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Problem: 8 LEDs of Simotion D445 flashes in red simultaneously during running

Created by: PineCone at: 5/17/2010 6:49 AM (7 Replies)

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5/17/2010 6:49 AM	Rate (0)
PineCone Posts: 8 Rating: (1)	Dear guys, I met a problem onsite, which is the 8 LEDs of Simotion D445 flashes in red simultaneously during running. There are 4 machines in the workshop. The problem only happens in one machine. According to the document, 8 LEDS flashes in red simultaneously means "Fault is present to which the user program (Simotion) cannot respond. The following actions may be required to rectify the fault: Power OFF/ON; Examine the CF card; New commissioning procedure; Replace the D4x5". We have taken the following actions, but all of them didn't solve the problem. 1. Power OFF/ON. This method can solve the problem temporarily. After Power OFF/ON, the problem disappeared, but it's not the real solution, because after some days the problem occurred again. 2. Replace D4x5. We have exchanged the D445 and the problem remains. 3. Replace CF card. We replace a new CF card and after the machine works well for 4 days, the problem happened again. This problem happens very irregularly. It's very hard to trace. According to customer's saying, this problem happened 5 times in one day once before. But when I was there, I saw only 1 time in a week. Do you meet such problem before and have any suggestions about this problem. Thanks a lot in advance. Best regards,
PineCone Posts: 8 Rating: (1)
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5/17/2010 12:20 PM	Rate (0)
ChristophD Grandmaster-Expert Joined: 5/12/2006 Last visit: 1/14/2026 Posts: 22800 Rating: (3073)	Hello, this is an internal system failure. Can you post the diagnostic log of the device? Regards Christoph

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5/18/2010 3:26 AM	Rate (0)
PineCone Posts: 8 Rating: (1)	Dear ChristophD, Thank you very much, but I didn't connect the computer to Simotion when the problem occured, so I can not provide the diagnostic log. It's very hard to trace the problem. Maybe I can provide it later. Anyway, thanks a lot for your advice. Best regards,
PineCone Posts: 8 Rating: (1)
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5/18/2010 4:20 AM	Rate (0)
ChristophD Grandmaster-Expert Joined: 5/12/2006 Last visit: 1/14/2026 Posts: 22800 Rating: (3073)	Hello, but you can save the diagnostic log after the error occurs and the machine is power off/on. The failure is logged in the diagnostic buffer. Regards christoph

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6/9/2010 5:15 AM	Rate (0)
PineCone Posts: 8 Rating: (1)	hello ChristophD, Thanks for ur help. I get Simotion Scout online with D445 to trace the diagnostic buffer, but I found when the problem occured, the scout went offline immediately, and the diagnostic buffer can not refresh in time, so i couldn't see any useful diagnostic infomation. In addition, I also use the service selector switch to (SIM/NCK) to write diagnostics data to the CF card when the problem occured. But i think the CPU has crashed that time and maybe can not perform this function correctly. But anyway, i have done this and you can find the DIAG data in the attachment. Maybe u can help to find some useful infomation for me. Thanks a lot in advance. Attachment DIAG.zip (392 Downloads)
PineCone Posts: 8 Rating: (1)
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6/9/2010 5:59 PM	Rate (0)
ChristophD Grandmaster-Expert Joined: 5/12/2006 Last visit: 1/14/2026 Posts: 22800 Rating: (3073)	Hello, i have analyzed the diagnostic data: there ar many time Overflows of a cyclic task and after 103 Overflows the system will be set to defective because the IPO System Task is overflowed. Have you programs in servosynchronous/iposynchronous Task? Or a heavy load of TO's? Regards Christoph

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6/10/2010 8:39 AM	Rate (0)
PineCone Posts: 8 Rating: (1)	Dear ChristophD, Thank you very much for your kindly help. I alsoanalysed the DIAGBUFF file and found there are about 98 F360BE02 events, afterthe F360BE02 events, the F760B288 event(DEFECTIVE operating mode) occured immediately which maybe made the 8 LEDs flash in red color. The machine has 83 real axes totally. The configuration is :D445_Master(42 real axis) + D445_Slave(32 real axes) + D435(9 real axes). The problem occured in D445_Master. There are some programs in IPOsynchronousTask_2, but no programs in ServosynchronousTask and IPOsynchronousTask. The cycle clock of IPOsynchronousTask_2 is 24ms. But what makes menot understand is there is another same machine(not 100% same), but the problem never happened in that machine. So if the program has problem, that machine should also have the sameproblem. How to explain it? Thank u very much. Best regards,
PineCone Posts: 8 Rating: (1)
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7/28/2010 12:57 PM	Rate (0)
PineCone Posts: 8 Rating: (1)	hello guys, After changing all Profibus-DP connectors, the problemdisappeared. Thanks a lotfor your help. Best regards,
PineCone Posts: 8 Rating: (1)
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