TM920 Diagnostics and service (2018)

Troubleshooting

Recommended procedure for replacing a PC:

• Check product ID of replacement device.

• Remove supply voltage.

• Remove hard drive and CompactFlash card.

• Install hard drive and CompactFlash card on new device as

needed.

• Reinstall Technology Guard on the new device.

• Remove plug-in cards.

• Insert plug-in cards in new device as needed.

• Set node number switches.

• Install backup battery (included in delivery) on replacement de-

vice.

• Restore power supply.

• Wait for startup to complete.

Figure 80: Automation PC 910

What should be considered before replacing a B&R PC?

Be sure to note the BIOS settings before replacing a PC. These must then be set identically

in the replacement device. A description of how to do this can be found in the user's manual

of the respective PC.

If interface cards are built into the PC then they should be built into the new device in the same

position. If dongles are used to protect software then they should be moved to the new PC.

Automation Panel

An Automation Panel is a display device and can only be used in connection with an Automation PC.

Does the new touch screen have to be calibrated after replacing

the module?

Touch screen recalibration may be necessary after replacing an Au-

tomation Panel. On Windows systems, this can be done in the Con-

trol Panel.

On devices with hardware keys, the key configuration is stored on

the PC. When the PC is replaced, the key configuration must be

transferred to the new PC. This can be done using the "Automation

Device Interface" (ADI) in the Control Panel. The ADI software is

Figure 81: Automation

described in the user's manual of the PC.

Panel 5AP981.1043-01 with

touch screen and hardware

keys

7.2.4 Motion control - Drive systems

Drives generally provide a mains connection and connections to the motor. Drives must only be replaced

when the power is turned off.

After replacing the drive, check the grounding of the drive and the cable, the wiring of the digital inputs (E-

stop, quick stop, trigger, enable, limit switch inputs) and the torque of the fastening screws for ACOPOS-

multi modules.

TM920 - Diagnostics and service

Troubleshooting

Additional information about this is provided in the respective user's manual.

Figure 84:

ACOPOSmotor

Figure 82:

ACOPOS

Figure 83: ACOPOSmulti (in back), ACOPOSmicro (on

the left) and ACOPOSinverter

User's manuals include danger notices with important information about how to use the respec-

tive systems. The instructions in the user's manuals must be followed.

7.2.5 Motion control - Motors

B&R motors and 3rd-party motors (motors from other manufacturers) are handled entirely dif-

ferently. The following applies to B&R motors.

Figure 85: 8LSA56.E0060D000-0 - Synchronous

motor, size 5, with EnDat encoder

Figure 86: Premium planetary gearboxes

TM920 - Diagnostics and service

Troubleshooting

B&R motor type

Description of the document

8LVA, 8JS, 8LT, 8MS, etc.

"Data sheet 8LVA", "Data sheet 8JS", etc.

Stepper motors

"User's manual for stepper motors"

Planetary gearbox

"System overview of planetary gearbox"

ACOPOSmotor

"User's manual for decentralized motion control"

Table 6: Overview of user's manuals for motors on the B&R website

7.2.6 Integrated safety technology

Safe I/O modules, SafeLOGIC, SafeLOGIC-X

SafeLOGIC controllers handle safe evaluation of data from compo-

nents such as light curtains or E-stop buttons.

The user's manual for integrated safety technology de-

scribes exactly how to handle safety-related components

and maintenance scenarios. All safety notices and danger

specifications must be followed.

Figure 87: X20SL8100 - SafeLOGIC

In the user's manual for integrated safety technology, the technical data provided for the re-

spective SafeLOGIC controllers includes descriptions of maintenance scenarios.

The description of SafeLOGIC controller SL8100, for example, can be found in chapter 2 "X20

System", subchapter 2.6.7.2.6 "Maintenance scenarios". These scenarios include aspects like

replacing a module.

How are safety-related sensors, actuators and drives connected?

