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TM920 Diagnostics and service (2018) - page 2

Diagnostic tools

5 Diagnostic tools

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

Figure 26: Alarms, messages and

Figure 27: Trend curves for graphic

at a glance

warnings provide information about the

representation of process values

machine status

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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Diagnostic tools

5.1.3 LED status indicators on the control system

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

• Module status

I/O modules

• Module error

• Channel status

LED status indicators on a 2-

channel digital input module

• Module status

• Boot phase

Control CPUs

• 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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Diagnostic tools

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

Figure 31: LED status indicators of the

X20AT2222 module

2) Search for "Data sheet X20AT2222". For help, see 4.4 "B&R

website functions" on page 24

3) Download the data sheet

4) Read chapter "LED status indicators"

5) Interpret description

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Diagnostic tools

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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• Easy installation of B&R Windows CE and B&R Windows XP Embedded.

• 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

¹² The 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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Diagnostics using the System Diagnostics Manager

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.

¹³ SDM can generally be enabled on all B&R control systems with integrated web server by the machine

manufacturer. Alternatively, the 8.1 "Backing up and restoring using the Runtime Utility Center" on page

70 can be used. A comparison of the possibilities in SDM and in the Runtime Utility Center is provided

here: 10.2 "Where SDM and Runtime Utility Center can be used" on page 84

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Diagnostics using the System Diagnostics Manager

6.1 SDM functions

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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Diagnostics using the System Diagnostics Manager

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.

Figure 37: Hardware information and I/O status

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Diagnostics using the System Diagnostics Manager

With analog modules, volt-

ages and currents are con-

verted into numerical values

which can be processed on

the controller. Independent of

the resolution, the numerical

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

values exist predominantly in

manual)

the 16-bit 2s complement.

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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Diagnostics using the System Diagnostics Manager

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.

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).

Figure 45: "Application status" button in

SDM

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-

loading software objects. The Runtime Utility Center can be used for such application situations.

Further information:

•

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

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Diagnostics using the System Diagnostics Manager

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 47: Accessing the SDM via web browser

Figure 46: Connecting PC to controller via network cable

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".

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

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Diagnostics using the System Diagnostics Manager

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 49: Selection of the desired Logger file

Figure 48: Select the category "Logger"

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.

Figure 50: The Logger file is uploaded by pressing button

"Upload from target"

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Diagnostics using the System Diagnostics Manager

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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Diagnostics using the System Diagnostics Manager

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 53: Start a new system dump

Figure 55: Select option "Parameters

and data files"15

Figure 54: Confirm with OK

Figure 52: Press the "System Dump"

button

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

2) Start a new system dump

3) Save system dump

15 This option saves all of the control system Logger files in ZIP format and adds them to the system dump.

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Diagnostics using the System Diagnostics Manager

6.5 Information in the hardware tree

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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Diagnostics using the System Diagnostics Manager

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

Description of the element

module path

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

¹⁶ The abbreviation "ST" stands for slot and describes the position of a module slot in the respective hierar-

chy.

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Diagnostics using the System Diagnostics Manager

The descriptions of the interfaces (IF1, IF2, IF3, IF6, etc.) can be found in the data sheet of

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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Diagnostics using the System Diagnostics Manager

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:

•

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

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Diagnostics using the System Diagnostics Manager

6.6 Diagnostics via I/O and status data points

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

Figure 64: Enable to the I/O information

or fieldbus communication. By clicking on the button, all information

is displayed.

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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Diagnostics using the System Diagnostics Manager

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

Exercise: Diagnosis of the fieldbus connection using diagnostic data points

The X20BC0083 POWERLINK bus controller as well as all other fieldbus interfaces and devices have

diagnostic data points. The goal is to become familiar with the reaction of the complete system in the event

of connection interruption in the POWERLINK network and to read the diagnostic information related to

this.

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Diagnostics using the System Diagnostics Manager

1) Disconnect the connection between the X20 controller and Powerlink bus controller X20BC0083.

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

¹⁷ B&R recommends to use Google Chrome as browser.

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Troubleshooting

7 Troubleshooting

Once the problem has been identified and all the necessary infor-

mation has been obtained, the problem can be solved.

