1. ELAU Service Diagnostics
PacDrive M
PacDrive III
Dilhan Don Liyanage

2. Content
State LED´s
State parameter of the PLC Configuration (PacDrive Diagnostics)
Online help
DiagnosisCode
PD Diagnostics one of the best tools as can read from the controller and can’t write to it and hence can’t do any damage
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3. Diagnosis via LED state of the MAx 4
pow (Control voltage)
Off: Control voltage is missing or too low ( 24V - 15% => ca. 20V )
On : Normal mode
wd (Watchdog)
Off : Normal mode
On : Fatal error
e.g. HW-error, processor is standing still => reset necessary
err (error)
Off : Normal mode
Flash 1,7 Hz: Error class 1-5 active
DiagnosisCode: 1xxx ... 5xxx
Flash 10 Hz: Boot sequece failed
e.g. Configuration file demaged or Minimal boot
On : Fatal error during boot sequence
e.g. Cancelling boot sequence
Hint: State of bus err-LED is not definded during boot sequence.
The Controller and the MotorController have control - and error LED´s which allow initial diagnosis
even without Software. (see reference manual chapter and 4.2.2)
Minimalboot of the Controller MAx-4
Is there a fatal error in the boot sequence the user can start a minimal boot. Hereby the user files
(PLCconfiguration and IEC program) are not considered.
Press during the boot sequence ( err LED on) the reset button.
The Controller and the MotorController have control - and error LED´s which allow initial diagnosis even without Software. (see reference manual chapter and 4.2.2)
Minimalboot of the Controller MAx-4
Is there a fatal error in the boot sequence the user can start a minimal boot. Hereby the user files (PLCconfiguration and IEC program) are not considered.
Press during the boot sequence ( err LED on) the reset button.
buserr (Sercos bus error)
Off : Normal mode
On : Bus error fiber optics
e.g. Sercos Ring not closed, fiber optics broken
or intensity fiber optics not fit to length of cable
(PLC configuration | RTB | No. 2 - Intensity)
See Refernce manual chapter 3.1.6
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4. LED state of the C400, C600 and P600 C200 C400, C600 and P600
Content of display is programmable
Inquiry of keys via IEC program
Diagnosis of the LED´s are according to
MAx-4
The Display of the Controllers Cx00 and P600 are showing the IP-Address and the FW – Version .
The interface is an open IEC interface, with the possibility to program the display when
FW-Version >=
So you can display your individual values like e.g. Diagnosis code, diagnosis message etc.
The LED´s for
Power,
wd,
err,
Buserr
are having the same meaning as on the MAx-4 (see page 3)
The Display of the Controllers Cx00 and P600 are showing the IP-Address and the FW – Version .
The interface is an open IEC interface, with the possibility to program the display when FW-Version >=
So you can display your individual values like e.g. Diagnosis code, diagnosis message etc.
The LED´s for
Power,
wd,
err,
Buserr
are having the same meaning as on the MAx-4 (see page 3)
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5. Diagnosis via LED state of the MC- 4
reset
pow
err
buserr S1
x10 S2
x01
pow (Control voltage)
Off : Control voltage is missing or too low ( 24V - 15% => ca. 20V )
On : Normal mode
err (Fehler)
Off : Normal mode
Flash 0,5 Hz: Fatal Sercos-error
DiagnosisCode: x5xx
Flash 2 Hz: Error reaction A, B or C
See reference manual chapter 4.4 ‚Diagnosis classes and reaction‘
On : Fatal error during boot sequence
e.g. Cancelling boot sequence
Hint: State of bus err-LED is not definded during boot sequence.
Diagnosis LEDs of the MotorController MC-4
pow (Control voltage display)
Off: Control Voltage (24V) is missing or too low.
