program has been started successfully the err LED will switch off again The boot procedure is then complete bus err SERCOS real time bus error indicator err Page 20 OFF Normal operation ON Bus error fiber optic cable connection problem e g sending power too low or too high cable break PacDrive Controller P600 ELAU AG 4 1 1 top side here NOTE ELAU AG The condition of the bus err LED is undefined during the boot procedure The sending power fiber optic cable intensity is set on the PacDrive controller in the controller configuration Ethernet LEDs data throughput indicator and network activity There are two LEDs affixed to the Ethernet connection X10 of the PacDrive controller LED yellow ON PacDrive controller connected LED yellow flashing flickering current network traffic LED yellow OFF PacDrive controller not connected LED green ON 100 MB connection LED green OFF 10 MB connection Once you have opened the operating cover you have access to the PacDrive controller control elements CompactFlashTM card slot Battery compartment on off button reset button CompactFlashTM card slot The CompactFlash card slot is the receptacle for a data storage medium CF card You do not need a CompactFlash card to operate the controller The entire software used to operate the controller is stored
143. no 17 13 00 68 00x DE EN IT FR EPAS 4 Operating Manual Item no 17 13 00 70 00x DE EN PacDrive Controller MAx 4 Operating Manual Item no 17 13 00 71 00x DE EN IT FR OPC Server User Manual Item no 17 13 00 73 00x DE EN Device Net Operating Manual Item no 17 13 00 76 00x DE EN HMI Libraries Operating Manual Item no 17 13 00 77 00x DE EN INC 4 Incremental Encoder Module Operating Manual Item no 17 13 00 78 00x DE EN CANopen Operating Manual Item no 17 13 00 79 00x DE EN Motion Toolkit ECAM 4 Operating Manual Item no 17 13 00 80 00x DE EN PacNet Module PN 4 Operating Manual Item no 17 13 00 81 00x DE EN SR Motor Operating Manual Item no 17 13 00 82 00x DE EN BT 4 Bus Terminals Operating Manual Item no 17 13 00 83 00x DE EN TTS Training and Test Systems Operating Manual Item no 17 13 00 88 00x DE Automatic Controller Optimization User Manual Item no 17 13 00 89 00x DE EN PacDrive SCL Operating Manual Item no 17 13 00 93 00x DE EN PacDrive Controller P600 Page 155 Page 156 PacDrive PS 4 and PacDrive PD 8 Operating Manual Item no 17 13 00 94 00x DE EN Evaluation Kit User Manual Item no 17 13 00 95 00x DE PacDrive Controller P600 Operating Manual Item no 17 13 00 96 00x DE EN IT FR PacDrive Controller C200 Operating Manual Item no 17 13 00 97 00x DE EN IT FR PacDrive Controller C400 Oper
144. nosis messages umsmnensnnnnnnnnnnnnnnnnnnnsnannnnnnnnnnnnnnnnnen 97 3xx General diagnosis MESSAGES 2 2 uusnnnannnnnnnnnnnnnnnnnnnnnannannnennnnenannnnnnnnnn 104 4xx IEC Task diagnosis Messages ccsicincicsscesssicstioantanttenonSacstinennenainenboctesianead een 115 5xx SERCOS realtime diagnosis messages uuuunsnsensessnnnnnnnnnnnnnnnnnnnnn nenn 116 6xx master encoder diagnosis MESSAGES 2222444nnnnnnnnnnnnnnnnnnnnnnn nennen 124 7xx field buses and expansion module diagnosis messages men 125 8xx System diagnosis MESSAGES ernnnnannnannnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nn nannnannnnnn 146 9xx Software diagnosis MESSAGES uuuusnnnnnnnnnnnnnnnnnenennnnnannnnnnennnn anna 150 Uninterruptible Power Supply UPS 152 Retroactive installation of UPS u ae 152 Appendix 154 AdArESSeES see een eek 154 Additional Literature SPNDERARSPERSERPRPAEERERAERDERERENERSEREFENAESPERERERERELEEESEREERREIHEUBENR IEREEREREEURERR 155 Product Training Courses keinen een 157 PacDrive Controller P600 ELAU AG 10 4 10 5 10 6 10 7 11 ELAU AG Table of Contents Manufacturer s declaration sea ee 158 Safety ES S ae neuere 159 Hardware software compatibility list 224444444HHnn nenn nnnnnnnnnnnnnnnnennnnnnnnnnn nn 159 LS ie ple ae cee ee ee cee ne ee et er se re 159 Fault report form 160 PacDrive Controller P600 Page 5 1 1 Page 6 About this Manual Introd
145. nter see Status parameter Bit Error Data Length Code Two nodes are using the same identifier or COB ID gt Check the identifier or COB ID Bit Error Identifier Intermittent connection error to receiver gt Stuff Error Identifier Dominant signal level due to external interference gt Format error Acknowledge delimiter Critical bus time setting Baudrate or bus length gt Ext diagnosis count xx yy xx Contains the value of the ErrorCount at the time the error occurred yy Contains the value of the ErrorOffCount parameter at the time the error occur red The GlobalError parameter is set to Bit 4 Bus error gt 703 CAN layer2 errors reach warning limit Diagnosis class see 8 1 Diagnosis Classes standard 4 The number of send or receive errors specified in the warning limit register has been exceeded PacDrive Controller P600 Page 127 Meaning of ext diagnosis Meaning of ext diagnosis Page 128 The system displays the pending register information at the time the error occurred Structure SXXrXXtXX s Status register see Status r Receive Error Counter see Status parameter t Send Error Counter see Status parameter 704 CAN layer2 switched passive Diagnosis class see 8 1 Diagnosis Classes standard 4 128 send or receive errors have occurred In passive mode no CAN messages are acknowledged and no error messages are sent to the bus The system
146. o 15 of bus terminal BT 4 DIO1 gt Check power supply at connector X7 of bus terminal BT 4 DIO 039 file removed Filter type 13 extended system messages The system has deleted a file Deletion is triggered when for example there is a symbol filethat does not match the program file The file name is shown in Ext Diagnosis 040 file copied The system copied a file The Boot sbd symbol file is copied to Download sbd when for example Online Change is executed without downloading a program and the sys tem is reset boot procedure 041 file renamed The system renamed a file 042 SERCOS phase changed A SERCOS phase change has occurred The new phase is displayed in the message logger in Ext diagnosis e g Phase 4 DiagExtCode Meaning Phase 0 Phase change after Phase 0 Phase 1 Phase change after Phase 1 Phase 1 4MBd from V00 24 00 additional indication of baud rate Phase 1 xxx Internal error xxx during phase change after phase 1 Phase 2 Phase change after Phase 2 Phase 2 L 25 from V00 22 00 additional indication of SERCOS cycle load in percent Phase 2 xxx Internal error xxx during phase change after phase 2 Phase 3 Phase change after Phase 3 Phase 3 2ms from V00 24 00 additional indication of SERCOS cycle time Phase 3 xxx Internal error xxx during phase change after phase 3 PacDrive Controller P600 Page 59 Page 60
147. obe input 3 1 5 mm 5 T 04 Touchprobe input 4 1 5 mm 6 T 05 Touchprobe input 5 1 5 mm 7 T 06 Touchprobe input 6 1 5 mm 8 T 07 Touchprobe input 7 1 5 mm 9 T 08 Touchprobe input 8 1 5 mm 10 T 09 Touchprobe input 9 1 5 mm 11 T 10 Touchprobe input 10 1 5 mm 12 T 11 Touchprobe input 11 1 5 mm 13 T 12 Touchprobe input 12 1 5 mm 14 T 13 Touchprobe input 13 1 5 mm 15 T 14 Touchprobe input 14 1 5 mm 16 T 15 Touchprobe input 15 1 5 mm 17 T 16 Touchprobe input 16 1 5 mm 18 T 17 Touchprobe input 17 1 5 mm 19 T 18 Touchprobe input 18 1 5 mm 20 T 19 Touchprobe input 19 DC 20 30 V 1 5 mm PacDrive Controller P600 Page 41 Page 42 10 18 Table 7 5 Electrical connections C400 C600 P600 X4 X5 analog inputs outputs Pin Designation Meaning Max cross section 1 AI O Analog input 0 1 5 mm 2 J 0 Br current input 0 1 5 mm 3 Al 0 analog input 0 1 5 mm 4 A GND 0 analog ground 0 1 5 mm 5 12 V Out 0 Output voltage 0 1 5 mm 6 PE shield 1 5 mm 7 AO O analog output 0 1 5 mm 8 A GND AO 0 analog ground 0 1 5 mm 9 PE shield 1 5 mm 10 Al 1 Analog input 1 1 5 mm 11 J 1 Br current input 1 1 5 mm 12 Al 1 analog input 1 1 5 mm 13 A GND 1 analog ground 1 5 mm 14 12 V Out 1 Output voltage 1 1 5 mm 15 PE s
148. oller servo amplifier 113 Bleeder defective Diagnosis class see 8 1 Diagnosis Classes standard 1 Reaction see 8 2 Reactions A A defect in the bleeder was detected by the device Wiring The bleeder feed line has a short circuit gt Check the bleeder and feed lines The bleeder is not dimensioned correctly Ohm value too low gt Check the bleeder sizing also refer to the project planning guide and technical data Hardware error Bleeder defective gt Measure bleeder gt Replace bleeder if necessary Hardware error Servo amplifier defective gt Replace the servo amplifier 114 Error reading EEPROM Diagnostic class see 8 1 Diagnosis Classes standard 1 Reaction see 8 2 Reactions A The check sum in the EEPROM is wrong Device specific information such as device type serial number adjustment values etc are stored in the EEPROM Hardware error The EEPROM is defective gt Contact ELAU customer service gt Replace servo amplifier 115 Gate power failure Diagnosis class see 8 1 Diagnosis Classes standard 1 Reaction see 8 2 Reactions A There is no supply voltage at the output stage of the servo amplifier z Hardware error Servo amplifier defective PacDrive Controller P600 Page 79 Page 80 gt Replace the servo amplifier 116 Commutation error Diagnosis class see 8 1 Diagnosis Classes standard 2 Reaction see 8 2 Reactions A Unable to determine
149. onditions of the axes can be called up via the real time bus and processed by the PacDrive controller In addition to digital and analog inputs and outputs each PacDrive controller has two serial interfaces and one Ethernet interface available Thanks to the integrated OPC interface it is possible to connect various process visualization and control systems to PacDrive Additional peripheral components can also be connected using the field bus interface module A PacDrive controller can be the field bus master or the slave The international field bus standards CANopen PROFIBUS DP and DeviceNet are supported The built in interfaces enable remote diagnosis via telephone modem or Internet PCs can communicate via TCP IP with the PacDrive controller and directly diagnose the conditions of the controller PacDrive Controller P600 ELAU AG Ethernet TCP IP OPC ftp http SMS SMTP Motion Logic Control Scalable HMIs a pEr FETI li A User Program amp Libraries 21CFR part11 Technology packages cGMP a N Equipment modules EN Function Blocks Template Firmware Field bus e g Profibus CAN ASI Safety Motion bus SERCOS Figure 3 2 System overview of the PacDrive automation system Alternatively the PacDrive controller can be coupled with a conventional PLC higher level than the PacDrive controller via a field bus 3 3 Components Today s requirements mean that machinery concepts of
