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Diagnostics and service

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Documentation

X20 system user's manual - Version 3.50 (October 2018) Installation / EMC guide - Version 1.20 (June 2018) ACOPOSmulti user's manual - Version 1.10 (April 2018)

Redundancy for control systems - Version 1.14 (September 2017) ACOPOSinverter P74 user's manual - Version 2.60 (December 2018) Integrated Safety Technology user's manual - Version 1.120 (July 2017) SafeMOTION user's manual - Version 4.5 (November 2018)

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Table of contents

1 Introduction...5

1.1 Learning objectives... 5

1.2 Safety notices and symbols...6

1.3 Terminology...7

2 Situation analysis and problem identification...9

2.1 Checking possible sources of error... 9

2.2 Source of information: Machine manufacturer...12

2.3 Source of information: B&R... 13

3 System overview and topologies... 15

3.1 B&R system overview...15

3.2 Typical topologies... 16

4 Obtaining information about the B&R system...20

4.1 Serial numbers and model numbers... 20

4.2 Data sheets and user's manuals... 23

4.3 Structure of B&R user's manuals... 23

4.4 B&R website functions...24

5 Diagnostic tools...32

5.1 Diagnostics without a PC...32

5.2 Diagnostics via PC...36

6 Diagnostics using the System Diagnostics Manager...39

6.1 SDM functions...40

6.2 Establishing a connection to the SDM... 44

6.3 Saving Logger files... 45

6.4 Generating and saving a system dump...47

6.5 Information in the hardware tree... 48

6.6 Diagnostics via I/O and status data points...52

6.7 Information about the application status in WebXs... 54

7 Troubleshooting...56

7.1 Service parts... 56

7.2 Replacing a module... 57

7.3 Starting up again and functional testing... 68

8 Backing up and restoring...70

8.1 Backing up and restoring using the Runtime Utility Center...70

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10.5 Power supply and fuses... 91

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1 Introduction

For decades, the company B&R Industrial Automation GmbH1 has been a leader in innovation and full- line supplier of control technology in the field of mechanical engineering.

Our customers are machine and system manufacturers who use B&R products for automation. The machine and system manufacturers are generally responsible for software programming, maintenance, spare parts supply and warranty claims.

Figure 1: Examine surroundings Figure 2: Contact manufacturer Figure 3: Correct errors

The B&R website offers all of the documentation and user's manuals for our products as well as a complete product overview.

Further information

• 4.4 "B&R website functions" on page 24 1.1 Learning objectives

This training module provides an overview of the B&R system and corresponding documentation re- sources. It also provides an overview of available diagnostic options. Many exercises and application examples included serve to expand upon the lessons learned.

• Participants will learn about B&R's approach to integrated automation and where to find neces- sary sources of information.

• Participants will learn their way around the B&R website and find out how to download user's manuals and data sheets.

• Participants will be familiar with the diagnostic options that are available without using a PC.

• Participants will learn how to perform basic diagnostics without a PC and how to interpret the resulting data using the available data sheets and user's manuals.

• Participants will learn about the diagnostic options that do require a PC and how to evaluate the information they provide.

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Safety notices in this manual are organized as follows:

Danger: Disregarding these safety guidelines and notices can result in severe injury, death or substantial damage to property.

Warning: Disregarding these safety guidelines and notices can result in severe injury or sub- stantial damage to property.

Caution: Disregarding these safety guidelines and notices can result in injury or damage to property. These instructions are important for avoiding malfunctions.

Additional notices and information in this manual are organized as follows:

Note: Provides important tips and additional information

Help: References additional documentation (Automation Help, data sheets, user's manuals) Example:

Hardware \ Motion control \ <Device>2 \ Technical data \ (<Type>)3 \ Status indicators

Example: An example illustrates the topic in greater depth.

Result: The result of a completed exercise is summarized briefly.

Organization of safety notices in external manuals

This manual contains references to other manuals. How safety notices are organized in external manuals is listed in the respective manual.

Exercise: Tasks and exercises

Sections marked with an orange stripe on the left side contain information about exercises as well as the associated actions to be taken. The exercises are designed to provide a deeper understanding of the information provided.

2 Angle brackets indicate variable placeholders "<...>"

3 Parentheses indicate optional entries "(...)"

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1.3 Terminology

Below is a glossary of the most important terminology used in B&R systems. The definitions are of particular importance because these terms are used frequently throughout this documentation as well as in the respective user's manuals.

Term Short description

ACOPOS General name for B&R drives. These power electronics are controlled via a field- bus connection and used to control the movement of all types of motors.

Motion control Umbrella term for anything involving movement. Power electronics controls the movement of drive systems, such as synchronous, induction and stepper mo- tors.

Automation

Runtime Automation Runtime is the operating system installed on the controller. Different versions of Automation Runtime installed on the controller offer different func- tions and diagnostics options.

APC / IPC Automation PC or industrial PC: PC designed for industrial use.

CF CompactFlash is the external memory of the controller. Almost all B&R control systems use a CompactFlash card as an application memory. Other systems that do not use CompactFlash cards have the application memory integrated in the controller, and it cannot be replaced externally. Using CompactFlash cards provided by B&R ensures image compatibility and suitability for industrial envi- ronments.

Remote I/O Instead of being connected directly to the CPU, remote I/O modules can be op- erated remotely via a fieldbus system.

Node number The node number is set on the module via rotary switches. This number is re- quired to identify the module in the network.

Panel HMI devices are often described as operator panels or simply panels.

POWERLINK Open, Ethernet-based fieldbus for connecting controllers, drives, safety technol- ogy and remote I/O modules.

Safety General term for safety technology in the field of machine manufacturing. The safety components process safe input and output data, such as emergency switch-off, enable signals, safety doors and much more.

System 2000 General term referring to B&R's 2003, 2005 and 2010 control systems.

Technology Guard This is a USB dongle that is inserted in the controller CPU's USB port. The Technology Guard contains any required software licenses, two operating hours counters and permanent data storage.

Visualization Umbrella term for displaying processes and process values. An HMI device (e.g.

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X67 Components with IP67 protection5. B&R's remote I/O system.