On: Normal mode; Control voltage is within the limit
Switches S1 and S2
With the switches S1 and S2 you adapt the addresses of the MC-4. S1 is the 1st digit S2 the 2nd digit.
err (error display)
Off: normal mode
Flashing with 0,5 Hz: fatal SERCOS error
Flashing with 2 Hz: Error with reaction A, B or C
On: serious error duringboot sequence.
buserr
Off: Normal mode
On : Bus error fiber optics
e.g. Sercos-Ring not closed, fiber optics broken
or intensity setting incorrect for length of cable (Switch S3 )
Diagnosis LEDs of the MotorController MC-4
pow (Control voltage display)
Off: Control Voltage (24V) is missing or too low.
On: Normal mode; Control voltage is within the limit
Switches S1 and S2
With the switches S1 and S2 you adapt the addresses of the MC-4. S1 is the 1st digit S2 the 2nd digit.
err (error display)
Off: normal mode
Flashing with 0,5 Hz: fatal SERCOS error
Flashing with 2 Hz: Error with reaction A, B or C
On: serious error during boot sequence.
buserr
Off: Normal mode
On : Bus error fiber optics
e.g. Sercos-Ring not closed, fiber optics broken
or intensity setting incorrect for length of cable (Switch S3 )
buserr (Sercos bus error)
Off : Normal mode
On : Bus error fiber optics
e.g. Sercos Ring not closed, fiber optics broken
or intensity fiber optics not fit to length of cable (Switch S3 )
See Refernce manual chapter picture 3-2
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6. State parameter MotorController Controller DiagnosisCode is 2111
Diagnosis Message is Excessive Following error
MotorController
Every system event generates a 4-digit DiagnosisCode, which is shown in the PLCConfiguration in the folder Diagnosis of the Controller.
If the source of this diagnosis code is an expansion object you can see the diagnosis code also in the state folder of the expansion object itself.
In the upper example is the State - folder of the MotorController.
Because of that in the Diagnosis folder you can see also the object ( MC_4) and the instance name (MC_Drive_2).
The error ‚Excessive Following error‘ means, that the deviation between reference position (RefPosition) and actual position (Position) had more than 8-times the value as the parameter FollowingLimit in folder Controller.
The message logger records system, diagnosis and usage messages in a message log buffer in the RAM
of the MAx-4 Controller.
The errors are recorded in chronological order in a ring buffer (approx. 325 entries). A time stamp (ms
since system start), the time, object, instance, diagnosis code, external diagnosis and message text are
recorded. As the message buffer in the RAM can only be buffered for a maximum of 7 days in case of
power failure, it is possible to save the message log buffer in a messge log file on the flash disk in the
MAx-4 Controller. The MAx-4 Controller can save several message log files on its disk. The message log
files can be transmitted from the MAx-4 Controller to the PC with the help of EPAS-4. Several message
log files can be saved there as well.
The functions of the message logger in detail
Save and load a log file : Load the current message logger from MAx-4 Controller
in EPAS-4.
Save log file : message log buffer (RAM) 􀃖 message log file (MAx-4 file)
Reset log entries : clear message log buffer (RAM)
Save and reset log file : message log file (RAM) message log file (MAx-4 file)
clear message log buffer (RAM)
Load log file ... : message log file (MAx-4 file) PC file
display
Delete log file ... : delete MAx-4 file
Load from file ...: PC file display
Save as file ...: display PC file.
In folder ‚State‘ of the instance ‚MC_Drive_2‘ are DiagnosisCode and
DiagnosisMessage stored also.
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7. Message logger (Principle)
Shift register
Stores the last 325 messages in the NVRAM
( on the main module of the Controller )
First In First Out ( FIFO )
Content is buffered for maximum 7 days (without power)
Display via EPAS-4 user interface, content storable as *.mel file
The message logger records system, diagnosis and usage messages in a message log buffer in the RAM
of the MAx-4 Controller.
The errors are recorded in chronological order in a ring buffer (approx. 325 entries). A time stamp (ms
since system start), the time, object, instance, diagnosis code, external diagnosis and message text are
recorded. As the message buffer in the RAM can only be buffered for a maximum of 7 days in case of
power failure, it is possible to save the message log buffer in a messge log file on the flash disk in the
MAx-4 Controller. The MAx-4 Controller can save several message log files on its disk. The message log
files can be transmitted from the MAx-4 Controller to the PC with the help of EPAS-4. Several message
log files can be saved there as well.
