Troubleshooting manual for I/O Link communication alarm (System Alarm PC050/PC150/971)

Preface

I/O Link communication alarm is sometimes reported from MTBs and End-users, and generally, it can take much time to solve the trouble. In this manual, we are analyzing actual examples, and conclude how to troubleshoot these troubles. This manual is for Service people to learn about this alarm, and to solve these troubles quickly.

1. Alarm Message

When I/O Link communication fails, System Alarm is issued with one of the following messages.  The message changes according to the series and edition of PMC Management Software, however, its meaning and the process of troubleshooting are common.

·    PC050 IOLINK CH1 a₁b₁-x₁y₁:x₂y₂

·    PC050 IOLINK CH2 x₁y₁:a₂b₂-x₂y₂

·    PC050 I/O LINK(CHn) x₁:y₁ x₂:y₂

·    PC050 NMI SLC(CHn) x₁:y₁ x₂:y₂

·    PC050 NMI SLC x₁:y₁

·    PC150 NMI SLC x₁:y₁

·    971 NMI OCCURRED IN SLC (note)

·    SLC ERROR x₁(y₁) : PC050

·    SLC ERROR x₁ : PC050

(note)     This message has the register value “x1y1” in memory dump.  Refer Chapter 1.2 ‘Register value in “971 NMI OCCURRED IN SLC”’ for detail.

In these messages, “CHn” (n ≥ 1) means the channel of communication failure.  The messages without “CHn” means the error was detected in channel 1. The portion “a₁b₁”, “x₁y₁”, “a₂b₂” and “x₂y₂” are the register values of SLC, which is I/O Link communication controller LSI.  The value “a₁b₁” and “x₁y₁” are of channel 1; “a₂b₂” and “x₂y₂” are of channel 2. The register value of channel 2 will always be displayed at PMC software that supports “I/O Link expansion” option, whether the option is purchased or not. Some messages have “a₁b₁” and “a₂b₂”, which are earlier value than “x₁y₁” and “x₂y₂”.

	earlier	later
Channel 1	a1b1	x1y1
Channel 2	a2b2	x2y2

The register values are clues certainly, however, they may not be enough evidence to find out the cause of troubles because of following reasons:

·    These values are not the values at the instant when the first communication error was detected, but are the values when the communication disconnected finally.  This means that the values may not reflect the direct cause, and can reflect its side effect.

·    In case of hardware malfunction or electric noises, the register value may become improper value.

·    The same causes may show different register value depending on the timing of error.

Therefore, it is important to analyze not only register value, but also the situation how the alarm occurred.