150. open master provides the application objects described in the operating manual If more application objects are configured in the CANopen master configura tion than are actually available this diagnosis message will be triggered Meaning of ext diagnosis Structure Nxxx Cxxxx Rxx CID Pdo Cobld hexadecimal Coplf Identifier of the Pdos in which the application object has been mapped S size of the application object of the hexadecimal application object size N hexadecimal CANopen node address configuration error gt Check the configuration 770 Option modules area exceeded Diagnosis class see 8 1 Diagnosis Classes standard 4 An overlapping of the IO area of the optional module was detected The DiagExt Code displays the number code of the type key of the overlapping module Example DiagExtCode 3 01 2 02 i e the IO address of the PROFIBUS DP master module 2 02 is within the IO address area of the DeviceNet slave module 3 01 The IO area of the optional module has not been set properly in the controller gt Check the IO area settings based on the operating instructions for the option modules PacDrive Controller P600 ELAU AG ELAU AG 771 Double IRQ config of the option modules Diagnosis class see 8 1 Diagnosis Classes standard 4 A double interrupt use by the optional module was detected The DiagExtCode dis plays the interrupt that was used twice The interrupt of the optional module has not be
151. or 0 switch to phase 0 The time mark in ms of when the error occurred is shown in connection with this error type Page 68 PacDrive Controller P600 ELAU AG NOTE ELAU AG All axes whose receive error counter nerr has changed since the last diagnosis ac knowledgement or phase startup line number 8 are then listed The error counter is assigned to the axis via the Object and Instance columns The value displayed in connection with nerr x is only reset during phase startup If more than one single SERCOS cycle error occurs during operation the error counter will increase each time accordingly The remaining information refers to the error status line no 9 Each error status is reset during each phase startup and each error acknowledgement This information always consists of a letter and a number r 1 The letter indicates the error type while the number indicates the frequency of that error type The meaning of the letter is the same as the letter in the ext diagnosis messages for SERCOS cycle errors R double miss of drive telegrams RMISS R double miss of the synchronous telegram MSTMISS F fiberoptic break FIBBR 1 late reception of the synchronous telegram MSTLATE e early reception of the synchronous telegram MSTEARLY d receive distortion r single miss of a drive telegram RERR Hence the first diagnosis block would be interpreted as follows Simple SERCOS cycle error at
152. or multi turn encoders and configures itself using the elec tronic type plate in the SH motor Highlights of the PacDrive MC 4 Broad voltage range Integrated power supply unit Max 34 5 69 kVA power Automatic motor identification Minimal size Inverter Enable safety input 250 overload Integrated SERCOS interface SH motor The AC servo motors of the SH series meet the highest demands on dynamics and precision Five flange sizes with different torque gradations offer the right drive solution for almost any application New wind technology with single tooth winding allows for compact size and reduces production costs compared with traditional motors Compared to other AC servo motors the SH motor has a low inherent moment of inertia and a high load capacity which allow the SH motor to satisfy any demand with regard to precision dynamics and efficiency SH motors are compatible with SM motors and are available in five different flange sizes SH 055 SH 070 SH 100 SH 140 SH 205 Brief summary of technical data Developed for the highest dynamics and precision Single tooth winding Compact size High power density Low inherent moment of inertia High load capacity High resistance to winding damage Low cogging torque ISH Servo Drive System The innovative iSH combines motor final stages and the digital servo regulator for one axis in a space saving housing Due to its compact construction with integrat
153. or the configuration file is defective gt Transfer the configuration file with EPAS 4 again 203 Faulty parameter file Diagnosis class see 8 1 Diagnosis Classes standard 4 The parameter file is not readable In controller firmware version 00 16 30 or higher the name ofthe temporary parameter file is displayed in the ext diagnosis in the message logger There is no parameter file in the PacDrive controller or the parameter file is de fective gt Transfer the parameter file with EPAS 4 again 204 IEC program cannot be loaded Diagnosis class see 8 1 Diagnosis Classes standard 4 Unable to load the IEC program Additional information on how to limit errors is stored in the DiagExtCode or the ext diagnosis in the message logger Page 98 PacDrive Controller P600 ELAU AG ELAU AG Ext diagnosis Meaning prog xhhhhhhhh IEC program code is too big bad version The IEC program is not compatible with the PacDrive controller firmware V00 10 00 or higher data xhhhhhhhh IEC data area is too large gt adjust number of data segments ret xhhhhhhhh The retain area is too large DOWNLOAD Unable to load and prepare the IEC program miscellaneous Other data errors Cause of data xhhhhhhhh A project was developed for an older version of the PacDrive controller firmware In this project the number of data segments is greater than two e g three If you now transfer the program to the controller
154. osis Classes standard 4 This diagnosis message is used to differentiate from the 209 Last boot failed see 8 5 3 10 209 Last boot failed message for minimal boot boot not complete In such a case the last boot failed Ext diagnosis RAM lt 32MB If this diagnosis message appears the minimal boot is also in error However this is caused by having insufficient RAM in the MAx 4 PacDrive controller RAM lt 32 MB gt Replace MAx 4 PacDrive controller with a device that has newer hardware or Use an older firmware version in the MAx 4 PacDrive controller V00 15 03 or lower 211 Invalid configuration Diagnosis class see 8 1 Diagnosis Classes standard 4 A configuration error has occurred Cause Firmware V00 20 00 The Connector parameter is set for the Bottom 1 connector but there is no expan sion module present in the PacDrive controller C600 or P600 gt Check the Connector parameter in the control configuration gt Check whether an expansion module is present in the PacDrive controller Cause Firmware V00 16 41 This diagnosis message will be triggered if there are two field buses configured in PacDrive controller C600 or P600 that cannot be connected at the same time CAN Layer2 and DeviceNet Slave are configured or CANopen Master and DeviceNet Slave are configured or PROFIBUS DP master and PROFIBUS DP slave are configured gt Check the control configuration ELAU AG PacDrive Controller P
155. perature sensor is defective gt Replace device 104 PowerOff due to control voltage error Diagnosis class see 8 1 Diagnosis Classes standard 2 Reaction see 8 2 Reactions B The control voltage is incorrect The control voltage is too low a brief voltage failure of the 24 V DC has occurred gt Check the 24 V control voltage 105 Feedback error track monitoring Diagnosis class see 8 1 Diagnosis Classes standard 1 Reaction see 8 2 Reactions A A hardware encoder error has occurred The device that triggered this error must be reset Wiring error Encoder cable at the encoder or the servo amplifier PacDrive controller has been removed or is defective gt Check the encoder cable and replace if necessary gt Check the ground connection shield The encoder voltage is unavailable or incorrect gt Check the encoder voltage Hardware error the encoder is defective gt Replace the encoder 106 Communication error DC controller Diagnosis class see 8 1 Diagnosis Classes standard 2 Reaction see 8 2 Reactions A An internal system error has occurred EMV faults gt Reset the PacDrive system PacDrive controller and servo amplifier Hardware error The servo amplifier is defective PacDrive Controller P600 ELAU AG ELAU AG gt Replace the servo amplifier 107 Excess current Diagnosis class see 8 1 Diagnosis Classes standard 1 Reaction see 8 2 Reactions A
156. r encoderposition see 8 5 2 42 141 EncoderPosition Reading Error in MotorController firmware version 00 20 00 or higher The DrvEncSetPosition function was called and could not be processed prop erly gt Call the DrvEncSetPosition function again Encoder in the motor is defective gt Replace the motor 171 Encoder communication warning Diagnosis class see 8 1 Diagnosis Classes standard 6 Reaction see 8 2 Reactions D An error occurred in reading the encoder via the serial interface Wiring error Encoder cable is not correct gt Check the wiring Hardware error Encoder is defective gt Change out the motor or the encoder 172 Extended diagnosis message Diagnosis class see 8 1 Diagnosis Classes standard 8 Reaction see 8 2 Reactions E For now this diagnosis message is only intended for ELAU internal use To view the diagnosis message in the message logger Filter Typ 15 must be selected via Set filter 173 Feedback warning track monitoring Diagnosis class see 8 1 Diagnosis Classes standard 8 Reaction see 8 2 Reactions E For now this diagnosis message is only intended for internal ELAU use To view the diagnosis message in the message logger Set filter must be used to set Filter Type 15 PacDrive Controller P600 ELAU AG 8 5 3 ELAU AG 174 Excess current warning Diagnosis class see 8 1 Diagnosis Classes standard 6 Reaction see 8 2 Reactions E Filter typ