Table 1: Terminology

5 IP67 = Protection against dust and temporary immersion in water

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2 Situation analysis and problem identification

Before contacting the manufacturer of the control electronics or the machine manufacturer, it is necessary to get an overview of the sys- tem to isolate and localize the problem. Working one step at a time and documenting each step along the way is the most productive approach.

It is often external influences that occur with daily use of the ma- chine that cause the smaller problems. The following contents help to identify problems and analyze the current situation.

If the problem is recognized correctly, it is easier to initiate the next steps. In addition, the time required to solve the problem can be significantly reduced.

2.1 Checking possible sources of error

Acquiring as much information as possible for a clear overview is the first line of action.

The general conditions under which the machine is operated are crucial factors as is the timing of actions performed by the machine operator.

"Has anything been changed on the machine? Were the actions taken also documented?"

This information helps to isolate the cause of error step by step and helps develop a solution.

2.1.1 Operating materials

Operating materials are crucial to the lifespan of a machine. Neglecting these materials can lead to machine downtime or have negative effects on functionality.

Operating materials include:

• Lubricant

• Compressed air

• Hydraulic fluid

• Coolant

• Electricity 2.1.2 Mechanics

The mechanics in a machine are often subject to demanding conditions. Years of operation will eventually lead to wear and tear.

Typical problems

• Worn bearings6

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First the electricity supply makes machine operation possible. A stable supply network is a requirement for permanent and reliable machine operation.

Potential problems with the supply:

• Voltage fluctuations

• powerfail message

• Phase failure

• Defective or weak fuse

• Differences in potential

• Uneven network load 2.1.4 Wiring, cabling, shielding

Sensors and actuators are connected to the I/O system through wiring. Likewise, all remote control components, such as the controller itself, are connected with higher-level fieldbuses or networks.

Potential wiring problems:

• Open lines

• Poor contact

• Unplugged connector

• Unsuitable cable

• Bus, sensor and motor cables with poor or no shielding7

• Poor or worn insulation

• Short circuits and cross faults

• Ground fault

• Insufficient flex radius

• Coupling of disturbances caused by inappropriate shielding

• Excessive cable lengths (voltage drop and reflections)

• Missing terminating resistors during network coupling (e.g.

CAN Bus)

Where can I find information about wiring, shielding and grounding concepts?

Descriptions regarding wiring, shielding and grounding concepts for the B&R system can be found in the respective B&R user's manual. Connection examples for individual hardware com- ponents are also included.

Further information

• 4.3 "Structure of B&R user's manuals" on page 23

7 10.4 "Notes regarding grounding and shielding" on page 87

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2.1.5 Environmental and time factors

In addition to other defects that can occur due to damaged mechanics or wiring, environmental factors and the effect of time are also causes of errors.

This includes the following influences:

• High and low temperatures, temperature fluctuations (temperature limit values are documented in the user's manual)

• Heat accumulation from incorrect installation position or from minimum spacing not being ob- served

• Humidity and condensation, incorrectly configured climate control systems

• Dust and dirt

• Oily or aggressive vapors in the air

• Vibrations

• Aging, material fatigue

• UV radiation

• Derating due to elevation (specification listed in the user's manual)

Where are the limit values listed?

All limit values, such as ambient temperature or humidity, for operating the B&R product can be found in the respective user's manual.

Further information:

• 4.3 "Structure of B&R user's manuals" on page 23 2.1.6 Process parameters

Modern machines are capable of performing flexible manufacturing processes for a wide range of prod- ucts. Settings and configurations make it possible to adapt the machine to the production process.

Process-related variables affect the machine's response.

Influences for the machine:

• Changed parameters

• Changed controller settings

• Change in behavior by the machine operator

• New recipe loaded

• Changed limit values

• Different raw material or product

• Different material or temperature

• Higher or lower material hardness

• Other tool properties

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• 2.2 "Source of information: Machine manufacturer" on page 12

• 5 "Diagnostic tools" on page 32

• 7 "Troubleshooting" on page 56 2.1.8 Software, process

The software on the machine controller represents and controls complex machine processes. Software errors do not simply appear without reason, but occur mostly when process values have changed and the corresponding software function has not been adequately tested.

If limit values are exceeded without consideration, this represents a potential source of error.

Potential sources of errors:

• All of the factors described above

• Faulty programming, insufficient software tests

• Limit values are exceeded due to incorrect entries but not regarded in the software

• Combinations of different machine functions were not completely tested

• Program for sequential control doesn't take account of all machine conditions 2.2 Source of information: Machine manufacturer

Required information for machines should be obtained ideally from the machine manufacturer. The following list provides an overview of the information that can be requested from the machine manufac- turer or that can be found directly on the machine.

The following information is available:

• Images on the HMI application

° Overview pages

° Alarm pages

° Diagnostic pages8

° Error logs, log files

° Trend curves

• Manual of the machine

° Machine data

° Error descriptions

° Suggested corrective measures

° Maintenance guidelines

° Lubrication chart of mechanical parts

° Tightening torque for belt tension

° Contact data

• Circuit diagrams of the machine

• Website of the machine manufacturer

8 System Diagnostics Manager is a web-based interface that is used for diagnosing B&R systems. The con- tents of System Diagnostics Manager can be directly integrated in the HMI application by the machine manufacturer, see:6 "Diagnostics using the System Diagnostics Manager" on page 39.

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Contact the machine manufacturer

If replacement parts or service is needed, the first point of contact is always the machine manufacturer.

They know the machine's structure, the mechanics, electronics and application software.

Contact data can usually be found in the control cabinet or in the user's manual. Most manufacturers have their own website that also contains contact data.

When contacting the machine manufacturer, make sure you have the machine number and a clear description of the problem prepared.

2.3 Source of information: B&R

B&R's systems are completely documented and operated the same way. A broad range of diagnostics options provide information about the system status and help to perform initial diagnostics and error localization.

Further information:

• 4 "Obtaining information about the B&R system" on page 20

• 5 "Diagnostic tools" on page 32 Checklist for contacting B&R

In some rare cases, the machine manufacturer may no longer be in business. In this case, be sure to contact the nearest B&R subsidiary. You can always find contact information for the nearest subsidiary on the B&R website:

www.br-automation.com → "Company"/"Locations"

There are a few things to clear up before contacting the manufacturer or B&R. The following checklist can be used as a guide when preparing to contact B&R.