Instructions on connecting safety-related sensors, actuators and drives with the STO function

can also be found in the user's manual for integrated safety technology. Information about

switching on safety-related actuators can be found in chapter 2 "X20 modules" under connec-

tion descriptions of secure digital output modules.

TM920 - Diagnostics and service

Troubleshooting

Remote Control dialog box

SafeLOGIC-X controllers have neither selector

switches nor confirmation buttons. Instead, a Re-

mote Control dialog box can be embedded in the

HMI application by the machine manufacturer. This

can be used, for example, to confirm a replaced

module. The same dialog box can also be used for

the current model of the X20SLxxxx series.

Figure 88: Remote Control dialog box embedded in the HMI

application

"$safety" logger file

The Logger (6.1 "SDM functions" on page 40) also saves important information related to the state of

the safety controller. These files can be stored locally when Logger file "$safety" is selected.

Further information:

•

6.3 "Saving Logger files" on page 45

TM920 - Diagnostics and service

Troubleshooting

ACOPOSmulti with SafeMOTION

In contrast to standard ACOPOSmulti inverter modules, ACOPOS-

multi modules with SafeMOTION are able to evaluate encoder sig-

nals internally with regard to safety.

The user's manual for ACOPOSmulti SafeMOTION de-

scribes exactly how to handle safety-related components

and maintenance scenarios. All safety notices and danger

specifications must be followed.

The maintenance scenarios are described in the user's

manual for SafeMOTION.

Maintenance scenarios are described in chapter 6 "Safety

technology", subchapter 6.7.5. Included are descriptions of

ACOPOSmulti SafeMOTION inverter module replacement,

motor replacement and updates.

Figure 89: 8BVI0014HCDS.000-1 -

ACOPOSmulti SafeMOTION inverter

modules

System

Title of user's manual

Safety technology

"Integrated safety technology user's manual"

Safe motion control

User's manual for SafeMOTION

Table 7: Overview of user's manuals for safety on the B&R website

TM920 - Diagnostics and service

Troubleshooting

7.3 Starting up again and functional testing

The following step sequence can be used when replacing a defective module. System Diagnostics Man-

ager is available as support for diagnostics.

Figure 90: Required steps for replacing a module

The status of System Diagnostics

Manager in the image shows that

there are no more errors identified

by the control system.

Functional testing must be used

to ascertain whether the machine

runs properly.

Figure 91: System Diagnostics Manager start page

TM920 - Diagnostics and service

Troubleshooting

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 92: SDM system overview

Figure 93: SDM system logger

Figure 94: SDM drive technology

diagnostics

Description

Information source

• Machine manual

Safety and general notices

• B&R user's manuals

• HMI application

• LED status indicators

Status of B&R controller, I/O modules and drives

• System Diagnostics Manager

• Runtime Utility Center

Turning on and starting up the machine

• Machine manual

• HMI application

Machine process function

• Machine manual

• mapp technology WebXs24

Table 8: Information sources for starting up again and function testing

²⁴ If the machine application uses mapp technology, then there is a web-based diagnostics for the mapp

functions.The machine manufacturer, however, must document in the machine manual which mapp com-

ponents are responsible for controlling a certain machine function.

TM920 - Diagnostics and service

Backing up and restoring

8 Backing up and restoring

Software updates and software installation packages are only available from the machine manufacturer.

A software update is only necessary if there is a software error or if changes have been made to the

functions in the software.

The following chapters describe how to back up and restore the CompactFlash card and how to create

your own Instruction Lists using the Runtime Utility Center.

There are many conditions dictating whether or not the software on a machine controller can be

backed up and restored. In many cases, the source files for the control software are not stored

on the CompactFlash card or on the internal Flash memory.

Battery-backed data from the machine controller is not applied when backing up and restoring

data. Backing up data requires knowledge of the control software. All necessary information is

provided by the machine manufacturer and the maintenance manual for the machine.