157. r data buffering with out battery is approx 5 minutes Change the battery as follows If it is necessary to change the battery use the following type of battery 3V Lithium Renata Type battery 2450N see also chapter entitled Accessories see 6 8 3 Acces sories Replace battery only with Renata Type 2450N There is a risk of explosion fire if an other battery is used see also chapter entitled General safety information see 6 8 3 Accessories gt Use insulated pliers to lightly pull the old battery out of its slot Danger of explosion when removing replacing battery Risk of injury and or property damage Use suitable insulated pliers When replacing the battery use tools which contain no current conducting material on the contact points In general be careful not to short circuit the battery poles Do not recharge dismantle or throw battery into fire gt Carefully place the new battery on the guide and lightly push it into the device Switching the PacDrive controller P600 on off and resetting The PacDrive Controller P600 is equipped with the VxWorks real time system and the Windows XP operating system Take into account both systems when switching the controller on off or resetting the controller You can only restart the VxWorks real time system or Windows XP and VxWorks perform reset Restarting the VxWorks real time system Restarting VxWorks via the Automation Toolkit EPAS 4 reset R
158. ransfer error ST 99 Error while processing reset ZK1 ST 99 ChangeBit Error while processing reset ZK1 change bit was not set or protocol error no SYNC Communication synchronization with slave disrupted DiagExtCode no SYNC There are SERCOS slaves MC 4 with a firmware version below V00 15 00 in the loop that are not responding as real devices If this occurs during the phase startup ofthe SERCOS bus a fatal error will be triggered that cancels the phase startup gt If there are SERCOS slaves MC 4 with a firmware version below V00 15 00 that have not responded as real devices the SERCOS address on the device must be set to zero EMC problem gt Check the electrical environment Hardware problem with a SERCOS slave e g servo amplifier MC 4 or a SER COS master e g PacDrive controller Max 4 gt Contact your ELAU representative 504 Read cycle overflow Diagnosis class see 8 1 Diagnosis Classes standard 4 The transfer of the actual position of the axes servo amplifiers to the PacDrive con troller occurred too late The actual values of the next SERCOS cycle have already been read The actual velocity provided for the IEC program may be incorrect SERCOS bus is overloaded gt Increase the CycleTime parameter in the control configuration One or more SERCOS slave have been switched off and therefore no longer supply data to the SERCOS bus gt Switch on SERCOS slave 505 Single SERCOS error MASTE
159. rated when the drive is in control mode MC4State gt 16 20 except with PS 4 If the DC link voltage drops further while the drive is in control mode the diagnostic message 109 under voltage see 8 5 2 10 109 Undervoltage is triggered Hardware Enable and Software Enable are there but the mains voltage is too low gt Check mains voltage refer also to technical information of device the mains contactor may not be switched Parallel connected DC links servo amplifier error gt Find servo amplifier with error gt Eliminate error 136 Inverter enable warning Diagnosis class see 8 1 Diagnosis Classes standard 6 Reaction see 8 2 Reactions D An attempt is being made to start the drive but Inverter Enable is still LOW Hardware Enable and Software Enable are available but Inverter Enable is still LOW gt Activate Inverter Enable 137 Motorless Diagnosis class see 8 1 Diagnosis Classes standard 2 Reaction see 8 2 Reactions A PacDrive Controller P600 Page 85 Page 86 When switching the MC 4 servo amplifier from motorless to normal mode a message reporting a motor error that has occurred will appear Motor errors that result in the diagnosis message 102 Motor PowerOff due to overtemperature see 8 5 2 3 102 Motor PowerOff due to overtemperature 105 Feedback error track monitoring see 8 5 2 6 105 Feedback error track monitoring 111 Excessive following error
160. re long enough to shut down the controller properly and not lose any data The pre set time of shut down can be up to 5 minutes If necessary the battery pack can also be installed or replaced after the fact for the UPS see Retroactive installation of UPS see 9 1 Retroactive installation of UPS Retroactive installation of UPS PacDrive C400 C600 P600 Geh use P Elektronik Modul slide in module Figure 9 1 PacDrive controller UPS installation gt Open operating cover 1 gt Remove electronic module fastening screws 2 gt Remove electronic module 3 from housing Battery pack not properly secured Mechanical damage of PacDrive controller possible Use only the supplied cable ties to secure the battery pack Item no 53130050 Check that the battery pack is properly secured gt Adjust the battery pack and attach with 2 cable ties 4 PacDrive Controller P600 ELAU AG gt Connect battery cable 5 Do not force the electronic module into the housing Damage to display supply cable possible Take care that during installation of the electronic module the display supply cable 6 does not get caught or torn Carefully push the electronic module back into the housing 7 Screw the electronic module to the housing with the fastening screws 2 Close operating cover See chapter on how to charge battery Yv v Vv The maintenance interval for replacing the battery is 3 ye
161. real time operating system centrally implements the PLC and motion functions One PacDrive controller synchronizes coordinates and generates the motion func tions for a maximum of 8 drives for the PacDrive controller MAx 4 8 8 drives for the PacDrive controller C200 16 drives for the PacDrive controller C400 99 drives for the PacDrive controller MAx 4 99 99 drives for the PacDrive controller C600 22 drives for the PacDrive controller P600 of a food and packaging machine The most diverse standard HMls are used for the HMI tasks Whether it is low cost plain text or IPC it is no problem for the flexible PacDrive controllers The PacDrive controller P600 is also equipped with a full fledged PC Due to its PC based architecture it can perform HMI tasks with no problem in addition to the usual motion functions PacDrive Controller P600 ELAU AG State of the art technology Highly dynamic AC servo mo tors PacDrive iSH ELAU AG PacDrive MC 4 servo amplifier The MC 4 digital servo amplifier features compact closed wall mountable construc tion as well as state of the art technology The innovative MC 4 has a power supply unit power amplifier and a software servo controller for one axis all installed in a single space saving housing Since it communicates with the PacDrive controller exclusively via fiber optics it is also suitable for decentralized structures It does not require a user program processes single
162. rive Controller P600 ELAU AG ELAU AG Hardware error Short circuit in the motor phase to phase or phase to housing gt Replace the motor z Hardware error The output stage of the servo amplifier is defective gt Replace the servo amplifier 120 Overload PowerOff of output stage Diagnosis class see 8 1 Diagnosis Classes standard 2 Reaction see 8 2 Reactions B The output stage is overloaded In contrast to the 107 Excess current see 8 5 2 8 107 Excess current diagnosis message the power is switched off as soon as the max current value is exceeded The thermal overload of the devices over a specific time period is observed The output stage is overloaded Check the motor actuator Check the calculation of the motor and the actuator Drive the system at a slower speed v vV V u The motor brake is not open gt Check the wiring of the motor brake voltage reversal cable break x Hardware error The servo amplifier is defective gt Replace the servo amplifier 112 Bleeder temperature too high Diagnostic class see 8 1 Diagnosis Classes standard 2 Reaction see 8 2 Reactions B The braking resistor is overloaded The drive has incorrect dimensions gt Check drive sizing u Hardware error The braking resistor or addressing is defective gt Contact ELAU customer service 112 Max motor speed reached Diagnostic class see 8 1 Diagnosis Classes standard 2 Reaction see 8
163. rror has occurred Meaning of ext diagnosis displays the pending register information at the time the error occurred Structure eXXSXXrXXtXX XX indicates a hexadecimal number e error register error code capture register Bit 7 Bit 6 0 0 Bit error 0 1 Format error 1 0 Stuff error 1 1 Other error Bit 5 0 Send error 1 Receive error Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Description 0 0 0 1 1 Start of frame 0 0 0 1 0 ID 28 to ID 21 0 0 1 1 0 ID 20 to ID 18 0 0 1 0 0 Bit SRTR 0 0 1 0 1 Bit IDE 0 0 1 1 1 ID 17 to ID 13 0 1 1 1 1 ID 12 to ID 5 0 1 1 1 0 ID 4 to ID O 0 1 1 0 0 Bit RTR 0 1 1 0 1 Reserved bit 1 0 1 0 0 1 Reserved bit 0 PacDrive Controller P600 ELAU AG ELAU AG Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Description Data length code Data field CRC sequence CRC delimiter Acknowledge slot Acknowledge delimiter End of frame Intermission Active error flag Passive error flag Tolerate dominant bits 0 1 0 0 0 0 0 0 0 0 0 A 1 o0 2 1 21lo0lo0 o0 olololoJo 1 Error delimiter 2 1 1 2 1 1 2 2 1 21l010 o o 1 01 1 0 0 1 0 0 10 1 1 0 Overload flag Table 8 7 Bit 4 to Bit 0 indicate the position of the error s Status Register see Status parameter r Receive Error Counter see Status parameter t Send Error Cou