1.1SLC’s register value

1.1.1        Detail of a₁, a₂, x₁ and x₂

xn#7

xn#6

xn#5

xn#4

xn#3

xn#2

xn#1

xn#0

xn#0	Bad data was received: If xn#1 is 1, xn#0 will always be 1. So check xn#1 first.
xn#1	Slave device detected an error.  See yn for more detail.
xn#2	Slave did not respond.  Link was disconnected.
xn#3	SLC, I/O Link controller LSI, detected parity error of internal RAM.  Exchange PMC control module, or the board with I/O Link connector.
xn#4	Parity error in I/O RAM was detected.  Exchange PMC control module, or the board with I/O Link connector.
xn#5~7	Meaningless 1.1.1        Detail of b1, b2, y1 and y2 yn#7 yn#6 yn#5 yn#4 yn#3 yn#2 yn#1 yn#0 When slave detected communication error (in case xn#1 is 1), this value shows the slave number and the detail of the error. Otherwise (in case xn#1 is 0), this byte will be the slave number of which master communicated last, or of which master was trying to communicate.  But this slave number does not mean the very slave with problem.  For example, in case that connection between 1st slave and 2nd slave was cut when master was trying to communicate with 3rd slave, this byte will show the number for 3rd slave. yn#0~4 Number to identify slave: the value is “<group number> + 1”, where the 1st slave is group 0.  For example, the value 4 means the group 3, which is 4th slave from master. yn#5 Slave detected communication error.  (not effective if xn#1 is 0) yn#6 Slave raised System Alarm other than one about I/O Link.  Check what System Alarm was raised at slave.  (not effective if xn#1 is 0) yn#7 Slave detected watchdog error or parity error.  (not effective if xn#1 is 0) 1.2 Register value in “971 NMI OCCURRED IN SLC” In some CNC and PMC model, the following screen is displayed at I/O Link communication failure.  In this screen, the SLC’s register value is not shown in the error message itself, however, you can pick up the value from following dump display. 1.2.1 Dump with register names ・  Models CNC models PMC models Series 21i-A/B PMC-SA1 Series 16-B PMC-SB3/SB4 Series 18-B PMC-SA1/SA3 Series 21-MB PMC-SA1/SA3 Series 21-TB (B type) PMC-SA1/SA3 ・  Position of SLC’s register (bold and underlined)   1.2.2     Dump without register names ・  Models CNC models PMC models Series 16-A PMC-SB/SB2/SB3 Series 18-A PMC-SA1/SA3 Series 21-TB (A type) PMC-SA1/SA3 Power Mate-D PMC-PA1/PA3 Power Mate-H PMC-PA3 ・  Position of SLC’s register (bold and underlined) 2   Cause of communication failure I/O Link communication failure can be caused by various causes such as followings: (a)      Wrong communication cable, disconnection, unstable connection The electric cables used for I/O Link connection can be distinguished into the types below.  Check cables are properly used.  Check wiring of cables with “CONNECTING MANUAL”.  Wiring of twisted-pair needs special care: SIN must be paired with *SIN, and SOUT with *SOUT.  If wrong signals are paired, the cable may easily affected by electric noises.  Do not wire unused terminal: There are power lines such as +24V and +5V, and unintended wiring of these lines may cause malfunction of devices. ·    K1X                 : connects groups. ·    K2X                 : connects bases. ·    K3X                 : connects Optical I/O Link Adapter or I/O Link Dummy Unit. ·    (no name?)      : connects I/O Link Signal Divider. (b)      Wrong connector I/O Link connection between groups starts from “JD1A” and ends to “JD1B”.  Check the connector’s name. (c)      Loose connection Check all connectors are firmly plugged.  Just plugging again sometimes solves troubles. (d)      I/O assignment data mismatch Mismatch between I/O assignment data and actual I/O device configuration may cause communication failure.  For example, combination of assignment data with “base expansion” and actual I/O configuration without expanded base will cause System Alarm at start. (e)      Electric noises Refer “CONNECTING MANUAL (Hardware)”, and take measures to avoid influence of noises. If communication cable and power cable are tied together, noises from power cable may affect communication.  They should be tied separately.  Shield of a communication cable must be grounded via cable clamp.  (See “CONNECTING MANUAL (Hardware)”) via cable clamp.  (See “CONNECTING MANUAL (Hardware)”) (a)     Short circuit of DO With some model of I/O module for operator's panel, short circuit of DO with ground or other DO by wrong wiring or malfunction of some device, may cause communication failure. (b)     Insufficient power supply or low voltage Check the capacity of power supply.  Even if the power supply had enough capacity at first design, later modification may need more capacity.  In some cases, we had no trouble at power supply capacity in usual operation, but specific operation caused low voltage. (c)     Insufficient connection to power supply Check the power cable.  We had several cases that the loose connection with power supply unit disturbed stable power supply, and caused System Alarm that occurred rarely. (d)     Malfunction of power supply unit Malfunction of power supply unit may cause instant power failure and then communication failure. (e)     Restarting CNC without restarting slave I/O devices I/O Link slave devices must be restarted when I/O Link master device (CNC) is restarted.  