The functions of the message logger in detail
􀂃 Save and load a log file : Load the current message logger from MAx-4 Controller
in EPAS-4.
􀂃 Save log file : message log buffer (RAM) 􀃖 message log file (MAx-4 file)
􀂃 Reset log entries : clear message log buffer (RAM)
􀂃 Save and reset log file : message log file (RAM) 􀃖 message log file (MAx-4 file)
􀃖 clear message log buffer (RAM)
􀂃 Load log file ... : message log file (MAx-4 file) 􀃖 PC file
􀃖 display
􀂃 Delete log file ... : delete MAx-4 file
􀂃 Load from file ...: PC file 􀃖 display
􀂃 Save as file ...: display 􀃖 PC file.
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8. Message logger (Call)
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9. DiagnosisCode ( Diagnosis class)
The real DiagnosisCode is contained in the last 3 digits.
The second digit (xXxx) relates to the object which activates the DiagnosisCode.
In case of the object is the MotorController.
The Controller assigns a „DiagCode“ to every exceptional case. This code consists of a diagnosis
class and a diagnosis group.
􀂃 The PacDriveM System distinguishes between 8 different Diagnosis classes, which have their own
system reactions
􀂃 The assignment of diagnosis classes to groups can be configured (with exceptions) by the
programmer. ( see function „DiagConfigSet“ in System.Lib )
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10. DiagnosisCode ( Diagnosis groups )
The classification of the diagnosis groups depends on the last 3 digits of the diagnosis code :
x x Messages
x x Motorcontroller MC-4
x x Object administration
x x General
x x IEC-Task
x x RealTimeBus
x x Physical Encoder
x x Option modules
x x System failure
x x Software failure
x x Motorcontroller MC-4
The real DiagnosisCode is contained in the last 3 digits.
The second digit (xXxx) relates to the object which activates the DiagnosisCode.
In case of the object is the MotorController.
The real DiagnosisCode is contained in the last 3 digits.
The second digit (xXxx) relates to the object which activates the DiagnosisCode.
In case of the object is the MotorController
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11. Additinal system reactions of the MC-4
111
excessive following error
132
Following error warning
The diagnosis code is subdivided into different diagnosis groups, e.g belong to the MotorController MC-4.
Additional to the Controller the MotorController has its own defined errorhandling. The MotorController distinguishes between 5 reaction classes (A .. F).
The MotorController reacts independently from the Controller. Only the diagnosis code will be sent to the Controller via fiber optics.
The MotorController MC-4 reacts independently . Merely the Diagnosis code will be transfered to the Controller.
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12. Error Reactions A
Motor immediately loses all torque; brakes engage immediately
e.g:119 "Short circuit or ground fault in output stage“ B
Best automatic standstill: Motor decelerates with maximum delay, brakes engage when n<nmin (10 revolutions/min
e.g:112 "Communication error real-time bus“ C
Motor decelerates with max. delay yet remains under control, brakes do not engage
e.g: 124 Overload D
Warning message to PacDrive controller; program can be used for controlled, synchronous standstill; if no reaction occurs, then a state class 1 error may result
e.g: 125 "I2t motor warning“ E
Message
e.g: 133 "Speed-dependent power reduction"
The diagnosis code is subdivided into different diagnosis groups, e.g belong to the MotorController MC-4.
Additional to the Controller the MotorController has its own defined errorhandling. The MotorController distinguishes between 5 reaction classes (A .. F).
The MotorController reacts independently from the Controller. Only the diagnosis code will be sent to the Controller via fiber optics.
The MotorController MC-4 reacts independently . Merely the Diagnosis code will be transfered to the Controller.
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13. Online help Online help F1 ELAU Training Center DilMotion Control
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14. Exercise
4.0 PD Diagnostics
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15. Try also: Remove fibre optics and check Remove encoder wire and check
Change sercos address and check