1. Software Troubleshooting Eliminate possible programming and timing errors by stopping all programs ( and ). Use the Executive program terminal and send on-line commands. Know the PMAC’s “Chain of Command”, what order things must happen in PMAC. 1. Proper encoder counts per revolution. Both directions! 2. DAC output gives proper encoder count direction? 3. No faults in Status Screens. Look at FULL status, not condensed status.

2. UMAC Hardware Troubleshooting Eliminate possible hardware conflicts by disconnecting as much as possible and using a “Known” GOOD configuration. I use a demo-box whenever possible. Now the software should reflect the input status and the outputs should reflect the commands. If not, is there a software reason for this? Does the “connector status” screen see the inputs? Does a voltmeter see the inputs and outputs? Can you point an M-variable at the source? M102->DAC

3. Machine Troubleshooting If you have followed the previous two slides, then you should know if the trouble is internal or external to PMAC or external. Try measuring or commanding to I/O directly with the PMAC disconnected and using a voltmeter to see the changes.

4. UMAC Troubleshooting Tools l PMAC Executive Software –Motor Status l Fatal Following Error, Amplifer Fault, Position Limits –Coordinate System Status –Program Status –Data Gathering -- Motion Programs: List PE, S, % l Manuals l Schematics l Multi-Meter, Oscilloscope l 24-28 Gauge Wire l Extra Motors, Amplifiers, & Cables

5. UMAC Troubleshooting Examples l Definition of Working System l Position Feedback l Motor not Running l Inputs/Outputs not working l Watchdog Timer l Changing Firmware

6. Definition of Working System l If it is a traditional Servo system –Position Limits (if it is a linear axis) –Home Flags –Motor can servo (closed loop) l Jog and Run Motion Programs l Has proper PID settings for the application l Homing has been setup l Machine I/O is working l Emergency Stop Procedure is working l Complete back-up of Source Code and UMAC Configuration files

7. No Position Feedback l Check I4900 to make sure UMAC sees the Servo Card l Check Encoder Decode parameter I7mn0 l Check Encoder Conversion Table Setup (I8000-I8191) l Check Ixx03 (and Ixx04) for proper assignment l Check 5V supply to encoder l If quadrature encoder, check Gate Array up/down counter –Suggested M-variable Mxx01 points to this location l Check the encoder inputs to UMAC with Oscilloscope l Check Encoder Shields

8. Motor Does Not Move l Check I4900 to make sure UMAC sees the Servo Card l Check I7mn6 (Motor Output Mode) l Check Fatal Following Error l Check ± 15V supply for DAC’s l Check Limit Status –If limits are active motor will not move l Change Ixx24 if necessary l Check Ixx25 to see if Amplifier Enable is directed to proper memory location l Check Ixx02 to see if Effort Command is directed to proper location l Check PID and/or Motor parameters –If at defaults, motor might not move l Check Feedrate Override (% Command)

9. Machine IO Troubleshooting l Inputs are not Working –Check indicator LED’s –Check Inputs Directly at UMAC memory location –Make sure IO board is addressed properly –Check the actual input state coming into IO card. –Check power to Card l Outputs are not working –Write Directly to output UMAC memory location –Make sure IO board is addressed properly –Check indicator LED’s –Check power to Card To troubleshoot Inputs or Outputs the user may have to turn off the PLC which is servicing the read/write functions of the hardware. If problems persist you can re-initialize the card to factory defaults and create simple definitions to the memory locations.

10. UMAC Watchdog l Watchdog occurs immediately at power-up –Check 5V supply –Not enough background time? –Re-initialize UMAC to Factory Defaults (E3) and download working Source Code or UMAC Backup configuration l Watchdog occurs randomly –Check 5V supply –Check Watchdog Timer counter (M7000->Y:$000025) –Run PLC’s one at a time If problems persist you can re-initialize the card to factory defaults and then download and run programs one at a time

11. Changing Firmware l Obtain firmware file from Delta Tau l Make a backup configuration file (or know where the files are at your company) l Power Down System l Jumper E23 to put UMAC into bootstrap mode l Download TURBO2.BIN for UMAC using PMAC Executive Software l Power down system and remove bootstrap jumper (E23) l Download configuration file or source code to the UMAC l SAVE configuration to UMAC memory l Restart UMAC ($$$ command or cycle power)

12. Important Information l Where are the Delta Tau Hardware and Software References located at your company? l Where is the known working Backup Configuration file for your machine? l Where is the known working Source Code for your machine? l Where is the PMAC Executive Software CD? l Who is the machine integrator? –Name and Company

13. Our Test System On our test system here we have. 1. KNOWN hardware state. 2. KNOWN software state. We clear memory and load our own programs. With this we check all major connections. This includes gate-arrays, DAC’s, opto-couplers, and line-drivers.