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TM920 Diagnostics and service (2018) - page 1

Introduction

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 3: Correct errors

Figure 2: Contact manufacturer

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.

• Participants will learn how to replace modules and resume operation of the B&R system.

• Participants will learn whom to contact in order to obtain specific information.

• Participants will know the possibilities for backing up and restoring data

• Participants will learn how to backup and restore the values of process variables on a B&R

controller.

1

www.br-automation.com

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Introduction

1.2 Safety notices and symbols

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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TM920 - Diagnostics and service

Introduction

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

Automation Runtime is the operating system installed on the controller. Different

Runtime

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.

with touch screen) can be used to interact with the visualized machine functions.

X2X Link

Connects controller CPUs to X20 or X67 components. Serves as a remote back-

plane for transferring I/O data to the bus controller or CPU.

X20

Components with IP20 protection4. Complete control system with CPUs, remote

I/O modules and broad fieldbus support.

Table 1: Terminology

4

IP20 = Protection against ingress of solid foreign bodies >12.5 mm and no protection against ingress of

water. Source: IEC/EN 60529

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Situation analysis and problem identification

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

• Poor lubrication

• Warping

• Increased play (worn toothed gears, gear backlash)

• Belt tension on the drives not as specified by the manufacturer

• Damage caused by jolts and vibrations

6

The ability to predict machine and system failures before they happen reduces costs and increases avail-

ability.Condition monitoring modules from B&R precisely detect potential cases when service work may be

needed.

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Situation analysis and problem identification

2.1.3 Power supply, supply network

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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Situation analysis and problem identification

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

Company name, location, contact data

Machine manufacturer?

Packaging machine, pump controller, etc.

Machine type?

Brief description of the production process

What is being produced?

What type of problem is

Description of the type of problem: Standstill, noises, product quali-

occurring?

ty, communication failure, etc.

How often does the prob-

Approximate frequency of problem:

lem occur?

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

When did the problem

Started: "... last Wednesday at ..."

first occur?

Is the behavior repetitive? Under what conditions does the behavior

Reproducibility

occur?

Table 2: Checklist for B&R contact

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Situation analysis and problem identification

Question

Notes

Under what environmental conditions (temperature, humidity, etc.)

Environmental conditions

is the machine being operated. Installation of electromagnetic com-

patibility (EMC)

Different product being produced, mechanical modifications,

Has anything been

changes to cabling, software update from the manufacturer,

changed?

changed parameters, etc.

Contact person, documentation of the changes, reasons for

Who made the changes?

changes, etc.

What controller is being

Hardware being used, control concept, etc.

used?

What fieldbus is being

How the components and modules are connected together, etc.

used?

Have a topology diagram ready, state the important components,

etc.

What does the topology

Further information:

look like?

•

3.2 "Typical topologies" on page 16

What states are being signalized by the LED status indicators?

LED status indicators

(Controller, I/O modules, interfaces, bus controller, drives, etc.)

Who is responsible for the

Control program for the machine controller, source control system,

software?

archiving

Are there any backups?

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.

System dump

Further information:

•

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

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?

serial numbers

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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System overview and topologies

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-

site at www.br-automation.com in section "Products".

The entire product catalog can be downloaded in section "Downloads" selecting "Catalogs and

Brochures" / "Products" / "Product Catalog" in the respective drop-down menu.

Further information:

•

4.4 "B&R website functions" on page 24

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System overview and topologies

3.2 Typical topologies

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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System overview and topologies

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.

The maximum distance between two modules is

100 meters. Up to 254 modules are supported per

line.

Figure 8: X20 and X67 modules can be connected to the CPU

via X2X Link or POWERLINK. X20 and X67 modules are

linked together using X2X Link.

9

A few examples of fieldbus systems include: POWERLINK, Profibus, DeviceNet, etc.

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System overview and topologies

3.2.2 Redundancy

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

Figure: Example of ring redundancy

shown in System Diagnostics Manager (SDM).

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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System overview and topologies

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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Obtaining information about the B&R system

4 Obtaining information about the B&R system

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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Obtaining information about the B&R system

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 13: Side view of motor

Figure 11: X20 digital module, X20

backplane module

Figure 12: Rear side of Power Panel

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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Obtaining information about the B&R system

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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Obtaining information about the B&R system

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

Figure 15: Table of Contents of the X20

system user's manual

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Obtaining information about the B&R system

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

Figure 16: X20 CPU - X20CP1586

• 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

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...

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

used.

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Obtaining information about the B&R system

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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Obtaining information about the B&R system

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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Obtaining information about the B&R system

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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Obtaining information about the B&R system

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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Obtaining information about the B&R system

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.

Figure 22: The "X20 system user's manual" can be downloaded via the search function.

4.4.4 Download section of the website

Downloadable contents can be found on the B&R website in the "Download" section.

www.br-automation.com→ In main menu "Downloads"

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Obtaining information about the B&R system

The following content can be found in the Downloads section:

■

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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Obtaining information about the B&R system

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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