8.1 Backing up and restoring using the Runtime Utility Center

The Runtime Utility Center is a system tool that provides a range of utilities for diagnostics and service

on B&R controllers. The installation program for the Runtime Utility Center is included in the Automation

Studio installation or can be downloaded separately from the B&R website.

Figure 95: Runtime Utility Center - Start page

The most important functions are:

• Performing service functions via an online connection to the controller

• Variable functions for backing up and restoring process variables

• Creating individual Instruction Lists for testing and installation procedures

• Backing up and restoring a CompactFlash/CFast card

• Offline installation of a control project on a CompactFlash/ CFast card

• Creating project installation packages for USB installation

• Custom mode allows the creation of a user-defined user interface

TM920 - Diagnostics and service

Backing up and restoring

How can I open the Runtime Utility Center help documentation?

The Runtime Utility Center contains complete help documentation. This help documentation is

opened by pressing the "F1" key . The Runtime Utility Center must be opened before doing

this. The following entries provide additional important information about using the Runtime

Utility Center.

Runtime Utility Center \ Start page

Runtime Utility Center \ Operation \ The Workspace

Runtime Utility Center \ Operation \ Commands \ Establish connection, wait for new connection

Runtime Utility Center \ Operation \ Commands \ PLC Info \ Logger

Downloading the Runtime Utility Center

The Runtime Utility Center is part of the PVI development setup and can be downloaded from the B&R

website:

www.br-automation.com → Download → "PVI development setup".

Figure 96: Downloads section, product groups filter "Software"→"Automation NET/PVI"

TM920 - Diagnostics and service

Backing up and restoring

Installing the Runtime Utility Center

The downloaded installation package must be extracted before installation. The installation program can

then be started. No changes have to be made during the installation for use of the Runtime Utility Center.

Figure 97: Select a language

Figure 98: Click on "Start installation"

8.1.1 Backing up and restoring a CompactFlash card

The following section will demonstrate the steps necessary to back up and restore the machine con-

troller's CompactFlash card. When backing up, an image of the CompactFlash card is created and saved

to the PC. When restoring, an existing image is copied to the CompactFlash card.

When restoring an image, all of the data stored on the CompactFlash card will be lost. A con-

ventional card reader is required to back up and restore a CompactFlash card.

Backing up and restoring a CompactFlash card only involves the contents of the CompactFlash

card25. Process data in the battery-backed memory area is not taken into account. These data

can be backed up using the Runtime Utility Center (8.1.4 "Online connection and Instruction

Lists" on page 78).

Procedure

The Runtime Utility Center is started via the Windows start menu.

In order to back up and restore the data on a CompactFlash card, it must first be connected to the PC

using a card reader. By clicking on menu option "Create / restore a drive image", the dialog box for

backing up and restoring the CompactFlash card is opened.

²⁵ Configuration and program modules on systems without CompactFlash cards are stored directly in the CPU's

memory. These contents can only be backed up using an Instruction List in the Runtime Utility Center.

Program modules can be uploaded using the "Module functions" category.

TM920 - Diagnostics and service

Backing up and restoring

Backing up a CompactFlash card

Step 1

Step 2

Figure 99: Select "create image from disk"

Figure 100: Select CompactFlash card from the list

The connected drives are reloaded via the "Re-

fresh" button.

Step 3

Step 4

Figure 102: An image file of the CompactFlash is created

Figure 101: Specify storage location and click on "Create

image"

The memory location of the image file is selected

by clicking on the "Browse" button.

Restoring a CompactFlash card

Which CompactFlash card is suitable for recovery?

The CompactFlash card can only be restored on a CompactFlash card that is the same size or

larger. This function is limited to CompactFlash cards from B&R.

TM920 - Diagnostics and service

Backing up and restoring

Step 1

Step 2

Figure 103: Select "restore image to disk"

Figure 104: Select CompactFlash card from the list

The connected drives are reloaded via the "Re-

fresh" button.

Step 3

Step 4

Figure 106: When restoring an image, all data on the

CompactFlash card will be deleted Proceed?