164. rrupt file size detected Diagnosis class see 8 1 Diagnosis Classes standard 807 Multiple used cluster block detected Diagnosis class see 8 1 Diagnosis Classes standard 808 Corrupt directory name detected Diagnosis class see 8 1 Diagnosis Classes standard ELAU AG PacDrive Controller P600 N N N N N N N N Page 147 Page 148 809 Circular linked clusters blocks detected Diagnosis class see 8 1 Diagnosis Classes standard 2 810 Error reading directory entry Diagnosis class see 8 1 Diagnosis Classes standard 2 811 Error writing directory entry Diagnosis class see 8 1 Diagnosis Classes standard 2 812 Lost cluster block found Diagnosis class see 8 1 Diagnosis Classes standard 2 813 Device lt ide0 gt not found Diagnosis class see 8 1 Diagnosis Classes standard 2 814 Initialization of lt ideO gt failed Diagnosis class see 8 1 Diagnosis Classes standard 2 815 error using function with lt ide0 gt Diagnosis class see 8 1 Diagnosis Classes standard 2 816 Bootrom sys Diagnosis class see 8 1 Diagnosis Classes standard 2 817 No devicename Diagnosis class see 8 1 Diagnosis Classes standard 2 818 File not found Diagnosis class see 8 1 Diagnosis Classes standard 2 819 File open error Diagnosis class see 8 1 Diagnosis Classes standard 2 820 File read error Diagnosis class see 8 1 Diagnosis Classes
165. s Mtype 0 wrong No module was found on PacNet Switch on the control voltage on the module Ext diagnosis M xx n res The module with bus address xx repeatedly gives no response This may be caused by a power failure or a defective module The module cannot be used Check the module address on the module Check the module address in the control configuration Check the power supply of the module Replace the module if necessary Ext diagnosis Powerfail 0 7 The power supply for outputs 0 through 7 of the BT 4 DIO1 is not available or too low lt 14 V The outputs cannot be used Check the power supply of the outputs The message can be disabled with the DiagPFO_7Enable parameter NOTE ELAU AG Ext diagnosis Powerfail 8 15 The power supply for outputs 0 through 7 of the BT 4 DIO1 is not available or too low lt 14 V The outputs cannot be used Check the power supply of the outputs PacDrive Controller P600 Page 143 NOTE NOTE NOTE Page 144 The message can be disabled with the DiagPF8_15Enable parameter 5 Ext diagnosis no FPGAfile No c2_xpxx bin file was found on the flash disk of the C200 xpxx is the FPGA firmware version The C200 controller cannot be used The pinout of the C200 controller must match the pinout of the FPGA firmware The pinout of the FPGA firmware is the number represented by p in the xpxx of the FPGA firmware ver sion The pinout of the controller can be read i
166. s message removed in V00 22 00 or higher see 339 UPS active system temperature too high see 8 5 4 40 339 UPS active system temperature too high The system has detected a temperature that is too high and will change the state to System Shutdown 4 after 70 seconds See also UPS State parameter 054 Temperature Warning Diagnostic class standard 6 The temperature in the device C400 C600 and P600 is not within the specified range If the temperature falls any further the controller may shut itself off DiagExtCode Temp lt 5 C The temperature in the device is lower than approx 5 C The following message text appears on the display 1st line temperature warning 3rd line Temp lt 5 C PacDrive Controller P600 ELAU AG Error groups Cause of error VoltageError ELAU AG This message can be acknowledged The warning is only issued from PIC version software version 0512 or later The ambient temperature is dropping rapidly The switch cabinet door may be open gt Check ambient temperature The device will be switched on and the ambient temperature is too low gt Check ambient temperature 055 Hardware Monitoring Debug Message Diagnosis class standard 8 MsgFilter Bit 14 Filter Type 15 See also Diagnosis message 056 Shutdown due to supply voltage outage Diagnosis message 827 Power Off due to hardware monitoring DiagMsg gt specific error message for debuggin
167. s not available or not correct gt Check to see if there is a valid firmware file available Optional module in the controller not available gt Install module in controller or send controller in to be converted An optional module was entered in the PLC configuration that is not available gt Check PLC configuration A phys encoder SinCos encoder is entered in the PLC configuration at BT 4 ENC1 but no phys encoder is recognized at plug connector BT 4 ENC1 gt Put incremental encoder cable on BT 4 ENC1 connector gt Check encoder cable The I O address is incorrectly set gt Check I O address Hardware error Module defective gt Replace module Hardware error Controller defective gt Replace controller PacDrive Controller P600 Page 129 Page 130 721 Module not ready Diagnosis class see 8 1 Diagnosis Classes standard 4 The module does not respond after initialization by the controller gt Module defective Replace module in controller Ext diagnosis no answer Watchdog monitoring for the Profibus module has triggered The module does not respond within the preset monitoring time see default configuration Replace module in controller Ext diagnosis FPGA defect Unable to program FPGA The module is not ready Replace module in controller Ext diagnosis FPGA PinOut The FPGA firmware file does not match the FPGA pinout This may result in damage to the mo
168. s refer to the occurrence of the first fault as a simple cycle error Secondly they refer to the occurrence of a multiple cycle error which results when simple cycle errors occur directly after each other Finally a recording is made directly before the controller returns to phase 0 These recordings are displayed in the message logger To prevent these messages from being displayed when a machine is shut down intentionally they will be displayed with a delay of 10 seconds and then triggered at a lower priority level If during this time the pending errors are acknowledged the message will also be displayed without delay Requirements PacDrive Controller P600 ELAU AG The following requirements must be observed when using the extended SERCOS diagnosis PacDrive controller firmware version V00 16 30 or higher EPAS 4 as of V 16 22 or higher PacControl CD V16 SP3 Operation Activation To activate the extended SERCOS diagnosis the BitO of the TestSwitch1 must be set NOTE ELAU AG to 1 in the PLC configuration The Testswitch1 may only be set in version V00 16 30 V00 16 40 or higher It will no longer be required in the final version In versions above V00 16 40 expect the Testswitch to have a new purpose with different functions E Steuerungskonfiguration B Steuerungskonfiguration 4 te Name Bersch _ p AutoRun Sf PacDeive C600 lt PacDrveM gt Er deasch j0 dutsch SyAligemein 3
169. s shown in the ext diagnosis in the message logger e g V00 02 05 MAx4 004 IEC program started The IEC program in the PacDrive controller was restarted 005 automatic program start active The autom program start of the IEC program is active in the PacDrive controller 006 IEC program stopped The IEC program in the PacDrive controller was stopped 007 login A login to the PacDrive controller was performed The application that performed the login e g EPAS 4 is shown in the extended diagnosis PacDrive Controller P600 Page 55 NOTE Page 56 008 logout A logout from the PacDrive controller was performed The application that performed the logout e g EPAS 4 is displayed in the extended diagnosis 009 IEC program reset A program reset was triggered with EPAS 4 010 write file File transfer via communication server The file name is displayed in DiagExtCode 011 connect to WEBS Connecting to webserver 012 disconnect from WEBS Disconnecting from webserver 013 connect to TCP IP server Connecting to communication server of PacDrive controller 014 disconnect from TCP IP server Disconnecting from communication server of PacDrive controller 015 filesystem lt ideO gt repaired Error in filesystem detected and corrected The filesystem is consistent again This may also mean that files have been deleted 016 system reset Warmstart 017 CanOpen emergency message reset A CANopen node h
170. sage continues to exist this diagnostic message will be recognized in the PacDrive system again Instanz Diag Code Ext Diagnose Meldungstext 17 Mi08 Dez 2004 08 00 51 923 0x0002 MC_4 Servol 1118 Fehler auf ser Schnittstelle zum Geber 16 Mi08 Dez 2004 08 00 51 923 0x0002 MC_4 Servol 1105 Feedbackfehler Spurtiberwachung 15 Mi08 Dez 2004 08 00 51 897 0x0002 LZS LZS 8001 Error Ouit Diagnosequittung 14 Mi08 Dez 2004 08 00 37 032 0x0002 MC_4 Servol 1118 Fehler auf ser Schnittstelle zum Geber 13 Mi08 Dez 2004 08 00 37 032 0x0002 MC_4 Servol 1105 Feedbackfehler Spuriiberwachung Figure 8 4 Message logger example for diagnostic messages produced again follow ing acknowledgement With the following errors it is also necessary to reset the triggering device for reasons of safety or due to the far reaching consequences of the error This occurs with the reset button on the device or by switching the device s control voltage off and on again 105 Feedback error track monitoring 107 over current 113 braking resistor defective 114 Reading error EEPROM 115 Gate power failure 117 Reading error encoder EEPROM 118 Error in servo interface with encoder 119 Short or ground circuit in output stage 138 Prohibited motor 144 DC bus short circuit 145 DC bus ground circuit 148 Internal voltage error 15V 160 Under voltage power stage driver 202 Faulty configuration file
171. see 8 5 2 12 111 Excessive following error 116 Commutation error see 8 5 2 17 116 Commutation error 117 Reading error encoder EEPROM see 8 5 2 18 117 Reading error encoder EEPROM 118 Error on serial interface to encoder see 8 5 2 19 118 Error on serial interface to encoder 112 Max motor speed reached see 8 5 2 23 112 Max motor speed reached The above error messages are disabled in the motorless mode Motorless Parameter yes and result in the 137 Motorless error message when reverting to normal mode Motorless parameter no Note here that the 105 117 and 118 diagnosis messages can also result in the 137 Motorless diagnosis message if the messages occur in normal mode and afterwards the mode is switched to motorless and then back to normal A motor error has occurred gt Perform a hardware reset on MC 4 or switch back to motorless mode The MC 4 was not switched off when coupling a motor to a servo amplifier that was set to motorless The servo amplifier was switched to normal mode after wards gt Perform a hardware reset on MC 4 or switch back to motorless mode 138 Impermissible motor Diagnosis class see 8 1 Diagnosis Classes standard 1 Reaction see 8 2 Reactions A An impermissible motor is connected to the servo amplifier An SM 070 60 010 is connected to the MC 4 22 A gt Use a larger motor e g SM 070 60 020 or a smaller servo amplifier e g MC 4 10 A An SM
