S210 Crashes on Comissioning

I'm working with an S210 controlled by a S7-1500.
I got a manual for it and tried following the steps for the initial configuration, but at the very start, it goes wrong.

I connect to the service port of the drive, using the webserver address provided.
I gave the Drive it's name, opened it for connection on the other port, all like the manual said.
Then I attempt to do the "One Button Tunning". The webpage hangs for a bit, then tells me the Drive is not available. If I check the drive itself, both Red LED's are on, there's no Fault number indicated and it stays like that until I power it off and on again. I think I've tried messing with all possible settings on the webserver before reseting everything to factory defaults and the problem persists.

I wondered if maybe the S210 needs to be connected to a PLC to work at all (a colleague told me no, but I'm willing to try anything) so I opened my project.

I configured the S210 with Telegram 105, added a Technology object, everything went smooth. Online shows the PLC and drive connected and I can even read position values and everything.

Then I open comission and activate Master Control. No trouble so far.
the moment I click "Enable Axis", it crashes just like with the webserver.

Looking at the alarms, before it crashes it throws an error about a faulty communication with the Encoder. And then another error about a faulty communication with the Drive.

I've tried switching with all sorts of Telegrams, tried every kind of setting I could change/tweak and asked another colleague to check the wiring, TWICE.
So far, nothing works, and by the time we try to move the bloody thing, it simply crashes into a state where it cuts all comunication and won't even accept acknowledgement to clear errors.

What the hell is going on here? Has it happened to anyone else?

When commissioning Siemens drives and motors with encoders, if during commissioning you have any kind of message about an encoder, change the control mode from whatever it is "with encoder", to "whatever it is (encoderless)".

Then try again.

It could be phase rotation on the motor is backwards from the factory that built the motor and the drive rotates the motor the opposite way from the encoder configuration in the motor.

If it suddenly starts working in "encoderless" operation, reconfigure the encoder to invert rotation direction, and then switch back to "with encoder" mode and try again.

Now if the motor goes the wrong way with + rpm, you can invert that in motor configuration, or swap motor leads out of the drive (the simple way).

Keep in mind, the encoder will be configured wrong if you just swap the wires.

After you get the encoder / encoderless mode worked out, post back your results and the next problem.

Hopefully the shielded twisted pairs encoder wiring is not picking up noise, and hopefully it is not ty-wrapped to the motor wiring.  And of course, hopefully the motor is connected using quality VFD cabling with proper bonding / shielding to reduce EMC problems.

Koriath

I'm working with an S210 controlled by a S7-1500.
I got a manual for it and tried following the steps for the initial configuration, but at the very start, it goes wrong.

I connect to the service port of the drive, using the webserver address provided.
I gave the Drive it's name, opened it for connection on the other port, all like the manual said.
Then I attempt to do the "One Button Tunning". The webpage hangs for a bit, then tells me the Drive is not available. If I check the drive itself, both Red LED's are on, there's no Fault number indicated and it stays like that until I power it off and on again. I think I've tried messing with all possible settings on the webserver before reseting everything to factory defaults and the problem persists.

I wondered if maybe the S210 needs to be connected to a PLC to work at all (a colleague told me no, but I'm willing to try anything) so I opened my project.

I configured the S210 with Telegram 105, added a Technology object, everything went smooth. Online shows the PLC and drive connected and I can even read position values and everything.

Then I open comission and activate Master Control. No trouble so far.
the moment I click "Enable Axis", it crashes just like with the webserver.

Looking at the alarms, before it crashes it throws an error about a faulty communication with the Encoder. And then another error about a faulty communication with the Drive.

I've tried switching with all sorts of Telegrams, tried every kind of setting I could change/tweak and asked another colleague to check the wiring, TWICE.
So far, nothing works, and by the time we try to move the bloody thing, it simply crashes into a state where it cuts all comunication and won't even accept acknowledgement to clear errors.

What the hell is going on here? Has it happened to anyone else?

Update: after a while I ended up figuring it out.

One of the Technicians that was assembling the machine switched two cables. Specifically, the U and V phases on the servo. Since servos work with vectorial phase control, this would of course "confuse" the drive and lead to a myriad of problems.

It is however, quite annoying that once again, whatever error TIA Portal displays, never has anything to do with the source of the problem. I was lucky enough that a colleague of mine had a "dumb" idea that ended up being correct, otherwise I would have ended up ordering a new motor to "fix" the issue when it was correctly assembled.

Protip for anyone else finding this topic in the future: if TIA Portal gives you an error about something, look everywhere else because whatever the error is pointing at, it's never the actual problem.

FYI, disabling encoder feedback, and manually moving the motor (using the control panel) excludes telegram problems, and lets you see what the drive wants to natively do with the wiring and motor.

If it runs backwards, you know right away the phases are reversed.  You can configure the drive to rotate in reverse in software, or swap wiring at the drive output.  Then enable the encoder and all should be good provided the encoder phasing is the same as the motor (which can also be switched in case you want + rpm to indicate the opposite direction). 

Koriath

Update: after a while I ended up figuring it out.

One of the Technicians that was assembling the machine switched two cables. Specifically, the U and V phases on the servo. Since servos work with vectorial phase control, this would of course "confuse" the drive and lead to a myriad of problems.

It is however, quite annoying that once again, whatever error TIA Portal displays, never has anything to do with the source of the problem. I was lucky enough that a colleague of mine had a "dumb" idea that ended up being correct, otherwise I would have ended up ordering a new motor to "fix" the issue when it was correctly assembled.

Protip for anyone else finding this topic in the future: if TIA Portal gives you an error about something, look everywhere else because whatever the error is pointing at, it's never the actual problem.