Figure 105: Select image file and click on"Restore image"

The memory location of the image file is selected

by clicking on the "Browse" button.

Runtime Utility Center \ Creating a list \ Data storage medium \ CompactFlash functions \ Gen-

erating CompactFlash

Exercise: Backing up the CompactFlash card

For precautionary reasons, create an image file of the CompactFlash card's contents. This image can

then be restored at a later point in time. Before turning off the CPU, refer to the LED status indicators or

the SDM to check the status of the backup battery.

1) Check the status of the backup battery

2) Turn off control CPU

3) Remove the CompactFlash card

4) Insert CompactFlash card to card reader and connect to PC

5) Start Runtime Utility Center, select "Create / Restore a disk image"

TM920 - Diagnostics and service

Backing up and restoring

6) Select CompactFlash

7) Select the memory location for the image

8) Create image file

8.1.2 Backing up files from CompactFlash

A CompactFlash card can contain multiple partitions. In Windows, only the "C" drive of the CompactFlash

card can be seen. Runtime Utility Center can be used to back up and restore files from the other partitions.

Click on menu option"Create, edit and execute projects (.pil)" to open the dialog box for backing up

the CompactFlash files.

In the Runtime Utility Center, the "Tools" tab is used

to get to option "Back up files from Compact-

Flash card / image file" where the dialog box for

saving the files can be opened.

The CompactFlash card is connected to the PC us-

ing a card reader.

Figure 107: Runtime Utility Center "Tools" \ "Backup files from

CompactFlash card" / "Back up image file"

TM920 - Diagnostics and service

Backing up and restoring

Step 1

Step 2

Figure 108: Select CompactFlash card from the list

Click on "Select disc", select CompactFlash card

and click on "OK"

Figure 109: Back up Logger file "$arlogsys" from

CompactFlash card

Select Logger file, set destination directory and

click on "Start"

The files selected will be stored in the destination directory with the same structure shown in

the selection dialog box.

The files can be copied to another CompactFlash card via tab "Extras", option"Restore files

to CompactFlash card".

Runtime Utility Center \ Operation \ Backing up \ Restoring files on CF

Exercise: Back up the Logger file from the CompactFlash card

The Logger file is stored on the CompactFlash card. While the Logger file can be uploaded using SDM,

the Runtime Utility Center offers the possibility to back up the Logger file directly from the CompactFlash

card. The Logger file name is "$arlogsys". The goal of this exercise is to find the Logger file on the

CompactFlash card and then back it up.

1) Start Runtime Utility Center

2) Select "Tools - Back up files from CompactFlash" from the main menu

3) Select CompactFlash

4) Select the Logger file "$arlogsys".

TM920 - Diagnostics and service

Backing up and restoring

5) Specify destination directory

6) Create file backups

The Logger file can be used by the machine manufacturer or B&R for analysis.

If the control CPU is no longer operational, the Logger file can still be backed up by the Com-

pactFlash card for further analysis by following the procedure described above.

8.1.3 Generate project installation package

Updating the control software is performed using a project installation package. Using a USB flash drive,

the software can then be transfered directly to the CPU via a DHCP/FTP server or a CompactFlash card.

The project installation package is created from a Runtime Utility Center export package provided by

the machine manufacturer.

Loading Runtime Utility Center export package

Select "Open project (ZIP, .pil)" to load the Runtime Utility Center export package. Then, the following

functions are available:

Figure 110: Runtime Utility Center start page with export file already loaded, see header of window

• Performing offline installation

This function can be used to perform an initial transfer to a CompactFlash/CFast card.

• Creating project installation package

This function can be used to create a project installation package, e.g. for USB installation.

Runtime Utility Center \ Creating a list / data medium \ Project installation

If the project installation package has been transfered to a USB flash drive, for example, this can be

inserted in the controller's USB port. The next time the controller is restarted, it checks the version of

the application and, if necessary, transfers it to the controller. However, this function has to have been

enabled in the control project.