If the problem can be solved by replacing a module, it is important to

deal with backing up the process data and parameter data of the ma-

chine control. The network topology must be examined beforehand.

If the problem was caused by material wear, the affected mainte-

nance part can be easily replaced.

Is there anything to consider before replacing or servicing the product?

It is recommended to download the component data sheet and user's manual from the B&R

website. These documents contain important information on handling. If the documentation is

not followed, irreparable damage may occur.

Further information:

•

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

7.1 Service parts

The B&R system contains only a small amount of service parts. All service parts are externally accessible

and easy to replace. These parts must be replaced from time to time in order to ensure long-lasting

operation.

All required accessories and maintenance parts are linked to the serial number. All maintenance parts

and their maintenance intervals are listed in the user's manual . The regional regulations regarding the

replacement of service parts during operation of the machine must be observed.

Service parts include:

• Fans for PCs, drives and CPUs

• Filter pads for fan kits

• Backup batteries for all CPUs

• Backup batteries for Power Panels

• Backup batteries for PC BIOS

• Backup batteries for EnDat 2.2 encoder interfaces

Figure 69: Lithium battery,

suitable for most B&R

components18

18 1 piece 4A0006.00-000 or 4 pieces 0AC201.91

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When replacing batteries, be sure to follow the procedure specified in the user's manual and

the recommended service intervals. Failure to do so can result in a loss of data. According

to the user's manual, the controller bridges data buffering for a certain time so that the battery

can be changed.

The process variables can be listed and then saved in the Runtime Utility Center using com-

mand "Variable List". Step-by-step instructions, see 8.1.5 "Outputting data via online connec-

tion" on page 78. Find out from the machine manufacturer which data is stored in the bat-

tery-backed memory area.

The battery status can be read via LED status indicators, System Diagnostics Manager as well

as the Runtime Utility Center. Usually the battery status is shown in the alarm system of the

HMI application.

Further information

•

5.1.3 "LED status indicators on the control system" on page 34

•

6 "Diagnostics using the System Diagnostics Manager" on page 39

Exercise: Replacing the battery

Replace the backup battery in the control CPU.

Follow the instructions in the user's manual.

1) Check the battery status (SDM, LED status indicators)

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

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

"B&R website functions" on page 24

4) Download user's manual

5) Back up all process variables, see 8.1.5 "Outputting data via

online connection" on page 78

6) Read chapter "Changing the Lithium Battery"

7) Change the battery as described in the user's manual.

7.2 Replacing a module

The following section lists the most important information about module switching. Before replacing the

module, make sure that all relevant measures have been taken. Detailed instructions as well as danger

notifications and warnings are documented in the user's manual of the respective system.

Node numbers

The topology and functioning of the B&R system was designed so that all programs and configuration

data is saved on the CompactFlash or on the internal Flash memory of the machine controller.

This means that all of the necessary settings and parameters are loaded to the devices connected to

the machine when it is started. Each unique node number is used to identify the devices on the fieldbus.

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The node number is set right on the device using the selector switch19 and must be unique on the

respective fieldbus. The backplane modules on remote X20 I/O modules can also contain node number

switches.

Figure

71: Node

number

Figure 70: All stations are networked together via POWERLINK. Each station has a unique node number

switch

on bus

controller

X20BC0087

What should be kept in mind regarding the node number?

When replacing a device, make sure that the node number set for the new device is the same

as that of the old device. New devices delivered by B&R are set to node number $00. The node

number on the B&R system is set to hexadecimal form, e.g. $1B corresponds to decimal 27.

Module type

Before replacing the module, make sure that the right module type is being used. The original device

model number must match that of the replacement. This can be checked using the model number located

next to the serial number. The control CPU will not be able to configure or start an incorrect module

that is connected.

The serial number of modules that are difficult to access can be read using the hardware tree in the

System Diagnostics Manager.

Further information:

•

4.1 "Serial numbers and model numbers" on page 20

Backing up and restoring

All fieldbuses, I/O modules and drives are configured and started by the controller's CPU. If you replace

CPU of the controller yourself, you should be aware that all data that's saved on the controller will go

missing. Therefore it's necessary, if possible, to back up important data in advance.