Question Notes

Machine manufacturer? Company name, location, contact data Machine type? Packaging machine, pump controller, etc.

What is being produced? Brief description of the production process What type of problem is

occurring? Description of the type of problem: Standstill, noises, product quali- ty, communication failure, etc.

How often does the prob-

lem occur? Approximate frequency of problem:

Once a day, every hour, just once, etc.

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Environmental conditions Under what environmental conditions (temperature, humidity, etc.) is the machine being operated. Installation of electromagnetic com- patibility (EMC)

Has anything been changed?

Different product being produced, mechanical modifications, changes to cabling, software update from the manufacturer, changed parameters, etc.

Who made the changes? Contact person, documentation of the changes, reasons forchanges, etc.

What controller is being

used? Hardware being used, control concept, etc.

What fieldbus is being

used? How the components and modules are connected together, etc.

What does the topology look like?

Have a topology diagram ready, state the important components, etc.Further information:

• 3.2 "Typical topologies" on page 16

LED status indicators What states are being signalized by the LED status indicators?

(Controller, I/O modules, interfaces, bus controller, drives, etc.) Who is responsible for the

software?

Are there any backups?

Control program for the machine controller, source control system, archiving

System dump

Generate system dump according to the instructions and have it ready. All hardware modules and software versions used as well as Logger and profiler files are saved in the system dump.

Further information:

• 6.4 "Generating and saving a system dump" on page 47

serial numbers

Every B&R module has a serial number. The serial number provides important data and information.

Which parts of the machine and which hardware is affected?

Further information:

• 4.1 "Serial numbers and model numbers" on page 20

Table 2: Checklist for B&R contact

Exercise: Preparing the B&R checklist

In this exercise you will draw up a brief list to determine whether all of the relevant data is available for an existing machine. If you're already certain that some important information is missing or cannot be determined, efforts can be made to obtain this information.

1) Go through the checklist for a machine one step at a time 2) Write down information that is already known

3) Note down the information that must be obtained later

4) Clarify whether the offered service and diagnostics methods are supported

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3 System overview and topologies

3.1 B&R system overview

B&R offers products for every aspect of a machine's electronics. Controllers, HMI units, I/O modules, motion control technology and a variety of infrastructure components such as cables, power supplies and network components make up the B&R product portfolio.

B&R products are divided into the following main categories:

• Control technology

• Motion control

• Safety technology

• HMI

B&R product overview

The following image provides an overview of the main B&R product groups. On the left you see some motion control components. Control technology, remote I/O modules and integrated safety technology are shown front and center. In the back and on the right you see an operator panels and industrial PC.

Figure 4: B&R product overview (from left to right: synchronous motor, ACOPOSmulti system, X20 system and integrated safety technology (yellow), Automation Panel, Power Panel, Automation PC)

Where can I find detailed product information?

For a detailed overview and description of the individual product groups, refer to the B&R web-

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If the problem can be solved by replacing a module, the existing topology must be examined first. The following image shows a typical control topology as those found on many other machines.

In the center you see the machine controller. It is connected to the other control components via a fieldbus, most commonly POWERLINK. This is what allows the machine controller to control the remote components.

An X20 CPU, an HMI device or an industrial PC can be used as the machine controller. Above this, HMI devices or other network components can also be connected via a network connection.

Figure 5: Typical control topology with an X20 CPU

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3.2.1 Expansion via fieldbus

Communication with 3rd-party devices via different fieldbus systems is a basic feature of B&R systems.

The fieldbus that is used to connect a device can be connected to various positions in the system.

Fieldbus connection to the control CPU All B&R control systems offer additional slots for fieldbus interfaces, which allows them to be ex- panded easily at any time without having to add new interfaces. A wide range of fieldbus interfaces9 are available for connecting different devices.

Figure 6: Connection of X20 I/Os via POWERLINK in addition to two other fieldbuses (blue and green)

Fieldbus connection to POWERLINK

An expandable bus controller allows B&R to also offer fieldbuses right at the level of the I/O system.

The additional fieldbus interface is connected right next to a POWERLINK bus controller. This makes it possible to add a fieldbus interface anywhere on the machine.

Figure 7: Additional fieldbus interface next to the POWERLINK bus controller

Remote backplane - X2X Link

Multiple I/O stations consisting of X20 and X67 modules can be connected via X2X Link.

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The B&R system offers a variety of redundancy options in order to maximize the availability of machines.

When using POWERLINK, it is possible to choose between ring redundancy and cable redundancy. In addition, controller redundancy is also available.

Ring redundancy

For ring redundancy, devices are connected in a line, with the last unit connected back to the mas- ter. When the connection is interrupted, the ring re- dundancy manager reacts by feeding in data from both sides. The master recognizes when the ring is closed again and once again supplies data only from one side into the ring. This guarantees con- tinuous communication.

Interruption of the ring can be evaluated on the controller using data points or on the modules us- ing the LEDs. The diagnostic data points are also

shown in System Diagnostics Manager (SDM). Figure: Example of ring redundancy

Cable redundancy

In this form of network redundancy, two networks are available and every device is connected to both networks. If an error occurs on one network, the link selector recognizes this and switches to the other. This solution also ensures maximum avail- ability of machinery and equipment.

Figure: Example of cable redundancy

Controller redundancy

B&R's controller redundancy solution ensures maximum availability for entire systems as well as indi- vidual machines. Controller redundancy allows data to be synchronized within microseconds with no more than 2 cycles lost when switching over to the respective controller. This functionality is seamlessly integrated in the real-time operating system and is easy to use.

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A second, identical X20 CPU is added to the existing control topology and configured as redundant in the software.

Figure 9: Schematic representation of controller redundancy with connection to the process bus

The user's manual "Redundancy for control systems" can be downloaded from the B&R website. For options and examples on the subject of redundancy, refer to the user's manual available via the following path:

Downloads \ Control and I/O Systems \ X20 system \ Hub & redundancy system \ X20 redun- dancy system

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B&R offers its customers a variety of information. All information is available online around the clock and is constantly updated.

Product-specific information can be found by entering the serial number on the B&R website. The corresponding data sheets and user's manuals can be easily downloaded. More details about the exact procedure is explained in the following chapters.