TM920 - Diagnostics and service

Backing up and restoring

8.1.4 Online connection and Instruction Lists

The Runtime Utility Center provides the option to create Instruction Lists for service purposes. This

makes it possible to group multiple commands into a single list. The entire list can then be executed

as a sequence.

As with SDM,26the Ethernet interface is available for connecting to the controller. The network settings

might have to be changed on the PC, see (10.3 "Changing network settings on the PC" on page 86).

Additionally, a connection via a serial interface is supported.

What has to be considered when connecting via the serial interface?

In this case, make sure the serial interface is not already being used by the control program. A

serial cable would also be required for this. For a description of the cable construction see:10.1

"Online connection cable" on page 84.

8.1.5 Outputting data via online connection

The following section describes how to establish a connection to the control CPU using the Runtime Utility

Center. The upload of the Logger file was used as an example. Further procedures must be configured

in the same way.

First, open the Runtime Utility Center and select menu option "Create, modify and execute projects

(.pil)". The following view is displayed:

Description of window:

1) Command set

2) Instruction List: The list of

commands to be executed

is created here

3) Short description of the

selected command

Commands are added to the In-

struction List using drag-and-drop

Figure 111: Runtime Utility Center main window

²⁶ The Runtime Utility Center and System Diagnostics Manager offer several diagnostic options in equal mea-

sure. For a comparison of the two tools, see 10.2 "Where SDM and Runtime Utility Center can be used"

on page 84.

TM920 - Diagnostics and service

Backing up and restoring

Establish the connection

Description of steps:

1) Drag command "Connec-

tion" from the command

set and drop it in the In-

struction List. The configu-

ration dialog box will open

automatically

2) Select device type "Ether-

net (TCPIP)"

3) Select "Properties"

4) "IP address / Set host-

name" and enter IP ad-

dress

5) "Select "Obtain destina-

tion address automatical-

Figure 112: Adding an Ethernet connection to the Instruction List

ly"

After completing the settings, close the dialog box by pressing "OK".

Which value must the destination and source addresses have?

The destination address is the node number of the communication interface set on the control

CPU. The source address must not be the same as the destination address. For example, if the

destination address has the value 1, then any other value can be used for the source address

except for 1. A connection cannot be established in some circumstances to the controller if both

values are the same.

Add command "Logger"

Description of steps:

1) Drag command "Logger"27

from the command set

and drop in Instruction

List. The configuration di-

alog box will open auto-

matically

2) Select "Load system log-

ger module"

3) Select output format

4) Select target path

After all settings have been made,

the configuration dialog box can be

closed by pressing "OK".

Figure 113: Adding command "Logger" to Instruction List

²⁷ Command "Logger" only works for systems whose user memory is organized as a file system. For all oth-

er controller CPUs, command "Logbook" must be used.

TM920 - Diagnostics and service

Backing up and restoring

Execute Instruction List

The Instruction List can now be ex-

ecuted. This is done by clicking on

the "Execute" icon in the menu bar

or by pressing the "F5" key. A con-

firmation window appears before

the Instruction List is executed.

Figure 114: Execute Instruction List

A progress indicator appears after

the sequence has been started. As

they are executed, the commands

appear with their status in the out-

put window. The sequence can be

aborted at any time by clicking on

"Stop".

Figure 115: Display of progress indicator for executing Instruction List

Runtime Utility Center \ Operation \ Workspace

Runtime Utility Center \ Operation \ Commands \ Establish connection, wait for new connection

Runtime Utility Center \ Operation \ Commands \ PLC info

Runtime Utility Center \ Operation \ Menus \ Start

TM920 - Diagnostics and service

Backing up and restoring

Exercise: Read Automation Runtime version and save Logger file

The Automation Runtime version provides information about the integrated functions of the controller.

The diagnostic data that can be provided depends on the Automation Runtime version, among other

things. Information on events on the controller is recorded in several Logger files. This information helps

to localize sources of errors. Read the installed Automation Runtime version and upload Logger file "$ar-

logsys" from the controller.