Further information

•

8 "Backing up and restoring" on page 70

¹⁹ Devices without a node number switch are automatically addressed and configured with an ascending node

number.

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Exercise: Creating a topology diagram

Having a topology diagram of the machine controller to hand can be very helpful when communicating

with other colleagues or with B&R Support. In the vast majority of cases, the topology is derived directly

from the machine's electrical diagrams.

In this exercise, we will be creating a topology diagram of the practice setup used. This is done by outlining

and noting all bus connections and the node numbers of the bus stations. The material numbers of the

individual modules can also be entered in the topology.

7.2.1 I/O, fieldbus devices, interfaces

In the control system, I/O modules serve to connect sensors and actuators. Different devices are con-

nected with the controller via interface and fieldbus modules.

Figure 72:

X20AT2222

Figure 74: X20IF1063-1

- Temperature

- PROFIBUS interface

measurement

module

module

Figure 73:

X20BC0083 -

POWERLINK bus

controller

When replacing I/O modules, fieldbus devices and interfaces, make sure that the new module is the

same type.

Also be sure to check the node number switches20 on the module. If the LED status indicators on the

module indicate "RUN" in accordance with the user's manual or data sheet, then the module replacement

has been completed successfully.

²⁰ Bus controllers, interface modules, X20 backplane modules and X67 modules mostly contain node number

switches. All other modules are addressed automatically.

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Figure 76:

CompactFlash

Figure 77:

Technology

Guard

Figure 75: X20CP1586 - Control CPU

Can the old CPU be exchanged with a new, different CPU?

The model number of the replacement CPU must match that of the original CPU. Different

CPUs use different processors. The operating system installed on the CompactFlash card must

match the original CPU type. The controller will therefore not start properly if a different CPU is

used23. This is signaled via the LED status indicators on the CPU.

CompactFlash cards are only permitted to be removed or inserted when the power is off.

When using a control CPU with an integrated application memory, the machine manufacturer

must provide either a replacement CPU with the application program preinstalled or the data

needed to generating a remote install structure.

Further information:

•

8.1.3 "Generate project installation package" on page 77

Does the data in the battery-backed memory get lost during CPU replacement?

Depending on the control program, some process data and parameters may be stored in the

control CPU's battery-backed memory. These data and parameters will be lost when the control

CPU is replaced and must therefore be backed up prior to replacement.

Only the machine controller's software project can indicate whether or not relevant process

data and parameters are stored in the battery-backed memory on the control CPU. Only the

machine manufacturer can provide this information.

²³ In this case, the machine manufacturer would have to change the hardware configuration of the control

application and create a new CompactFlash card.

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7.2.3 HMI devices, industrial PCs

Power Panels with and without touch screens

A Power Panel is essentially a controller with integrated display.

The same rules as for a control CPU apply for dealing with these

devices. Interface cards can be integrated into the device.

Figure 78: Power Panel

5PP520.0573-01

Does the new touch screen have to be calibrated after replacing the module?

Many B&R touch screen devices are equipped with a touch controller that supports hardware

calibration. This means that these devices are delivered pre-calibrated. Recalibration is gener-

ally not required after replacement. For detailed information about touch screen calibration see

section "Touch screen" in the respective user's manual.

The procedure for recalibrating a touch screen is usually a function of the machine's HMI ap-

plication and can be found in the user's manual of the machine.

Automation PC (APC), Panel PC (PPC)

An industrial PC works according to the same principles as a con-

ventional PC. The operating system and application programs are

stored on a hard drive or CompactFlash card. The mass storage de-

vices used in B&R's industrial PCs can be accessed and replaced

easily from the front without having to open up the device. An Au-

tomation Panel is usually used to display the user interface.

Figure 79: Panel PC 910 system unit

On a Panel PC, the monitor and PC are integrated into one device. On the newer generation of Panel

PCs, the PC unit is mounted on an Automation Panel. This allows users to replace the PC or display

unit independently of one another.

Hard drives, solid state disks (SSD), CompactFlash and CFast cards are only permitted to be

removed when the power is switched off.

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