172. sentative 754 CanOpen emergency message Diagnosis class see 8 1 Diagnosis Classes standard 4 A CANopen node has sent an emergency message to the bus Meaning of ext diagnosis The system displays the node address the error code and the error register Structure Nxxx Cxxxx Rxx N node address decimal CANopen node address C error code hexadecimal CANopen error code Error code hex Meaning 00xx Error reset or no error 10xx Generic error 20xx Current 21xx Current device input side 22xx Current inside the device 23xx Current device output side 30xx Voltage 31xx Mains voltage 32xx Voltage inside the device 33xx Output voltage 40xx Temperature 41xx Ambient temperature 42xx Device temperature 50xx Device hardware 60xx Device software 61xx Internal software 62xx User software 63xx Data set 70xx Additional modules 80xx Monitoring 81xx Communication 90xx External error FOxx Additional function FF xx Device specific Table 8 8 Error Code hex and meaning Bit M O Meaning 0 M Generic error 0 O Current 0 O Voltage 0 O Temperature PacDrive Controller P600 Page 137 Page 138 Bit M O Meaning 0 O Communication error overrun error state 0 O Device profile specific 0 O Reserved 0 O Manufacturer specific Table 8 9 R error register hexadecimal CANopen error register Bit Bit number in error register M O
173. slave is incorrect i The firmware version of the SERCOS slaves MC 4 SCL PS 4 is higher than the firmware version of the PacDrive controller in the first 4 positions gt Update the PacDrive controller firmware or import an older firmware version into the SERCOS slave z Ext diagnosis Vxx yy zz BLD The SERCOS slave is in bootloader mode The version of the bootloader is dis played in the message logger under Ext diagnosis The SERCOS slave can also be found using the information on the object and instance provided in the mes sage logger Disconnect the programming cable from the SERCOS slave Reset the SERCOS slaves Acknowledge the diagnosis message The SERCOS bus is running in phase 4 lt vvVv 510 EZB IRQ lost Diagnosis class see 8 1 Diagnosis Classes default 4 The interrupt of the SERCOS bus has not been received in at least twice the cycle time This diagnosis message normally occurs at the same time as other diagnosis messages 504 Read cycle overflow see 8 5 6 5 504 Read cycle overflow 507 Write cycle overflow see 8 5 6 8 507 Write cycle overflow The problem occurs when the system shuts down The 24 V control voltage of the SERCOS slave is removed faster than the 24 V control voltage of the Pac Drive controller gt Check the wiring or connection diagram Wiring error The fiberoptic conductor of the SERCOS bus is damaged gt Replace the fiberoptic conductor A SERCOS slave
174. st one slave is not exchanging cyclical I O data The error code specified after Err corresponds to the error code of the ErrorCodeparameter Slave has been disabled gt Reactivate slave At least one slave is not configured correctly gt Check the configuration Wiring error Cable fault in bus gt Check cable Wiring error Incorrect bus topology gt Check terminals transmission lines 732 Slave not responding Diagnosis class see 8 1 Diagnosis Classes standard 4 Slave with bus address preceded by S1 is not exchanging cyclical I O data The error code specified after Err corresponds to the error code of the ErrorCodepa rameter If the Activation parameter is set to false then this diagnosis message will not be triggered in V00 20 00 or higher Slave has been disabled gt Reactivate slave At least one slave is not configured correctly gt Check the configuration z Wiring error Cable fault in PROFIBUS DP gt Check cable Wiring error Incorrect bus topology gt Check terminals transmission lines 733 Fatal bus error Diagnosis class see 8 1 Diagnosis Classes standard 4 Further bus communication is not possible due to a severe bus error ELAU AG PacDrive Controller P600 Page 133 Page 134 No data exchange with bus terminal BT 4 ENC1 Position loss of the master encoder connected to bus terminal BT 4 ENC1 Acknowledge the diagnosis message only aft
175. stance OutputGroup The status of the digital outputs remains unchanged until the supply voltage connector X1 has fallen to 0 volts The diagnosis message can be entered in the message log when the controller is switched off as the voltage drop of the supply voltage causes a Spi error before the CPU detects a power failure Instance InputGroup The digital inputs cannot be evaluated The diagnosis message can be entered in the message log when the controller is switched off as the voltage drop of the supply voltage causes a Spi error before the CPU detects a power failure gt Check the supply voltage Page 142 PacDrive Controller P600 ELAU AG Ext diagnosis Ref PowerFail Evaluation of the digital inputs in accordance with the en61131 2 type 1 standard is no longer guaranteed The diagnosis message can be entered in the message log when the controller is switched off as the voltage drop of the supply voltage causes a Ref PowerFail error before the CPU detects a power failure Check the supply voltage 786 Asynchronous to SERCOS bus Diagnosis class see 8 1 Diagnosis Classes standard 4 787 Configuration error Diagnosis class see 8 1 Diagnosis Classes standard 4 A configuration error has occurred Yv vV v Ext diagnosis Mtype xx wrong xx detected module A non configured module was detected on PacNet The module cannot be used Check the configuration of the module in the control configuration Ext diagnosi
176. standard 2 821 File not continuous Diagnosis class see 8 1 Diagnosis Classes standard 2 822 Cluster read error Diagnosis class see 8 1 Diagnosis Classes standard 2 823 Contents of file different Diagnosis class see 8 1 Diagnosis Classes standard 2 PacDrive Controller P600 ELAU AG ELAU AG 824 No filename Diagnosis class see 8 1 Diagnosis Classes standard 2 825 Invalid directory size Diagnosis class see 8 1 Diagnosis Classes standard 2 826 Error During PIC FW Update Diagnosis class see 8 1 Diagnosis Classes standard 1 An error occurred during a firmware exchange for the PIC controller on C400 C600 or P600 The PacDrive controller is in bootloader mode and is attempting to exchange the firmware again The firmware such as file c6p_0511 bin is on the flash disk C400 and C600 or on the hard disk P600 When the firmware has been exchanged the controller will be reset Reset PacDrive controller P600 has no automatic reset A note appears on the display After the real time system successfully starts up the firmware file is deleted automatically Ext diagnosis bootl active This message appears after an unsuccessful PIC firmware update gt The PacDrive controller attempts to exchange the firmware again gt If this attempt also fails contact your ELAU customer service representative x Ext diagnosis File not found This message appears with message bootl active
177. stic message 107 over current see 8 5 2 8 107 Excess current switch off does not occur as soon as the current threshold has been exceeded The thermal overload of the device is observed for a specific period of time Too many loads e g ServoDrive SCL are connected to the DC circuit gt It may be that the existing device constellation will be sufficient by adapting the application e g less acceleration gt Use another mains device PS 4 and distribute supply of loads 147 24V power supply overload Diagnostic class see 8 1 Diagnosis Classes standard 1 Reaction see 8 2 Reactions B The 24 V available at the output of the PS 4 to supply the ServoDrive SCL is over loaded Wiring error Short circuit occurred gt Check wiring ofthe 24 V supply from the PS 4 via the PD 8 incl the motor cable There are too many loads e g ServoDrive SCL connected to the 24 V supply gt Use another PS 4 power supply unit and divide up the supply of the loads 148 Internal voltage error 15V Diagnosis class see 8 1 Diagnosis Classes standard 1 Reaction see 8 2 Reactions A The device internal 15 V voltage is too low The device is defective PacDrive Controller P600 Page 89 Page 90 gt Replace the device 149 Internal voltage error 12V Diagnosis class see 8 1 Diagnosis Classes standard 1 Reaction see 8 2 Reactions B The device internal 12 V voltage is too low The device is defective
178. t function was used to change the times for monitoring single see 8 5 4 18 317 Cycle time overrun and excessive see 8 5 4 14 313 Excessive cycle time overrun cycles time overruns The times are shown in DiagExtCode 022 Calling SetTaskPriority The SetTaskPriority function was called 023 system shutdown SysShutdown is used via IEC function SysShutdown UPS shutdown DiagExtMsg Windows If Windows XP is shut down while the real time system is running then the message in the P600 PacDrive controller may have other causes Supply voltage is OV gt UPS shuts P600 down The user shuts down Windows XP through the Start menu Until version VO0 16 xx the 016 system reset see 8 5 1 16 016 system reset diag nosis message was triggered PacDrive Controller P600 Page 57 Page 58 024 modem connected Successful connection through a modem 025 modem disconnected Disconnection via a modem 026 user exception The SysUserCallStack function caused an entry in the message logger The value the function delivers is available in Ext Diagnosis in the message logger The mes sage logger call hierarchy function can be used to backtrace the function block call or nesting 027 open write file 028 close write file 029 UPS ok UPS monitoring reported UPS ok State 1 030 UPS active no power UPS monitoring reports that no power is available State 3 031 UPS power ok UPS monitoring