1) Start Runtime Utility Center

2) Click on menu option "Create, edit and execute projects (.pil)"

3) Add command "Connection" to Instruction List

4) Add command "AR Version" to Instruction List

5) Add command "Logger" together with Logger file "$arlogsys" to Instruction List

6) Start Instruction List

Exercise: Save profiler file using the Runtime Utility Center

If an error occurs, such as a cycle time violation, then the controller restarts in service mode. Information

about the causative task class is saved in the Logger file. The profiler file contains additional details on

the error. Every newly created profiler file receives a new name. The names of the profiler files end with

the string "$f" and can be identified by uploading a module list.

1) Start Runtime Utility Center

2) Click on menu option "Create, edit and execute projects (.pil)"

3) Add command "Connection" to Instruction List

4) Add command "module list" to Instruction List

5) Start Instruction List

6) Evaluate the names of the profiler files from the module list

7) Add command "Upload" to Instruction List and add the name of the desired profiler file

8) Start Instruction List

Exercise: Backing up all process variables

Perform a data backup by saving all of the variables on a control CPU to a file. The backup can contain

parameters, current process values or settings. The values can only be interpreted in combination with

the control project or through knowledge of the machine manufacturer.

1) Start Runtime Utility Center

2) Click on menu option "Create, edit and execute projects (.pil)"

3) Add command "Connection" to Instruction List

TM920 - Diagnostics and service

Backing up and restoring

4) Add command "Variable List" to Instruction List

5) Start Instruction List

Runtime Utility Center \ Operation \ Menus \ File

Runtime Utility Center \ Operation \ Commands \ Establish connection, wait for new connection

Runtime Utility Center \ Operation \ Commands \ List functions

Runtime Utility Center \ Operation \ Menus

After saving all variables from the controller, a file with all variable names and corresponding

values is created. This file can be used at a later point in time for restoring the process data.

This is done by using the process variable function, "Write variable list to PLC".

8.2 Access to the integrated FTP server

B&R control systems have an integrated FTP28 server. If the FTP server is enabled, then the Flash

memory of the controller can be accessed. In order to do this, the configured access rights must allow it

and the username and password must be known. Username and password cannot be reset or changed.

The access data for the FTP server can be found in the corresponding documentation of the machine

manufacturer

For example, configuration files and recipe files can be backed up and restored via this mechanism.

FTP can be accessed, for example, via the Windows command line with the command "ftp ip-adresse",

Internet Explorer or third-party tools (e.g. FileZilla).

²⁸ File Transfer Protocol (FTP) is a network protocol (specified in the RFC 959 from 1985) for transferring data

via IP networks. Source: de.wikipedia.org

TM920 - Diagnostics and service

Summary

9 Summary

First an attempt is made to create an overview for a comprehensive diagnosis. The resulting error de-

scription helps with narrowing down to the error source.

A wide range of influences from the surroundings, the raw materials used and process parameters can

affect how a machine works.

B&R products enable complete diagnostics via LED status indicators, System Diagnostics Manager and

Runtime Utility Center. Complete data sheets and wide-ranging user manuals document the technical

data, the installation and the maintenance of all B&R modules.

Figure 116: Examine surroundings

Figure 118: Correct errors

Figure 117: Contact manufacturer

The B&R system overview showed the basic structure of the B&R control system. The diagnostics pos-

sibilities that are available both with and without a PC were also discussed.

A complete overview of the user's manuals for the individual B&R product groups was provided. A check-

list was also introduced to help prepare yourself before contacting B&R.

TM920 - Diagnostics and service

Appendix

10 Appendix

10.1 Online connection cable

Ethernet connection cable

A standard crossover network cable is recommended when connecting the B&R controller to a PC.

Serial connection cable

A cable with the following pinout is required to connect a B&R controller to a PC via the serial interface.