Specially, slaves of intelligent type such as Series 0-C, Power Mate, β amplifier, and Spindle Monitor Unit, will raise System Alarm at power cut of master.  In this situation, restarting CNC will raise another System Alarm at CNC by bad status of slaves. (f)      System down of slave device When I/O Link slave of intelligent type is connected, System Alarm at slave device will cause System Alarm at master CNC.  And System Alarm at master CNC vice versa.  In this configuration, it is important which System Alarm occurred first, and caused other System Alarm. If slave device does not raise System Alarm while master raises, this may happen by power failure of slave device; master CNC raised System Alarm at power failure of slave device, and then the slave device restarted. (g)     Unstable grounding of Optical I/O Link Adapter I/O Link Adapter, which connects electric cable and optical cable, must be grounded to earth via its casing. (h)     Malfunction of CNC or I/O devices Malfunction of hardware is also possible.  Try to change the board with I/O Link connector such as Master PCB or PMC Board, PMC Control Module (not detachable in some PMC model), Back Panel, each slave devices. (i)       Wrong operation If the System Alarm occurred only once, it has possibility of wrong operation by human error such as cutting power of slave device by mistake. 1   Items to check Check the following items, judge them totally, and find the cause such as ones in previous section. (1)      How long did it work? “Did it work normally before?” If a machine that worked without problem suddenly started raising alarm, modification of the machine or related facilities may be the cause; the modification may generate electric noise, insufficient connection, short of power supply capacity.  Malfunction of some device can also be the cause. On the other hand, at trouble on a machine in assembling, you have to start with I/O Link assignment data and hardware connection. (2)     Device configuration and I/O Link assignment “What configuration?” Check the actual I/O Link configuration and assignment data; what kind of slave devices, how they are connected with master. And check whether the contents of I/O Link assignment data match the actual configuration, whether the number of I/O signals does not exceed the specification of I/O Link, whether necessary terminator is correctly attached, and so on, referring “CONNECTING MANUAL (Hardware)”. (3)     Timing “What was the machine doing?” If System Alarm occurs at power-on phase, check if cables connect correct pair of connectors, and I/O Link assignment data first.  If the assignment data has entry for base expansion while the base is not attached actually, System Alarm occurs at power-on. When the master CNC restarts, all slave devices must also restart.  Check the power for slave devices is surely cut when the power for master CNC is cut. If System Alarm occurs every time when some specific action is taken, the action can be the cause of unstable connection, electric noises, short of power supply capacity, or unexpected voltage by short circuit of DO. (4)     Operation “Does same operation always lead to same result?” In case that same operation always produces same System Alarm, you can find out the origin of trouble by removing slave device one by one starting from the one of largest group number.  Removing slave device, however, is dangerous in some cases and should be done carefully enough, because it may bring trouble at operating the machine; such as removing I/O device that is connected to operator’s panel. If System Alarm is hard to reproduce, and occurs rarely, it will be very difficult to find out the cause of trouble.  Try every countermeasure at once, then wait and see how things turn out; changing hardware such as master, slave and cable stuff, use power supply of more capacity, or use another power supply additionally, enhance grounding to earth and shield of cables, tying cables of different kind separately, and so on. (5)     Information at System Alarm “Does System Alarm always provide the same information?” Every time System Alarm occurs, the message of System Alarm including SLC’s register values, LED indicator of slave devices, and the message of System Alarm at slave if occurred, should be noted and checked.  As described in former section, these may change every time System Alarm occurs, in some cases.  If these actually change, the information from them is not so reliable. (6)     Alarm history / System Alarm history “Is there any other alarm?” Other alarm may occur just before System Alarm of I/O Link communication, and may cause the System Alarm.  Check the Alarm history and System Alarm history. If slave devices also have such histories, check them, too. (7)     SLC’s register value “What information is reported from SLC?” If all System Alarm messages show the same SLC’s register value, the value can be an efficient clue to the cause of trouble.  