179. t gt Fix All in the EPAS 4 and then Project gt Convert All Then transfer the project again to the controller and reset the controller EPAS 4 Online gt Resetting the PacDrive Controller 725 Firmware of the module was replaced Diagnosis class see 8 1 Diagnosis Classes standard 7 This message shows that the firmware of a fieldbus module was replaced In controller firmware version 00 16 40 or higher the version of the new fieldbus firm ware is displayed in the ext diagnosis in the message logger 726 Firmware of the module is incorrect Diagnosis class see 8 1 Diagnosis Classes standard 4 This message shows that the firmware of a fieldbus module is incorrect Firmware download for a fieldbus module via the controller failed gt Repeat the firmware download 730 Bad master parameter data Diagnosis class see 8 1 Diagnosis Classes standard 4 The slave and or master data of the configuration file are incorrect The error code specified after Err corresponds to the error code of the ErrorCodeparameter 5 Communication problems when transferring the control configuration from EPAS 4 to controller gt Transfer the controller configuration again Hardware error Controller or flash disk defective PacDrive Controller P600 ELAU AG gt Replace the controller 731 Automatic bus deactivation Diagnosis class see 8 1 Diagnosis Classes standard 4 The Auto Clear Bit in the master is set and at lea
180. t available or mappable write access to the index is not permitted for this node Electrical bus connection faulty or interrupted gt Check the electrical connection Ext diagnosis lt None gt Parameterization error gt See GlobalError parameter Bit 0 is set Contact your ELAU representative z Ext diagnosis Database Message is generated when a hardware error occurs gt Contact your ELAU representative PacDrive Controller P600 Page 139 Page 140 Ext diagnosis SI xx Err yy xx Contains the CANopen bus address of the slave that has configuration data with errors yy Contains the value of the Status parameter at the time the error occurred 758 Application object size not supported Diagnosis class see 8 1 Diagnosis Classes standard 4 The CANopen master provides the specified application objects If the application ob jects are configured in the CANopen node configuration with an application object size that is not available this diagnosis message will be triggered Meaning of ext diagnosis Structure Nxxx Cxxxx Rxx CID Pdo Cobld hexadecimal Coplf Identifier of the Pdos in which the application object has been mapped S size of the application object of the hexadecimal application object size N hexadecimal CANopen node address Configuration error gt Check the configuration 759 Application obj max count limit reached Diagnosis class see 8 1 Diagnosis Classes standard 4 The CAN
181. t nr gt 803 Inconsistency of FAT s 804 Corrupt cluster detected lt dirname gt 805 Corrupt filename detected lt dateiname gt 806 Corrupt file size detected lt dateiname gt 807 Multiple used cluster block detected lt dirname gt PacDrive Controller P600 ELAU AG DiagCode DiagMsg DiagExtCode 808 Corrupt directory name detected lt dirname gt 809 Circular linked clusters blocks detected lt dirname gt 810 Error reading directory entry lt dirname gt 811 Error writing directory entry lt dirname gt 812 Lost cluster block found lt number cluster gt 813 Device lt ide0 gt not found lt devicename gt 814 Initialization of lt ide0 gt failed lt devicename gt 815 Error using function with lt ide0 gt lt devicename gt 816 Bootrom sys 817 No devicename 818 File not found 819 File open error 820 File read error 821 File not continous 822 Cluster read error 823 Contents of file different 824 No file name 825 Invalid directory size 801 Error reading FAT Diagnosis class see 8 1 Diagnosis Classes standard 802 Error writing FAT Diagnosis class see 8 1 Diagnosis Classes standard 803 Inconsistency of FAT s Diagnosis class see 8 1 Diagnosis Classes standard 804 Corrupt cluster detected Diagnosis class see 8 1 Diagnosis Classes standard 805 Corrupt file name detected Diagnosis class see 8 1 Diagnosis Classes standard 806 Co
182. ta of the configuration file is incorrect Should occur together with the 730 Bad master parameter data diagnosis message If not the incorrect configuration will result in the Profibus card resetting z Communication problems gt Transfer the control configuration again The slave address has been assigned twice in the network gt Check the configuration Hardware error Flash disk defective gt Replace the flash disk PacDrive Controller P600 Page 131 Page 132 Hardware error Controller is defective gt Replace the controller 724 no I O area detected Diagnosis class see 8 1 Diagnosis Classes standard 4 The field bus server s did not detect an IEC I O area The I O area is prepared while loading the IEC program Subsequent error to diagnosis message 204 IEC program cannot be loaded gt See 204 IEC program cannot be loaded see 8 5 3 5 204 IEC program cannot be loaded diagnosis message 7 Libraries in the project were modified or replaced This can occur in controller versions below V00 16 20 gt Reset the controller EPAS 4 Online gt Reset PacDrive Controller z A project was transferred with EPAS 4 using a different setting from the Max NumOfPOUs in the EPAS 4 ini file gt Adjust the setting for MaxNumOfPOUs to match your EPAS R installations Re set the controller EPAS 4 Online gt Reset PacDrive Controller z Defective project gt Reconvert the project by choosing Projec
183. th a matching pinout was found on the flash disk C400 or C600 or hard disk P600 xpxx corresponds to the FPGA firmware version The FPGA programming was not executed The PinOut number p in the file name characterizes the required hardware version l e a specific hardware ver sion is required for each FPGA version gt Contact ELAU customer service to obtain the correct FPGA version for your hardware 047 PIC firmware download The firmware of the PIC controller on the PacDrive controller C400 C600 or P600 is being replaced The extended diagnosis code shows the name of the firmware file e g c6p_0510 bin If an error occurs during the firmware exchange the 826 PCI update error see 8 5 9 27 826 Error During PIC FW Update diagnosis message will be triggered 048 BT 4 DIO1 firmware download The firmware of the BT 4 DIO1 bus terminal is being exchanged In the following HW versions or higher an automatic FW update ofthe connected BT 4 DIO1 bus terminal is possible with controllers C200 C400 C600 and P600 P600 C600 C400 with FPGA version x311 or higher C200 with FPGA version x209 or higher Other requirements Firmware file for BT 4 DIO1 BD1_xxxx ESV ELAU AG PacDrive Controller P600 Page 61 Duration of the update NOTE NOTE Page 62 To execute the update the firmware file for the BT 4 DIO1 bus terminal must be copied to the root directory of the controller The update will be automatica
184. tic ring is closed and the light output at the receiver is optimal the LED is off Ifthe light output at the receiver is too high or too low high damping the LED will glow dimly The further away the light output moves from the optimal reception point i e too much or too little light output the brighter the LED glows The LED will glow at its brightest if the fiberoptic ring is interrupted Flickering or steady light indicates a problem with the SERCOS input of the device Controller Controller bus err LED flashing Cable Break Check intensity adjustment Figure 8 1 bus err LED flashes err LED of the PacDrive controller SERCOS Master Max 4 C200 C400 C600 P600 Other problems in the ring can be detected via the err LED PacDrive Controller P600 Page 51 LED permanent off no error normal mode an aus t s LED flashes 1 7Hz general error an aus 0 1 2 t s LED flashes fast 10Hz boot completed last boot failed an aus 0 1 0 t s LED flashes fast slow firmware download via SERCOS active an aus 0 6 1 2 1 8 2 4 tis LED permanent on fatal system error an aus tis PO_ErcecPacOrivecortoller_us the Figure 8 2 Display status of the err diagnosis LED of the PacDrive controller Page 52 PacDrive Controller P600 ELAU AG 8 4 ELAU AG err LED of the slave devices e g MC 4 PS 4 SCL LED permanent off no error an aus t s LED flashes general error an aus
185. time is too high gt Check the cycle time gt Check the BaudRate Ext diagnosis SercDrv lt number of licensed SERCOS SercDrv slaves gt lt number of configured SERCOS SercDrv slaves gt Limited by the hardware configuration licensing Before leaving the SERCOS phase 0 the number of configured real SERCOS SercDrv slaves in the control configuration will be checked The number must be smaller or equal to the licensed number for the PacDrive controller If this value is exceeded the startup will be cancelled The extended diagnosis shows the licensed and the configured number together with the SercDrv prefix gt Check the PacDrive controller type gt Contact your ELAU representative 6xx master encoder diagnosis messages 600 Serial interface problem Diagnosis class see 8 1 Diagnosis Classes standard 4 An error has occurred while exchanging data with the SinCos master encoder via the serial interface of the encoder InitPosition and EncoderPosition are possibly incorrect Damage may result from a non referenced machine Reset the PacDrive controller after you have corrected the error x Wiring error The encoder cable is not plugged in correctly or is defective gt Check the encoder cable and replace if necessary gt Reset the PacDrive controller E Data is exchanged using the encoder s serial interface during the functions PhyEncGetPosition PhyEncResetEncoder and PhyEncSetPosition The ac