4.1 Serial numbers and model numbers

Difference between serial number and model number

The serial number printed as a barcode is the unique ID of a B&R product. The serial number contains the model number, revision, certifications and the entire history of the component.

The model number is the unique identification of modules of the same type and is used, for example, to order modules. This is why the material number is called model number.

Figure 10: Elements of the serial number sticker

What information does the serial number provide?

Information about a specific serial number can be found using the search function on the B&R website.

Further information:

• 4.4.3 "Search function of the website" on page 28

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Attaching the serial number

The serial number is found on a free space on each B&R product. On devices with plastic housing, the data is laser-engraved directly onto the surface. On metal housing it is printed on a white sticker.

X20 system HMI devices Motors

Figure 11: X20 digital module, X20 backplane module

Figure 12: Rear side of Power Panel

Figure 13: Side view of motor

Table 3: Examples of serial number placement

Is the serial number visible in the software?

Machine manufacturers have the option of reading serial numbers in the control program. Alter- natively, the serial numbers of detected hardware can be viewed in System Diagnostics Man- ager and a list of them can be downloaded from the controller.

Further information:

• 6.5 "Information in the hardware tree" on page 48

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Exercise: Serial number search

Use the CPU's serial number, integrated in the practice setup, to find out what information is available.

1) Identify the serial number of the CPU

2) Visit the B&R website, www.br-automation.com

3) Enter the serial number in the search field in the upper right corner

Figure 14: The search function is located in the upper right corner behind the magnifying glass

4) Note down results and evaluate them

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4.2 Data sheets and user's manuals

Data sheets and user's manuals are available on the B&R website.

User's manualscontain complete documentation of the system characteristics, installation and mainte- nance guidelines, electrical installation and data sheets for each module of a product category.

Data sheetscontain information about a specific module. They document each module including general technical data, pinouts, equivalent circuit diagrams and a register description.

Where can user's manuals and data sheets be downloaded?

All B&R documents can be found on the B&R website.

There are 3 ways to find the desired document:

• Via the product section

• Via the search function

• Via the download section

The procedure for downloading the X20 system user's manual from the B&R website will be explained later.

Further information:

• 4.4 "B&R website functions" on page 24

4.3 Structure of B&R user's manuals

A B&R user's manual is available for each product group. All product variants are described in the user's manual. Therefore, it serves as reference documentation for the respective system. It contains all rele- vant data for installation, commissioning and maintenance.

Contents of a B&R user's manual:

• System characteristics

• Mechanical characteristics

• Electrical characteristics

• Installation instructions

• Module descriptions

• Technical data

• LED status indicators

• Maintenance guidelines

• Mechanical handling

• Standards and certifications

• Danger, warning and safety notices

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Search within the user's manual

In order to obtain information on a single product variant, it is advisable to search for the model number in the PDF of the user's manual. This is the quickest way to find the information you need.

Exercise: Search for and download the X20 user's manual This exercise involves searching for and downloading a user's man- ual from the B&R website. After that, the task is to gain an overview of the contents and structure of the manual.

Search for the following information in the X20 user's man- ual:

• Size of the X20CP1586 product's working memory

• Connection of the supply to the terminal and the supply voltage range of the X20CP1586 product

• Different shielding concepts on X2010 Modules

• Steps for mounting or dismounting the X20 system

• Replacing the backup battery

1) Visit the B&R website, www.br-automation.com

2) Search for the X20 system user's manual. For help, see 4.4

"B&R website functions" on page 24 3) Download user's manual

4) Search for product data and general information 5) Note down results and evaluate them

Figure 16: X20 CPU - X20CP1586

4.4 B&R website functions

The B&R website provides up-to-date information on all B&R products. The comprehensive search func- tion with different filters facilitates the targeted search for information.

The following information can be found on the B&R web- site:

• Product catalogs, user's manuals

• Data sheets, certificates

• Drivers, updates, CAD data

• B&R worldwide contact info

• Support Portal, Material Return Portal

• Global search function, e.g. for serial and model numbers

• And much more...

10This exercise can also be performed for a different B&R control system if an X20 system is not being used.

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An example of how to download B&R documents from the website are shown in each of the following chapters.

There are 3 ways to find the desired document:

• 4.4.1 "Product section on the website" on page 25

• 4.4.3 "Search function of the website" on page 28

• 4.4.4 "Download section of the website" on page 29 4.4.1 Product section on the website

Information about B&R's range of products can be found in the product section of the B&R website.

www.br-automation.com→ "Products" in the main menu

Figure 17: The different product groups can be opened via the main menu

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Download X20 system user's manual from the product section

Navigate to "Control systems" via the product section. Then, select "X20 system". Scroll down to category "Documentation". When this category is open, click on the X20 user's manual "MAX20- GER". A new page opens. The user's manual can now be downloaded in the "Downloads" tab.

Figure 18: The X20 system user's manual can be downloaded from the product section.

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4.4.2 Compare products

The available variants of each B&R product are listed in the product section. The product variants are compared by selecting the checkbox of the respective variant. Then, click on the "Compare" button to open the comparison.

www.br-automation.com → "Products" in main menu - Select category - "Compare"

Figure 19: The checkboxes of the X20 product variants "X20CP1301" and "X20CP1381" are marked

After clicking on "Compare", the detailed product comparison opens. Differences and similarities be- tween the two product variants are shown in a table and highlighted in color.

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Figure 20: Differences between the selected variants are highlighted in color

4.4.3 Search function of the website

The search field is located at the top right of the B&R website.

Serial numbers or product names are suitable as search terms, for example. When searching for a product whose name starts with "X20CP1", it is recommended to enter "X20CP1*" to get optimal results.

The results matching the search term are categorized. The results can be filtered according to these four different categories under "Content type".

The following categories are available for the search result:

• Page content

• Product

• Download

• Press releases

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Figure 21: Results for "X20CP1*". Under "Content type", results can be filtered by category.

Download the "X20 system user's manual" using the search function

Enter "X20 user's manual" in the search box at the top right and press ENTER (if the desired result is not included, results can be filtered by content type "Download"). Clicking on the result opens another page from which the user's manual can be downloaded.

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Data sheets

User's manuals

Catalogs

Drivers and updates

Tools

Certificates

And much more...