But as described before, this value is not 100% reliable.  From our experiences, the value other than “n3:4m” is not meaningful, where n and m are any hexadecimal numbers. (8)     Retry counter “Is the communication stable?” I/O Link makes an attempt to recover communication at communication error.  When it fails to recover it, it raises System Alarm. When I/O Link retries communication, counter register below is incremented by one.  This counter register is allocated at same address regardless of PMC model. meaning of register PMC address size Retry Counter R9051 1 byte By watching this counter register, you can know whether the communication is not stable, or the communication is generally stable but sudden error may be detected. If communication error occurs intermittently, and this counter is incremented frequently, this counter can be an indicator to find out the cause; when you exchange some hardware, and then this counter stops, you can conclude that the exchanged hardware is the cause. This counter register is volatile memory.  It will be cleared at every power-on. 2   Examples 2.1  System Alarm occurs about once a day.      Wrong communication cable, snapping of wire, loose connection        C4:01     Cable with +5V power line was used between group 0 and 1 “C4:01” can be read as communication error, which means that a slave suddenly stopped responding. The cable with +5V power line is for connection to Optical I/O Link adapter.  To connect devices other than Optical I/O Link adapter, the cable without +5V power line must be used.  (In this case, because the I/O module for operator’s panel was also exchanged when the cable was exchanged with correct one, the module may also be the direct cause of this trouble.) 1.1  System Alarm occurs two or three times per day.      Wrong communication cable, snapping of wire, loose connection        C4:03, C6:62, C7:E2, C3:24, C4:01, C3:21             The cable between group 2 and 3 had short circuit internally. The register values look random, and provide no helpful information.  But because the System Alarm occurred with considerable frequency (two or three times a day), we could find out the cause by removing slaves one by one starting from one of largest group number. 1.1  System Alarm occurred at power-on after loading Ladder program at BOOT screen      Wrong I/O assignment data        unknown unknown           Expanded base was assigned in I/O assignment data while the I/O Unit-A had no expanded base. This machine was designed with optional devices connected by expanded base, and in this case, the Ladder program with this option was loaded into the machine without this option.  The register value was not mentioned in this case, however, this cause generally produces the register value of “n4:3m”.  Therefore, if System Alarm is raised at every power-on, and the register value matches with “n4:3m”, and the slave number m points to a slave of I/O Unit-A, you should examine the I/O assignment data first. In this case, CNC can not start up.  To avoid System Alarm and let CNC start up, you can start it with I/O Link cable disconnected, or at BOOT screen, you can remove Ladder program or load correct Ladder program.  To check the I/O Link assignment data, you need Edit function on CNC, or you need to transfer Ladder to Programmer software such as FAPT LADDER-III.           Group and base are confused in I/O assignment data. correct wrong Group Base Slot Module name Group Base Slot Module name 0 0 n Module 1 0 0 n Module 1 1 0 n Module 2 0 1 n Module 2 2 0 n Module 3 0 2 n Module 3 In most cases, I/O assignment data with wrong base number will prevent CNC from starting up by System Alarm.  But System Alarm may also occur at restarting I/O Link connection after storing new Ladder program just like this case. 1.1  System Alarm sometimes occurs at action of conveyer after machining.      Electric noises        C4:01           None of master, slaves, and cables had grounding connection to earth. If the trouble occurs at specific action of some device, the action can be supposed to bring low voltage of power supply, electric noises, insufficient connection or short circuit. 1.2  System Alarm occurs at almost every automatic execution.      Electric noises        84:01, C4:01           Communication cable was tied with power supply cable. After tying communication cable separately from power cable, the alarm has stopped being raised.  This case is supposed to be caused by electric noises.  Generally, the cause of electric noises does not have obvious trigger to raise System Alarm.  In most cases, System Alarm is raised rarely, and very hard to find out the condition of the alarm.  If System Alarm occurs not so frequently, check connections between devices and earth.  When you find devices with no grounding, too thin grounding, or communication cable lies near power cable, take measures against them, and wait and see how things turn out. 1.3  System Alarm occurs at cycle start.      Short circuit of DO with ground.        