9-pin female DSUB

9-pin female DSUB connec-

Control

connector

tor

2 (RXD)

-----

3 (TXD)

-----

2 (RXD)

5 (GND)

-----

5 (GND)

Table 9: Cable pinout for online connection cable

9-pin female DSUB

Control

X20 controller terminal block

connector

2 (RXD)

-----

11 (TXD)

3 (TXD)

-----

21 (RXD)

5 (GND)

-----

22 (GND)

Table 10: Cable pinout for direct connection to an X20 terminal block

10.2 Where SDM and Runtime Utility Center can be used

The following tables compare the possibilities of the System Diagnostics Manager (SDM) and the Run-

time Utility Center (RUC).

In general, the SDM can only be used if a system has an integrated web server and it is enabled. Read

access is granted on the controller. No additional software installation is necessary on the PC.

The Runtime Utility Center can be used to diagnose systems without integrated web server and to back

up and restore data. A serial or Ethernet port can be used for connection. The Runtime Utility Center

must be installed on a PC with a Windows operating system before use.

General diagnostics

Function

SDM

RUC

Output and set time

Yes29

Yes

Output battery status

Yes

Table 11: Comparison of general diagnostics functions

²⁹ Time can only be output in SDM.

TM920 - Diagnostics and service

Appendix

Function

SDM

RUC

Output system version

Yes

Yes30

Read Logger31

Yes

Output hardware list

Yes

Detect hardware problems

Yes

I/O and read status data points

Yes

Determine system usage

Yes

Output memory usage

Yes

Output configured timing

Yes

Output module lists

Yes

Output axis errors

Yes

Reading network command trace

Yes

Install trace configuration32

Yes

Table 11: Comparison of general diagnostics functions

Backing up and restoring

Function

SDM

RUC

Saving Logger files

Yes

Saving profiler files

Yes

Yes33

Generate system dump

Yes

Upload software objects

Yes

Download software objects

Yes

Backing up and restoring a CompactFlash card

Yes

Back up and restore variables

Yes

Output and display variables

Yes

Table 12: Comparison of back up and restore options

³⁰ The runtime environment has software versions for the operating system, motion control and visualiza-

tion.In the Runtime Utility Center, only the operating system version can be output.

³¹ There are usually several Logger files on current B&R control systems for diagnosing different functional

areas of the controller. For control systems that do not have a USB interface or an onboard Ethernet inter-

face, function "Logbook" of the Runtime Utility Center must be used.

³² Installing a trace configuration makes it possible to record pre-configured process values on the runtime

system.The finished recording can then be uploaded from the controller for further analysis.

³³ The profiler file can be loaded via the "Upload" module function on the controller. The name of the profiler

file ends with the string "$f" and can be identified by uploading a module list.

TM920 - Diagnostics and service

Appendix

10.3 Changing network settings on the PC

The IP address of the Ethernet interface can be changed on the PC. This is done via the settings of

the network adapter, see Windows 10 "Control Panel" \ "Network and Internet" \ "Network and Sharing

Center" \ "Change adapter settings". All available network connections are displayed.

Right-click on the desired adapter, then click on "Properties". Select "Internet Protocol, version 4 (TCP/

IPv4)" and click on "Properties". Now the IP address can be changed.

As shown in the example, a static IP address with value "10.0.0.1" and subnet mask "255.255.255.0"

are assumed for the controller. The configuration of the PC must be in the same subnet.

Figure 119: Windows 10: Change adapter settings for the LAN Connection adapter under Network and Sharing Center.

We recommend writing down the original adapter settings before making any changes.

By entering "Show network connections" in the search field of the Windows 10 Start menu, the

selection is already restricted making it possible to get the list of network adapters more quickly.

TM920 - Diagnostics and service

Appendix

10.4 Notes regarding grounding and shielding

The following section compiles a few universally applicable recommendations for grounding and shield-

ing. The regulations in the respective user's manual always apply. The procedure for correcting prob-

lems on machines where grounding and shielding result in failures should be adapted on a case-by-

case basis.