The "Product groups" drop-down box is available to search for specific content. When a product group is selected, additional drop-down boxes are loaded to limit the content displayed.

The filters to the left of the results allow even more precise filtering.

The content will be downloaded as soon as you click on the download icon to the right of the entry.

Figure 23: To get access to the download section of product "X20CP1586", product group "Control and I/O Systems" must be selected

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Download the "X20 System user's manual" from the download section

Use section "Downloads" to navigate to the general download section. Then select option "Con- trol and I/O Systems" from drop-down menu "Product Group". Select "X20 system" and "Central units" from the drop-down menus that follow.

Scroll down to category "Documentation". Clicking on the result opens another page from which the user's manual can be downloaded.

Figure 24: The X20 system user's manual can be downloaded from section "Downloads"

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The following section describes the diagnostic possibilities for pre- liminary diagnostics, which can be performed with or without an ad- ditional computer. Before getting started, it is advisable to make sure you have all important information from the manufacturer such as data sheets and manuals.

It is recommended to have a computer with a network card and net- work cable ready for diagnosis. It is also helpful to have an Internet connection for the diagnostic computer. This makes it possible to quickly obtain further information as needed.

The following diagnostic methods can be used:

• 5.1 "Diagnostics without a PC" on page 32

• 5.2 "Diagnostics via PC" on page 36 5.1 Diagnostics without a PC

When an error occurs, the first line of action is to get an overview.

Does the HMI application already show the first status reports?

What is the behavior of the LED status indicators for the electromechanics and control electronics?

This information provides important hints for the initial diagnosis.

5.1.1 HMI application

Almost every machine has a visualization. This is used to operate and diagnose the machine. Overview pages display the most important information. Any message texts available or specialized alarm and diagnostics pages can also provide information about the cause of the problem.

Modern visualization applications also provide a help system and instructions for working with the ma- chine.

Overview screen Alarm page Trend page

Figure 25: Overview page - Everything

at a glance Figure 26: Alarms, messages and

warnings provide information about the machine status

Figure 27: Trend curves for graphic representation of process values Table 4: Sample visualization pages

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Can System Diagnostics Manager be embedded in the HMI application?

The machine's manual explains all the possibilities of the HMI application. The manufacturer of the machine can also provide more detailed information.

It is possible that some machine manufacturers integrate System Diagnostics Manager in the HMI application.

Further information:

• 6.1 "SDM functions" on page 40 5.1.2 Electromechanical parts, sensor, actuator

Most machines contain some optical signaling devices for diagnos- tics of the devices connected to the machine controller. Thus many sensors and actuators have LED status indicators.

More complex devices often feature status displays for displaying error codes or textual information. The manufacturer's data sheet for the sensor or actuator should explain how to interpret and under- stand this information.

The LED status indicators on devices are generally assigned specific functions. For example, some LED signals indicate the quality of the measured value, while others indicate the quality of communication with the higher level system. Different blinking patterns are used to display additional information.

In addition to the meaning of status indicators, further important in- formation is contained in the manufacturer data sheet or the user's manual. For example, improper installation of a device can lead to errors. The image shows the metal EMC plate. The regulations for cable arrangement on the EMC plate can be found in the corre- sponding user's manual. In the ACOPOSinverter P74 user's manu- al, it can be found in chapter "Installation", subchapter "Initial Instal- lation".

Figure 28: ACOPOSinverter P74 frequency converter with status display and operating elements; EMC plate below

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All B&R devices contain LED status indicators that indicate the cur- rent operating status and quality. The following section briefly de- scribes what information can be obtained from the LED status indi- cators and where to find additional information.

The LED status indicators on B&R devices are designed so that they are visible from the front in the control cabinet. HMI devices are the only exception since the LED status indicators are located on the back of the displays.

Figure 29: LED status indicators on an Automation PC 810

Types of LED status indicators

Each LED is assigned different functions. For instance I/O modules feature a general module status as well as one LED status indicator per channel in order to display the channel status.

Communication interfaces also feature one or two LEDs each for displaying communication activity in addition to the general module status. Each LED provides additional information using specific blink codes.

The following table provides an overview of the LED types on control systems.

Device LED information Overview on the device

I/O modules • Module status

• Module error

• Channel status

LED status indicators on a 2- channel digital input module

Control CPUs

• Module status

• Boot phase

• Battery status

• CompactFlash

• Communication

LED status indicators on an X20 CPU

Table: Example of some LED status indicators on the X20 system

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The image shows the description of the LED status indicators of the analog X20AI4322 input module. The LED called "r" shows the module status. If LED "r" blinks, then the module is in mode "PREOPERATIONAL". This means that the module is started internally and ready for operation. However, modules in module "PREOPERATIONAL" have not been initialized or configured yet. Reasons for this could be that the module has not yet been accessed, that there is no configuration for the module in the automation project or that the bus connection to the module is suspended.

Figure 30: Extract from data sheet X20AI4322, chapter 4 "LED status indicators"

After switching out a module, a firmware update is carried out by the controller CPU if required.

This is indicated by double flashing. You have to wait until this procedure is complete before proceeding.

Where can I find detailed description of the LED status indicators?

To get access to the description of the LED status indicators, the serial number of the device is required. With this information, the corresponding documents, such as data sheets and user's manuals, can then be downloaded from the B&R website.

Further information:

• 4 "Obtaining information about the B&R system" on page 20

Exercise: Interpret X20AT2222 LED status indicators

Use the data sheet of the X20AT2222 module to interpret the LED status indicators. LED status indicator "e" is blinking red (single flash). What does this mean and what could cause this?

1) Visit the B&R website, www.br-automation.com

2) Search for "Data sheet X20AT2222". For help, see 4.4 "B&R website functions" on page 24

Figure 31: LED status indicators of the X20AT2222 module

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A single flash on LED "e" means there is a pending warning or error on a channel. This can be caused by an open circuit or a value being too high or low. It is also possible that the wrong channel type was configured or the sensor was connected to the 2-wire connections instead of the 3-wire connections. The green flashing channel LED indicates which channel is affected.

Exercise: System overview using LED status indicators

This exercise focuses on obtaining a complete overview of the current practice system. The focus will be on the LED status indicators of the individual components.