186. tly gt Reduce the IO data of the slave 739 Double profibus address assigned Diagnosis class see 8 1 Diagnosis Classes standard 4 The Profibus Adr xxx has been assigned twice in a master configuration i Slave is not configured correctly gt Check the configuration gt Adjust the addresses manually or select Addresses automatic in the properties dialog box of the Profibus master object in the control configuration 750 CanOpen node does not exist Diagnosis class see 8 1 Diagnosis Classes standard 4 PacDrive Controller P600 Page 135 Page 136 The bus will be examined for existing nodes using the default Sdo index 0x1000 This diagnosis message will be triggered if the configuration contains nodes that have not been detected Ext diagnosis Displays the node addresses of the nodes that have been configured but not detected on the bus Structure Nodeld xxx xxx decimal node address Node not switched on or ready when the check is performed node does not permit Sdo access to the index 0x1000 node addresses are not set correctly gt Check the configuration Electrical connection incorrect or defective gt Check the wiring 751 CanOpen node not configured Diagnosis class see 8 1 Diagnosis Classes standard 7 The bus will be examined for existing nodes using the default Sdo Index 0x1000 This diagnosis message will be triggered if nodes are detected that do not exist in the con figuration
187. to the operating instructions of the SERCOS device The individual bits of this data word have the following meanings Bit Po Meaning Bit 0 n feedback n command Bit 1 n feedback 0 PacDrive Controller P600 ELAU AG ELAU AG Bit Meaning Bit 2 n feedback lt n x Bit 3 T gt T x Bit 4 T gt T limit Bit 5 n command gt n limit Bit 6 in position Bit 7 P gt P x Bit 8 Position feedback Active target position Bit 9 n feedback lt minimum spindle speed Bit 10 n feedback gt maximum spindle speed Bit 11 In coarse position Bit 12 Target position attained Bit 13 Interpolator halted Bit 14 Reserved Bit 15 Manufacturer specific operation status see 9168 Table 8 6 SERCOS C3D operation status assignment according to SERCOS specitications 168 SERCOS C3D manufacturer specific status Diagnosis class see 8 1 Diagnosis Classes standard 9 Reaction manufacturer specific A manufacturer specific SERCOS operation status of diagnosis class 3 C3D has changed The extended diagnosis contains a data word that provides information on the exact cause For information on what each bit means refer to the manual of the SERCOS device manufacturer 169 Single SERCOS error SLAVE Diagnosis class see 8 1 Diagnosis Classes standard 6 Reaction see 8 2 Reactions D A temporary signal fault on the SERCOS bus has be
188. trical machinery Ensure that the drives are at a standstill as life threatening voltages can occur in the motor lines of servo motors in generator mode Disconnect the plug in connectors that are not live Electrostatic discharge Damage to component possible Touch circuit boards only on edges Do not touch any of the circuit points or com ponents Before touching the circuit boards you should remove any static loads When do ing so first touch a grounded metallic surface such as the housing Do not put the circuit boards on a metal surface Avoid the production of electrostatic charge by having suitable clothing carpets and furniture and by moving the boards as little as possible Open master switch Secure it against being re energized Disconnect connecting lines from the PacDrive controller Loosen screws on the top and bottom of the housing Remove PacDrive controller vvvvy Electrostatic discharge Damage to component possible Use the original or similar packaging to send back electronic parts The compo nents must be packed in ESD packaging foil or the warranty is void gt Install new PacDrive controller and tighten screws gt Connect new PacDrive controller according to machine s circuit diagram PacDrive Controller P600 Page 31 6 5 6 6 Unpack and in spect Installation Connect to electricity Connect control voltage 24V Page 32 For commissionin
189. tual data exchange is performed by the system task TASK_TYPE_PHY_ENC_JOB_Server If the functions are active this task must query the serial interface on a regular basis usually lt 2ms Insufficiently allocated processing time may result in data loss diagnosis message 600 The TASK_TYPE_PHY_ENC_JOB_Server system task runs at IEC priority 5 PacDrive Controller P600 ELAU AG 8 5 8 ELAU AG same as system priority 225 If the above functions in the IEC tasks are called with a priority of 1 to 4 this problem may result when the processing require ments are too high gt Increase the priority of the system task gt Reset the PacDrive controller Example The PhyEncGetPosition function is triggered from an IEC task with IEC priority of 4 The IEC task normally requires 2 5ms for processing Increase the priority of the sys tem task from 225 or IEC priority 5 to 224 IEC priority 4 for example SetTaskPriority ITaskType TASK_TYP_PHY_ENC_JOB_Server IPriority 224 Hardware error The SinCos encoder is defective gt Replace the encoder gt Reset the PacDrive controller Hardware error The SinCos encoder interface in the controller is defective gt Replace the controller 601 Encoder track error Diagnosis class see 8 1 Diagnosis Classes standard 4 Unable to receive analog data from the SinCos master encoder Hardware encoder error Position loss of the master encoder Acknowledge the diagnosis m
190. uction Read this manual before you use ELAU Components for the first time Take particular note of the safety instructions see 2 General Safety Instructions As described in section 2 4 only those persons who meetthe Selection and qualification of employees see 2 4 Selection and Qualification of Employees are allowed to work on this unit A copy of this manual must always be available for personnel who are entrusted to work on ELAU components This manual is intended to help you use ELAU Components and its intended applica tions safely and properly You must observe the contents of this manual Doing so helps avoid hazards minimize repair costs and downtime extend service life and increase reliability You must also observe the rules and regulations on accident prevention and environ mental protection that apply in the country where the product is used and at the installation location PacDrive Controller P600 ELAU AG 1 2 ELAU AG Symbols Characters and Notation The following symbols and characters are used in this document Representation Meaning B First level bullet point Second level bullet point gt Activity symbol The text after this symbol contains an instruction Follow the instructions in order from top to bottom v Result symbol The text after this symbol contains the result of an action If the descriptive text contains technical terms such as parameters they Keyword are highlighted in
191. uipment Position EMERGENCY OFF switches so that they are easily assessable and can be quickly reached The functionality of EMERGENCY OFF equipment should be checked before start up and during maintenance periods Prevent unintentional start ups by disconnecting the power connection of the drive using the EMERGENCY OFF circuit or using a secure start up lock out Bring the drives to a complete standstill before accessing or entering the danger zone While working on the system de energize the electrical equipment using the main switch and prevent it from being switched back on Avoid operating high frequency remote control and radio devices close to the unit and system electronics and their feed lines If such usage is unavoidable you must check the system for possible malfunctions in all positions of normal use before initial start up Where applicable it is necessary to carry out a special EMC check of the system Protective extra low voltage The signal voltage and control voltage of the PacDrive devices are lt 33 Volts In this range and in accordance with IEC 60364 4 41 the specification as PELV system con tains a protective measure to guard against direct and indirect contact with dangerous voltage through safe separation of the primary and secondary side in the system machine ELAU strongly recommends that the system machine be run with safe elec trical separation High voltage due to incorrect conne
192. unauthorized program changes Order numbers PacDrive controller P600 Product ID Code P600 10 1 1 1 1 1 00 HW Variant ee Processor lt M 1 Intel Pentium M 1 6 GHz RAM 1 512 MB Flash memory Harddisk DVD Rom Optional Functions Figure 6 1 Type code PacDrive controller P600 PacDrive Controller P600 ELAU AG Order number Explanations 13 13 02 63 PacDrive P600 10 1 1 1 1 1 00 P600 Table 6 1 Order numbers and variants of the PacDrive controller P600 6 8 2 Cable Encoder cable Order number 15 15 42 11 XXX Item name E FB 065 MAx SIN ME UL Explanations on C400 C600 P600 X11 15 15 42 12 XXX E FB 066 MAx SIN ME on C400 C600 P600 X11 15 15 42 19 E FB 076 Incremental encoder on C400 C600 P600 X11 Table 6 2 Order numbers of encoder cables Interface cable Order number 15 15 43 01 Item name E SS 054 PC Explanations on C400 C600 P600 X17 COM1 15 15 43 03 XXX E SS 056 REAL TIME BUS on MC 4 X5 X6 on C400 C600 P600 X14 X15 15 15 43 04 030 E SS 057 PC on MC 4 X7 Table 6 3 Order numbers of interface cables 6 8 3 Accessories Order number Item name Explanations 13 13 02 57 Bus terminal BT 4 DIO1 for PacNet 13 13 02 64 Bus terminal BT 4 ENC1 for PacNet 17 19 50 04 ME SINCOS SRS50 STAND ALONE Master encoder 17 19 50 05 ME SINCOS SRM50 KVAF MULTITURN Master encoder
193. usAdr parameter in the control configuration 518 Too many real SERCOS Slaves Diagnosis class see 8 1 Diagnosis Classes standard 4 The number of real SERCOS slaves is too high Ext diagnosis HW lt maximum number of SERCOS slaves on controller gt lt number of configured SERCOS slaves gt z Limited by the controller type Before exiting the SERCOS phase 0 the number of configured real SERCOS slaves in the control configuration will be checked The number must be smaller or equal to the licensed number for the PacDrive controller If this number is PacDrive Controller P600 Page 123 8 5 7 Page 124 exceeded the startup will be cancelled The extended diagnosis shows the li censed and the configured number together with the HW prefix gt Check the PacDrive controller type by referring to the type plate Ext diagnosis BUS t lt cycle time overrun gt us The communication parameters of the SERCOS slave are queried in the SER COS phase 2 Together with the settings ofthe SERCOS master the time slots for the cyclical telegram traffic will be determined and set The BaudRate and CycleTime parameters determine the available BUS bandwidth Ifthe bandwidth is insufficient the startup will be cancelled with the 518 Too many real SERCOS Slaves diagnosis message The extended diagnosis shows the time by which the cycle time has been exceeded as a negative value The number of SERCOS slaves MC 4 PS 4 SCL for the cycle