Shielding and grounding for control systems

On all shielded cables, the shield must be grounded. These

include:

• Analog signals (input and output modules)

• Interface modules

• Counter modules

• X2X Link cables

• Fieldbus connections (POWERLINK, PROFIBUS DP, CAN,

etc.)

Figure 120: X20DC1176 connection

schematic - Encoder cable connection

with shielding

The following general guidelines apply for shielding:

• The top-hat rail must always be mounted to a conductive backplane.

• The control cabinet back wall must be connected with GND.

• Shielded cables must be grounded on both sides.

TM920 - Diagnostics and service

Appendix

Figure 122: Shielding via top-hat rail

or busbar

Figure 121: Shielding via X20 cable

shield clamp

Figure 123: Wiring diagram for X20

modules with an Ethernet cable

"X20 system user's manual"

Content

Chapter 4 "Mechanical and electrical config-

Direct connection of the shield to the ground

uration"

connection of bus modules

Cable shielding plate

Chapter 4.6

Shielding bracket

Shielding via top-hat rail or busbar

Chapter 4.7

Wiring guidelines for X20 modules with an

Ethernet cable

Chapter 7.10.2

General specifications for X2X Link cables

Chapter 8.2.2

Requirements for immunity to disturbances

Chapter 8.2.3

Emission requirements

Table 13: Notes regarding shielding and grounding in the control system

TM920 - Diagnostics and service

Appendix

Installation / EMC guide

Content

Chapter 3.3.3 "Installation with increased vi-

Padding, retaining clips, adjustment, cover-

bration requirements (4 g)"

ing unused slots, strain relief

Chapter 3.4.1.2 "Shield connection"

Ground connection, shield terminal blocks,

bend radius

Chapter 6.3 "Buffer module"

24 V power supply buffering

Table 14: Installation notes for control systems

Shielding and grounding for drive technology

• To prevent the effects of disturbances, the following cables must be properly shielded:

° Motor cables

° Encoder cables

° Control cables

° Data cables

• Inductive switching elements such as contactors or relays must be equipped with correspond-

ing suppressor elements such as varistors, RC elements or damping diodes.

• All electrical connections must be kept as short as possible.

• Cable shields must always be attached to the designated conductive shielding clamps and the

connector housing. Twisting the braided shield or extending it with individual conductors is not

permitted!

• Shielded cables with copper braiding or tinned copper braiding must be used.

• Unused cable conductors must be grounded on both sides whenever possible.

"ACOPOSmulti user's manual", chapter 5 "Wiring":

• Subsection 1.1 "EMC-compliant installation"

• Subsection 1.1.4 "Connection diagrams for ground connections and shield connec-

tions"

Exercise: Check the installation with regard to electromagnetic compatibility (EMC)

Downtime caused by EMC problems can be prevented by installing appropriate components. Corre-

sponding recommendations are provided in the data sheets and user's manuals. B&R components are

designed for complete shielding and grounding. This includes shield component sets available as acces-

sories for control and I/O systems, for example. B&R recommends connecting controllers and remote I/

O systems to the cables offered in the B&R product catalog. Detailed specifications for cables used in an

industrial environment are available in the respective data sheet.

1) Look up the shielding and grounding concepts for X20 modules in the X20 system user's manual

2) Cable shield for X20 modules - Shield component set

3) Look up the specifications for X2X and POWERLINK cables

TM920 - Diagnostics and service

Appendix

10.5 Power supply and fuses

The protection for the X20 system depends on the supply concept. Using the X20BM01 bus module and

organizing the power supply bus modules accordingly allows various potential groups to be implemented

(e.g. for input groups or various power circuits for the outputs).1)

Figure 124: Protecting various potential groups

It is possible to set up potential groups through the use of different supplies for the power supply modules.

Figure 125: Example of extended X2X Link power supply

¹⁾ A 1 A slow-blow fuse is recommended for the bus supply.

TM920 - Diagnostics and service

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TM920 - Diagnostics and service

TM920 Diagnostics and service (2018) - page 3