1) Note down all installed components

2) Visit the B&R website, www.br-automation.com

3) Search and download required data sheets and user's manuals. For help, see 4.4 "B&R website functions" on page 24

4) Evaluate the LED status for:

° Control CPU (general operating state, interfaces, battery, CompactFlash card)

° I/O modules (general operating state, channel status)

° HMI

° Motion control (axis status, communication, encoder interface)

° Safety technology (SafeLOGIC, SafeIOs)

When is the controller ready for operation?

Only when status "RUN" is signaled for all components, it can be assumed that the control system is working perfectly. If any component is signaling a different status, then the LED status indicators can be used to localize the affected component, which can then be replaced if necessary.

5.2 Diagnostics via PC

System Diagnostics Manager

System Diagnostics Manager is a web-based interface used for diagnosing B&R control systems. The hostname or IP address of the controller as well as a web browser are needed to gain access. A separate chapter in this documentation is dedicated to System Diagnostics Manager.

Further information:

• 6 "Diagnostics using the System Diagnostics Manager" on page 39 Which version of Automation Runtime is required?

System Diagnostics Manager was introduced with Automation Runtime version11 3.00 and later;

the integrated drive diagnostics was introduced with Automation Runtime 3.08 and later. To make System Diagnostics Manager available, it needs to be enabled in the application program.

11 The Automation Runtime version can be read in the Runtime Utility Center using command "AR Version".

For step-by-step instructions, see 8.1.5 "Outputting data via online connection" on page 78.

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mapp technology WebXs

If mapp Technology components were used for creating applications, they can be shown via the mapp di- agnostic page "WebXs". The components deliver comprehensive status information that is helpful when communicating directly with the machine manufacturer.

Further information:

• 6.7 "Information about the application status in WebXs" on page 54 Which version of Automation Runtime is required?

mapp Technology WebXs was introduced as of Automation Runtime 4.08 and later. mapp We- bXs must be enabled in the application program so that this diagnostic option becomes avail- able.

Runtime Utility Center

The Runtime Utility Center can be used for all B&R systems with Automation Runtime. It permits a connection to be created over a serial interface and the Ethernet interface.

The Runtime Utility Center is a service tool and can be downloaded from the B&R website. In some additional chapters in this documentation, the functions of the Runtime Utility Center are explained in more detail.

Further information:

• 8.1 "Backing up and restoring using the Runtime Utility Center" on page 70

• 10.2 "Where SDM and Runtime Utility Center can be used" on page 84 HMI Diagnostics tool

The HMI diagnostics tool is downloaded from the B&R website and is used for reading device data from B&R industrial PCs. The data provides information about operating hours, components used and the Windows installation used.

PVI Snapshot Viewer

The Process Visualization Interface (PVI) is a communication service between Windows applications and B&R controllers. The PVI Snapshot Viewer is used to troubleshoot the connection between the PC and controller. It displays the connected process variables and their statuses.

OPC UA is used to transfer data in modern applications. A separate logger file for troubleshooting can be found in System Diagnostics Manager.

HMI Service Center

HMI Service Center is delivered preinstalled on a bootable USB flash drive from B&R. It can be used to read device data from B&R Industrial PCs, Panel PCs, Automation Panels, interface options and I/

O boards.

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• Installation of customized Windows CE and Windows XP Embedded images.

• Simple installation of MS-DOS on a USB flash drive.

• Creating a USB flash drive for a B&R upgrade (Bios, MTCX12).

• Simple installation of Windows Embedded Standard 7 setup files on a USB flash drive.

• Disk image generation and backup.

• File manager for editing existing disk images.

The downloads for the HMI tools are stored in section "Downloads" in category "Software / HMI software".

The installation of the HMI tools is only possible on Windows operating systems.

Figure 32: HMI software in the download section of the B&R website

12The MTCX (Maintenance Controller Extended) is located on the CPU board of the device. It is responsible for the following monitoring and control functions.

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6 Diagnostics using the System Diagnostics Manager

B&R controller components come with an extensive diagnostics interface. This interface is called "Sys- tem Diagnostics Manager" or "SDM" for short. The controller is accessed using Google Chrome via the IP address or hostname of the controller13.

SDM is accessed using a web browser via the link "http://ip-address/SDM".

Figure 33: System Diagnostics Manager homepage

Can System Diagnostics Manager be embedded in the HMI application?

Depending on the machine visualization application, some of the SDM pages may already be embedded in the HMI application. This is described in greater detail in the manual provided by the machine manufacturer.

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The most important functions in SDM can be accessed via the home- page. A system dump can be generated via the button in the center, see 6.4 "Generating and saving a system dump" on page 47. All relevant information sources and Logger files from the controller are then loaded. These files can be used for further diagnostics.

The other buttons can be used to request information about the in- dividual parts of the controller. The information displayed on these in-depth pages can also be saved as a file.

Figure 34: Areas of System Diagnostics Manager

General system overview The general system overview con- tains data such as the battery sta- tus, CPU usage and the basic sys- tem settings. The configured CPU timing and memory usage is also displayed.

Figure 35: General system overview

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Displaying and saving Logger files

The B&R control system monitors itself. Relevant and important information about the system status is displayed in a list. The Logger files are displayed for further analysis in SDM or uploaded and saved by the controller. Data refer to the control system, integrated safety technology, fieldbuses or user events triggered by the control program. Machine manufacturers are provided with functions to create their own Logger files that, for example, log all events of the machine sequence.

Figure 36: Display of Logger files in SDM

Hardware modules and I/O status

The hardware diagnostics pro- vided by SDM are particularly helpful. This makes it possible to diagnose the entire control system status at once. The se- rial numbers of the hardware modules are listed. An addi- tional function is reading chan- nel data from various I/O mod- ules. At the bottom part of the window, information about the current values of inputs and outputs is displayed.

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ages and currents are con- verted into numerical values which can be processed on the controller. Independent of the resolution, the numerical values exist predominantly in the 16-bit 2s complement.

Figure 38: Display of measure values of voltage and currents (extract from X20 user's manual)

Additional information

• 6.5 "Information in the hardware tree" on page 48

• 6.6 "Diagnostics via I/O and status data points" on page 52 Motion control

Diagnostic options are avail- able for machines with drive technology via the SDM's Mo- tion diagnostics. The axis sta- tus, homing status, current po- sition and movement status are shown. If an error occurs, additional information such as the axis error list can be ob- tained by clicking on the traffic light icon.