194. versions of software for the controllers gt Contact your ELAU representative Ext Diagnosis Ping Master The synchronization master failed to respond to a ping gt Check the Ethernet connection to the synchronization master Ext Diagnosis Dupl Slave IP object SYN_MOD The IP address SlavelPAddress of the sync module is assigned twice gt Check the SlavelPAddress parameter of the sync module in the synchronization master controller configuration Ext Diagnosis SlaveCycleTime SlaveCycleTime is not a multiple of the SERCOS cycle time gt Adjust the parameter SlaveCycleTime or SERCOS cycle time Ext diagnosis Wrong config object SYN_MOD The addressed synchronization slave is not configured properly or is not re sponding gt Checks the confirmation of the synchronization slave e g same CycleTime gt Check the TCP IP connection synchronization master to synchronization slave PacDrive Controller P600 ELAU AG ELAU AG Ext Ext Ext v Ext Ext diagnosis Wrong config object SYN_S The SERCOS cycle time differs on synchronization master and synchronization slave or the synchronization slave configuration cannot be sent Adjust the 2178 CycleTime parameter of the synchronization master or the synchronization slave diagnosis Wrong State The addressed synchronization slave is in an error state Acknowledge the error in the synchronization slave diagnosis No
195. vices Refer also to chapter entitled Maintenance gt Connect devices beginning with the ground conductor gt Check that terminals are secure and check necessary cable cross sectional areas for correctness gt Check for smooth execution of shielding rule out short circuits and breaks Refer also to chapters entitled Technical information and Maintenance gt Check the power supply voltage and control voltage PacDrive Controller P600 ELAU AG Check safely functions Connect mains voltage Move axis Transmit con figuration and program Perform func tion test Continue start up of system ELAU AG v Connect external 24V control voltage The PacDrive controller initializes and the LEDs should display the following pow ON err ON buserr not defined wd ON Following the boot the following conditions should be reached pow ON err OFF buserr OFF wd OFF Refer also to chapter entitled Diagnosis gt Check motor thermal contact or PTC see operating instructions for connected components Check brake function if present Check EMERGENCY STOP chain and EMERGENCY STOP limit switch Activate EMERGENCY STOP switch Connect mains voltage Check status displays for proper function Disconnect EMERGENCY STOP switch Use a reliable small application program when moving axis for the first time in order to check the correct direction of rotation of the axis check
196. y Too much braking energy is being fed from the connected SCL back into DC bus gt Decelerate the drives before discharging at a reduced rate of speed if neces sary and then start the discharge procedure Incorrect shutdown sequence phase voltage has been present for too long see also 159 DC bus no discharged warning see 8 5 2 60 159 DC bus no dis charged warning gt Allow the mains contractor to release before activating the discharge The bleeder responsible for the discharge reaches its maximum load when the discharge begins gt Decelerate the drives before discharging at a reduced rate of speed if neces sary and then start the discharge procedure 154 Phase L1 warning Diagnosis class see 8 1 Diagnosis Classes standard 6 Reaction see 8 2 Reactions D The L1 phase of the mains connection to the device has failed If the warning persists for 10 s or longer the system issues the error message 150 Phase L1 failure see 8 5 2 51 150 Phase L1 failure 155 Phase L2 warning Diagnosis class see 8 1 Diagnosis Classes standard 6 Reaction see 8 2 Reactions D The L2 phase of the mains connection to the device has failed If the warning persists for 10 s or longer the system issues the error message 151 Phase L2 failure see 8 5 2 52 151 Phase L2 failure 156 Phase L3 warning Diagnosis class see 8 1 Diagnosis Classes standard 6 Reaction see 8 2 Reactions D The L3 phase of
197. y difficult to design the machine flexibly for various products Even minor changes in the packaging process especially during product changeover are associated with considerable conversion efforts and machine breakdown Packaging machines with an electronic shaft on the other hand enable complete flexibility Electronic servo drive systems are used instead of curves and linkage and a virtual electronic shaft ensures that the individual motion axes are synchronized Desired synchronous movements and movements with angular synchronism are specified by a central controller Unplanned machine conditions such as stop or emergency stop situations and initial ization motions can be realized with angular synchronism Dynamic changes of the packaged goods or packaging in the system such as slippage of the products to be packaged or a stretching of the packaging material can be recorded by sensors while the machine is running and eliminated by adapting the corresponding motion proc esses The classical mechanical machine design has been permanently changed and significantly simplified by this development The structure of the packaging machine can be broken down into clear and standardizable modules En Foil wrapping roll Nc Product feed conveyor Y D Cross sealing station Length wise gt sealing station Preservative gas system Take off conveyor Figure 3 1 Diagram of a packaging machine PacDrive Controller P600 Page 13
198. y transferring the IEC project dummy with the default configuration Check your program and send an error free project to the PacDrive controller DiagExtCode is not 19 Contact your ELAU representative The PacDrive controller was booted twice in quick succession This may have been caused by pressing the reset button twice or a drop in the control voltage Check the control voltage also refer to the technical data Insufficient RAM in the PacDrive controller for the project DiagExtCode out of memory Meaning A memory requirement could not be executed Memory requirements are exe cuted when booting resetting the IEC task calling a system functional block setting reading parameters establishing terminating an FTP connection trans ferring data remote device communicating with EPAS 4 establishing termi nating a Telnet connection and communicating with Telnet PacDrive Controller P600 ELAU AG Reduce configuration RamDiskSize must be decreased Reduce number of tasks Apply a PacDrive controller that has more RAM Yv v Vv A PacDrive controller with version 00 15 00 or higher is being used The user data area was increased from 2 MB to 3 7 MB in this version Ifthe PacDrive controller has less than 32 MB of RAM the PacDrive will start up in minimal boot mode gt Use a PacDrive controller that has least 32 MB of RAM or firmware version V00 15 00 or lower 210 Last boot failed Diagnosis class see 8 1 Diagn
199. y using protector type based industry standard quenching circuits during alternating current activity Only a suppression element that is arranged directly on the inductance fulfills the purpose In some cases even more interference may be generated by the shock of the switching current on the interference suppression lines It is far easier to avoid the source of interference than to eliminate the effects of existing interfer ence Contacts that do not switch suppressed inductive loads should never be arranged ina room with ELAU PacDrive components The same applies for connection lines that do not lead suppressed switched inductances and lines that run parallel to them Isolate the control from such interference sources using a Faraday cage separately partitioned switching cabinet PacDrive Controller P600 ELAU AG 6 4 ELAU AG Electromagnetic fields System errors or system failure may occur Mains filters and motor filters may by used depending on the combination of the servo amplifier motor and the cable length Refer to the project planning guide for the PacDrive system Device replacement In addition to the information given below please also observe the machine manu facturer s instructions when replacing the PacDrive controllers Replace PacDrive controller gt Take preliminary measures High voltage Risk of death Open the master switch and secure it against switching on again before working on elec
200. yed in the diag nosis message gt Check ifthe address setting on the SERCOS slave matches the address setting in the control configuration RealTimeBusAdfr The SERCOS address RealTimeBusAdr has not been specified correctly in the control configuration gt Check the RealTimeBusAdr parameter of the device displayed in the diagnosis message 513 Download result Diagnosis class see 8 1 Diagnosis Classes default 4 Filter type 2 Diagnosis messages An error has occurred during the program controlled firmware download Ext diagnosis SI lt SERCOS Address gt Err 479 An incorrect device type is indicated in the configuration file e g a PS 4 firmware for a MC 4 This diagnosis message is generated for each SERCOS slave gt Adjust the configuration file Ext diagnosis SI lt SERCOS Address gt Err 495 The Download Mode in the configuration file is specified as upgrade or downgrade and the current firmware version is higher or lower than the firm ware version that is to be programmed gt Check the firmware version of the SERCOS slave PacDrive Controller P600 ELAU AG ELAU AG gt Adjust the configuration file 514 Error download configuration file Diagnosis class see 8 1 Diagnosis Classes default 4 516 SERCOS wrong device position Diagnosis class see 8 1 Diagnosis Classes default 1 While starting up the SERCOS bus at the end of phase 3 the assignment of the SCLs to the PS

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