43:45           Mistake in wiring in operator’s panel made short circuit of a DO with ground. The register value says an alarm is raised in the slave of group 4, which is I/O module for operator’s panel.  At some I/O module for operator's panel, short circuit of DO may cause System Alarm of I/O Link.  So we searched for DO signal that turned on at cycle start, checked wiring from the signal, and found out the cause of trouble. 1.4  System Alarm occurs at activation of conveyer system about once in five times.      Short of power supply capacity, low voltage.        unknown           Activating conveyer system lowered voltage of power supply to slave device from 24V to 17V. If activating something looks to be a trigger of the alarm, the activation may be accompanied by low voltage, electric noises, insufficient cable connection. 1.5  System Alarm occurs at displaying external alarm message.      Short of power supply capacity, low voltage.        34:41           Alarm indicator light was to light at alarm of CNC, and then voltage of power supply to the slave devices fell from 24V to 10V. The register value says an alarm is raised in the slave of group 0, which is β amplifier.  LED of the β amplifier showed that NMI was raised.  Checking the voltage of power supply for the β amplifier, the voltage was lowered at lighting the alarm indicator light. 1.6  System Alarm occurs occasionally.      Insufficient connection to power supply.        C4:00           One of terminals between slave and power unit was loose.  Measuring the voltage at slave side, it dropped occasionally from 24V. When they measured voltage, it dropped by only 2V or so.  But if the voltage is not stable, it has possibility to drop much more amount instantly, and causes System Alarm.  Check the terminals are fixed firmly, exchange the power supply unit, or use stable power supply unit. 1.7  System Alarm occurs occasionally.      Malfunction of power supply unit.        43:49 unknown           Power supply unit malfunctioned, and power for CNC failed instantly. We do not have enough records about this case, but we can suppose that the slave of group 8 detected first communication error because of register value 43:49.  Assuming that the slave was Power Mate, β amplifier or LR Mate, we can suppose what happened; at power failure of CNC, slave of group 8 raised System Alarm, and after CNC restarted, System Alarm of group 8 made CNC raise System Alarm of 43:49. 1.8  System Alarm occurs sometimes at power-on.      Restarting master CNC without restarting slaves.        43:85 unknown           Wrong wiring of power supply left some slaves powered while CNC was not powered. I/O Link connection needs restarting all slaves at restarting master CNC.  It looks as if the System Alarm occurred occasionally, but actually, it just depended if the power of slaves were turned off or not. 1.9  System Alarm occurred after loading macro file at BOOT screen.      Restarting master CNC without restarting slaves.        43:43 unknown           When they loaded macro file at BOOT screen, CNC was restarted while slave was not. This case was reported as “after loading macro file”, but actually, any file will do the same.  First report may often come with unessential aspect enhanced like this case. 1.10                System Alarm occurs at power-on.      System down of slave device.        83:43           Power Mate-E of group 2 raised RAM parity error. The register value shows an alarm occurred in slave of group 2.  Because the slave of group 2 was Power Mate-E, we checked with DPL/MDI and found RAM parity alarm. 1.11                System Alarm began to occur on a machine that had worked for a year.      Insufficient grounding to earth of Optical I/O Link adapter.        40:00, 44:0A, 47:27 unknown           Inside of Optical I/O Link adapter was not fixed firmly on its casing. The casing of Optical I/O Link adapter is not painted, and works as medium for grounding to earth.  Optical I/O Link adapter must be grounded through this casing.  In this case, though the adapter was grounded correctly, the location had vibration and the inside had become loose from its casing gradually. 1.12                System Alarm occurs at power-on.      Malfunction of CNC or I/O devices.        46:06, 47:84                      Basic module of I/O module for connector panel at group 5 was broken. System Alarm occurred every time at power-on, we investigated this trouble by removing slaves one by one.  We found that removing group 5 enabled CNC to start up, and then attaching the basic module of group 5 to other CNC system, we concluded that the basic module was broken.   1.2  System Alarm occurs at “Restart I/O Link” after storing Ladder program by online function of FAPT LADDER-II/III.      Wrong I/O assignment data        83:41  Basic module of I/O module for connector panel at group 5 was broken.   System Alarm occurred every time at power-on, we investigated this trouble by removing slaves one by one.  We found that removing group 5 enabled CNC to start up, and then attaching the basic module of group 5 to other CNC system, we concluded that the basic module was broken.