Figure 39: Displaying the axis diagnostics, all axis objects are listed

In the axis error list, the axis error numbers are displayed with the corresponding clear text description and time- stamp.

Figure 40: Displaying the axis error list for a selected axis object

The network command trace logs commands that are sent to and from the drive. Button

"Snapshot" is pressed in or- der to take a snapshot of the data. Any data object on the displayed list can be uploaded or saved. It is only possible to analyze the data in Automa-

tion Studio. Figure 41: List of the recorded network command trace data objects

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Embedded SDM in the HMI application

Machine manufacturers are able to integrate the SDM right in the HMI application. The same functions are available as those provided when running the SDM in a web browser. Just the display of diagnostic pages differs a bit from the embedded SDM version.

System overview System logger Drive technology diagnostics

Figure 42: SDM system overview Figure 43: SDM system logger Figure 44: SDM drive technology diagnostics

Embedding of application specific data

The System Diagnostics Manager (SDM) enables application specific data be accessible by software developers. Status information relating to a controller application can be shown by pushing the "appli- cation status" button.

Figure 45: "Application status" button in SDM

If the "Application Status" function in the application is not used, you end up directly on the start page of mapp Technology WebXs (if this is enabled).

Can SDM be used to upload a software object?

System Diagnostics Manager can be used to view the system status and general system infor- mation. There are no functions provided for manipulating process variables or uploading/down-

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Exercise: System overview with the help of SDM

Use the SDM to get a general overview of the practice system. Check the general system status, the system usage, the overview of hardware modules and the status of the motion components.

1) Establishing a connection to the SDM 2) Check system status

3) Check system usage and make a note of the maximum values 4) Make a note of the battery status

5) Have a look at the overview of hardware modules and check the status of the individual modules 6) Call up the status of the motion components

While the LED status indicators can be used to obtain a good overview of the control system's overall status, SDM makes it easier to view all of this information at once. SDM is a better option for larger machines with distributed control cabinets, control components hard to access or when running remote diagnostics.

6.2 Establishing a connection to the SDM

Before connecting to the controller, the network configuration of the PC in use may have to be modified (10.3 "Changing network settings on the PC" on page 86). It is recommended to make a note of the original settings before doing this.

A standard network cable is used to connect with the controller. The LED status indicators of the PC and the controller indicate whether there is an online connection or not.

The connection to SDM is made via the controller's IP address or hostname. SDM is accessed via the browser14 using link"http://ip-address/SDM".

Step 1 - Connect PC to controller Step 2 - View SDM in web browser

Figure 46: Connecting PC to controller via network cable Figure 47: Accessing the SDM via web browser

Which browser is required?

An SVG-capable web browser is required to view SDM pages. Most current web browsers support this. An SVG plug-in is offered when using older browsers. If viewing SVGs is still not possible, then an HTML view of System Diagnostics Manager can also be accessed via

"http://IP-address/sdm-vga".

14B&R recommends using Google Chrome as your browser.

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Which IP address must be entered in the browser?

The controller's IP address or hostname can be found in the documentation provided or re- quested directly from the manufacturer. In some cases, the set IP address is written on the control cabinet.

6.3 Saving Logger files

The Logger records important system events in several Logger files. The events are displayed as a list using SDM. The machine manufacturer has the option to record events via the application program in Logger files.

Why are there multiple Logger files?

Several Logger files with different affiliations can exist on the B&R control system. The controller may also contain Logger files for fieldbuses, integrated safety technology or machine events, for example.

If necessary, back up each Logger file individually or perform a system dump.

Saving Logger files

Start by establishing a connection to the SDM.

Step 1 Step 2

Figure 48: Select the category "Logger"

Figure 49: Selection of the desired Logger file

Step 3 Finished

Depending on the web browser settings, the file will either be directly downloaded directly into the Downloads folder or a window will appear for se- lecting the location to save the file.

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At what times were Logger entries created?

When interpreting Logger events, the current time on the control CPU is of particular impor- tance. Before evaluating Logger entries, a potential deviation from the system time should be considered and noted. The system time is shown in SDM under category "System".

Figure 51: The current system time is displayed in category "System / General"

Exercise: Back up Logger file

This exercise will focus on displaying and saving the system log "$arlogsys". Take a moment to interpret the entries before saving. Also be sure to check and to make a note of the time of the controller.

1) Establish a connection to SDM 2) Open Logger

3) Take a moment to check the Logger files (time and entries) and evaluate their contents 4) Save $arlogsys

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6.4 Generating and saving a system dump

The system dump contains important information for hardware and software diagnostics on B&R sys- tems. This includes Logger files, profiler files, the I/O status and hardware configuration. Start by estab- lishing a connection to SDM.

The following instructions show how to generate a system dump.

Step 1 Step 2 Step 3

Figure 52: Press the "System Dump"

button

Figure 53: Start a new system dump

Figure 54: Confirm with OK

Figure 55: Select option "Parameters and data files"15

Step 4

Figure 56: Upload system dump

The system dump data contains important information about the machine controller. The machine man- ufacturer or B&R can use this data for further analysis.

Exercise: Triggering and saving a system dump

A full system dump including all Logger files and parameter files must be generated and saved.

1) Establish a connection to SDM

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System Diagnostics Manager displays and saves Logger files. In order to further evaluate the Logger data, some system knowledge and additional information delivered by SDM are required. The information is shown in SDM as a hardware tree.

An X20 controller controls a machine. Some X20 I/O modules are directly connected to the X2X interface of the CPU. The last module on the X2X Link network is an illuminated ring key field.

An X20 bus controller is connected via the POWERLINK connection in blue. This has node number 1. Some X20 I/O modules are connected to the integrated X2X interface of the X20 bus controller.

The POWERLINK connection continues from an X20 bus controller to an ACOPOS servo drive. This has node number 2.

Figure 57: Sample configuration with an X2X and POWERLINK connection

Hardware tree in the SDM

The enabled and configured hardware modules are shown in SDM "Hardware" category. They are dis- played in a tree structure, so it is possible, starting from the controller CPU, to navigate to the I/O module or drive via the individual fieldbuses.

The image shows that another X20 module was detected on the X2X interface, which is not part of the hardware configuration.

Figure 58: Depiction of the current hardware configuration in the SDM

What do the yellow "!" and the red "X" mean?

In the event of a faulty configuration or missing hardware, the interface where a problem is occurring will be highlighted by an exclamation point with a yellow background. The entry that caused the problem is marked with an "X" shaded in red.

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Module status and module details in the SDM

When a module is selected in the hardware tree, the module status and details about the module are shown on the right half of the screen. The X20DO6322 module is marked in the image. The module status shows "ModulOk" = TRUE. This means that the hardware module has been recognized and configured correctly. This module works correctly and delivers valid input data.

The module path and the B&R serial number are shown in the module details. If the serial number is known, the corresponding user's manual can easily be downloaded from the B&R website.

Further information:

• 4 "Obtaining information about the B&R system" on page 20

Figure 59: The module status and module details of the X20DO6322 module are shown

Module path

The module path in the module details clearly describes the place where a module is located. This provides information about the used fieldbus, the node number, the used interface and the slot of the individual module. The module path describes the position of the module in the hierarchy of the control system. If module path "IF6.ST2" is shown, for example, it must be read as follows:

Element of the

module path Description of the element

IF6 X2X interface of the X20CP1586 X20 controller. The interface name is documented in the data sheet of the X20 controller.

ST216 The X20DO6322 module is inserted in slot 2 on the X2X interface of the X20 bus controller.

Table 5: Module path decoding

Figure 60: X20AT4222 in the SDM hardware tree

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the respective device. Here, there is also information about the transfer rate, cable length and data transfer of the interface.

Figure 61: Excerpt of description "IF3" POWERLINK interface from "Data sheet X20(c)CPx58x"

Exercise: Remove bus connection or I/O module and analyze Logger entry

Cancel the connection to the X20 bus controller during operation or remove an I/O during runtime. The controller is restarted in service mode and the execution of the controller application is canceled. Read the Logger file and analyze the entries.

1) Disconnect the connection to the bus station 2) Wait for boot up in service mode

3) Establish a connection to SDM 4) Open the logger file

5) Interpreting the Logger file using the hardware tree in SDM

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The controller was automatically started in service mode by disconnecting from a bus station.

Text "Module removed while running" additional information "IF3.ST1" are shown in the Logger entry.

Figure 62: Logger entry in SDM - "Module removed while running"

A change can also be recognized in the hardware tree. The remote X20 module is marked red. The information "Not plugged" is listed in the module status and in the details for the cor- responding position in hardware tree "IF6.ST2".

If, for example, an entire X20 bus controller was removed, all I/O modules in the background would also be marked red.

Figure 63: Hardware tree in the SDM - IF3.ST1 is not inserted

How do I recognize a POWERLINK problem in SDM?

A problem can be identified on the POWERLINK fieldbus by displaying the Logger and the hardware tree in combination. However, it cannot yet be identified if the failure of the network participant was caused by EMC problems, a contact problem or a hardware problem. In this case, the status points of the fieldbus interfaces and bus controllers give additional information.

Further information:

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Via button "IO Info", which is located below the hardware tree in SDM, the data of the I/O modules are displayed. B&R modules have status data points that provide information about the module status or fieldbus communication. By clicking on the button, all information is displayed.

Figure 64: Enable to the I/O information

Status inputs of I/O modules

Besides input values of the I/O channels, further information about the validity of the measured values, wire breaks, short circuits or overcurrent is added to the I/O information. This is shown for each module marked in the hardware tree. This image shows an X20DO6322 digital output module. Input "StatusDig- italOutput01" shows value FALSE.

Figure 65: I/O information and status data of an X20DO6322 output module

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All data channels are completely described in "Data sheet X20(c)DO6322" in chapter "Status of the digital outputs". Input "StatusInput01" is described in this image. There is a meaningful channel status for each I/O channel.

Figure 66: Description of "StatusDitigalOutput01" in "Data sheet X20(c)DO6322"

Status inputs of fieldbus de- vices and interfaces

Each interface and each fieldbus station has its own diagnostic da- ta points. Using this data, it is possible to record the quality of the communication and communi- cation disturbances when the ma- chine is still running.

The image shows the diagnos- tic data points of the X20BC0083 POWERLINK bus controller. The X2X interface and the POWER- LINK interface of the controller it- self also offer such diagnostic data points.

Figure 67: Diagnostic data points of X20BC0083 e.g. EthPhys1LinkLoss shows the amount of connection disruptions to the 1st Ethernet port of the bus controller.

During operation, these diagnostic data points may only increase every two hours maximum;

otherwise, the network cabling should be checked.

When the system is booted, it's possible that some of these error counters are incremented until startup is complete.

Further information:

• 10.4 "Notes regarding grounding and shielding" on page 87

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2) Wait for the system to restart

3) Open the System Diagnostics Manager.

4) Read Logger entry

5) Open hardware tree in the SDM and enable I/O status

6) Read the error counter for the POWERLINK interfaces of X20BC0083.

7) Establish POWERLINK connection

8) Wait for reaction in SDM and at the I/O modules.

Connecting and disconnecting the POWERLINK cable over and over causes the error counters to increment. The system restart that was triggered by the interruption of the connection can be diagnosed using the Logger. Any potential disturbances in communication or wiring problems can be determined on the running machine via the statuts data points.

6.7 Information about the application status in WebXs

If mapp Technology components and the WebX library were used while creating the application, these components can be displayed via the mapp diagnostic page "WebXs". The components deliver compre- hensive status information that is helpful when communicating directly with the machine manufacturer.

The connection to WebXs is established by entering"IP address/mapp" in the address bar of the brows- er17 On the left of the image, a mapp component is being selected. The input parameters and status information of the selected mapp component are shown in the center of the image. The example below shows component MpAxisBasic that is used to control a drive axis.

Figure 68: mapp Technology WebXs: Input parameters and status information of MpAxisBasic 17B&R recommends to use Google Chrome as browser.

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What happens if function block output "Error" has value TRUE?

If output "Error" has value TRUE and if the statusID is not equal to 0, then an entry is generated in Logger file "$mapp". The Logger file can be shown and saved using System Diagnostics Manager.

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