YM:Sinamics Troubleshooting

1 General Information

1.1 Assign Interface

To establish a route from Ethernet to Profibus, you need to assign a network adapter. You need to do this to access for example PosmoA drives or Micromasters.

• Right click on the Station and select PLC -> Assign PG/PC
  Right click on the Station and select PLC -> Assign PG/PC
• Make sure to select the right Network adpater. To assign the Interface, press Assign
  Make sure to select the right Network adpater. To assign the Interface, press Assign
• Interface is successful assigned
  Interface is successful assigned

Template:Notice bms

1.2 Connect online to the drive

• For PROFIBUS Drives - Assign Interface

• Open the starter Software

• Open the Project

The drive project is content of the SIMATIC Project. Select the latest version of the SIMATIC project.

Usually this is located in Template:PathUncPublicplc\S7 as Zip file

• Connect online to the CU

Navigate to the right CU (check in the drawings) and right click -> Connect online

It will light up green if it is successful connected

1.3 Check the Alarm history

In every cu or drive object is a alert history. Simply upload the drive to the STARTER, disconnect the online connection and investigate the alert history

Cu Alarm history: Template:Image

Drive Alarm history: Template:Image

Besides the fault number (also indicated in PVSS parameter panel) there is also a fault value / description
this values and text helps a lot for a more detailed analysis

1.4 Ram2Rom

After every parameter adaption you need to perform a Ram2Rom, otherwise the settings are lost after a CU reboot

File:Encoder Replacement CU Ram 2 Rom.jpg

This step is necessary to save the changes on the control unit

• Right click on the control unit
• Select “Target device”
• Copy RAM to ROM Or use this button when the CU is selected Template:Image

1.5 Power on reset of the CU

File:Encoder Replacement CU Reboot.jpg

Press this button to restart the CU

1.6 Check the firmware version of components and perform an update if not done automatically

After replacing a drive cliq component you need to check if the firmware was updated at the CU reboot.

The Firmware update is usually performed automatically during the CU is starting. A hardware reboot of all components is in any case requiered after the Update is finished!

Connect online to the CU and check/update the Firmware is needed

• Overview Panel in the Starter Software
  Overview Panel in the Starter Software
• Firmware Version and Selection overview
  Firmware Version and Selection overview
• Firmware running
  Firmware running

Finalize with switching off/on all devices including drives, sensor modules, terminal modules because if a firmware update was performed automatically, the new firmware is effective only after a complete system reboot.

A successful firmware update is indicated by the Orange LED flashing with 0,5Hz during the update and with 2Hz.

2 Profinet CU replacement

A new control unit with a CBE20 (only at old lines with a CU320-2 DP) or PN on board needs an assignment of the device name. The device name is given to the CU the IP will automatically be assigned, as soon as there is a PROFINET connection to the PLC and a proper HW-configuration is loaded to the PLC.

Note the MAC address of each CU. The only unique identification of the CU is the corresponding MAC address. The MAC address will be shown later on in the dialogs.

NOTE:

Connect the PG to the line network, in the service network no assignment can be done. Assigning the device name:

• Open Hardware Configuration
• Click on the Profinet mastersystem
• PLC/Ethernet/Verify device name

• Open "Verify Device Name"
  Open "Verify Device Name"
• Select the device name that you want to assign Press "Assign name". The Device name will show up at the corresponding device
  Select the device name that you want to assign
  Press "Assign name".
  The Device name will show up at the corresponding device
• Check the device name with "Verify Device Name" There is now a green OK indication at the device status but still no IP-address if there is no PROFINET connection to the PLC
  Check the device name with "Verify Device Name"
  There is now a green OK indication at the device status
  but still no IP-address if there is no PROFINET connection to the PLC

3 Encoder / Encoder module

3.1 Encoder module replacement

3.1.1 Basic steps

• Turn off the power supply (Pull the Plug of the DC power supply of the encoder module).
• Disconnect the Drive Cliq and the Encoder cable.
• Replace the defect module with a the new one.
• Connect the Drive Cliq and the Encoder cable.
• Plug in the power supply!
• Reboot the CU and wait until the Encoder Module is green or flashing orange /green alternating with 1Hz
  • If the LED is green, the Drive should be ready
  • If the LED is flashing orange/ green alternating, the SMC Module was updated.
• Disconnect the Power supply of the SMC module and connect it back.
• Reboot the CU

3.2 Encoder/Motor replacement

3.2.1 Basic steps

• Turn off the power supply (Pull the Plug of the DC power supply of the encoder module).
• Replace the Encoder or Motor.
• Plug in the power supply!
• Reboot the CU

3.2.2 F07414 (Encoder serial number changed)

• change P10 (Drive commissioning parameter filter) from 0 (Ready) to 4 (Encoder commissioning);
• change P440 (Copy encoder serial number) from 0 (No action) to 1(Transfer serial number);
• change back P10 from 4 to 0;
• make on CU copy RAM to ROM
• restart CU

3.2.3 F01695 (Sensor module replaced)

• Open the Safety Integrated Screen

File:Encoder Replacement Open Safety Integrated Screen.jpg

• • Control unit, in which the module is replaced
  • Open the drives folder
  • Select the drive in which is the encoder replaced or changed
  • Open the “Function” – directory and select the Safety Integrated Screen

• Acknowledge hardware replacement

File:Encoder Replacement Open Safety Integrated Acknowledge HW Replacement.jpg

In the Safety Integrated window you have to press the “Acknowledge hardware replacement”

3.2.4 F31112(Encoder Serial protocol fault)

you need to activate the DST_ERM.

This you can do manual if there is an serial protocol fault. See steps below.

Siemens Starter:

1. Change Encoder settings:
   1. Change 10 to Encoder commissioning
   2. Change 400 to User defined Encoder (Old values are stored still (Original was most time 2055))
   3. Open 404 and deactivate Endat + absolute Encoder
2. Change Pole Position settings:
   1. Change 1980 to 1
   2. Change 1981 to 90
   3. Change 1982 to 1
   4. Change 1993 to the half of the Motor nominal current (Motor nominal current / 2, which you see in ~300 parameters).
3. Finishing:
   1. CU: RAM 2 ROM, right click on CU, copy RAM to ROM
   2. CU 972: CU reboot

3.3 EnDat encoder adjustment (e.g. TDO Inlet direct drives)

3.3.1 Identifying the encoder offset for TDO direct drives with open chain

For the TDO direct drives the encoder offset can be identified by commissioning script in the starter.
OR
For the TDO direct drives the encoder offset can be identified by using the parameter 1910 in the starter.

3.3.1.1 Take control of the drive and check the parameter

1. Connect online to the drive and open the expert list.
2. If the drive configuration is finished check the value of the parameter p 431 it should be 0.00

File:TDODriveOffset1.png

3. If the encoder commissioning is already done check the p 431 and set to 0.00 (p 10 need to be on [4] encoder commissioning. Set the parameter p10 back to 0 before you continue.

File:TDODriveOffset2.png

4. Open the control panel of the drive and take the control of the drive. This is only working if no E-Stop of the TDO is present.
5. Set the parameter p1910 to -1 start motor data identification without acceptance.

File:TDODriveOffset3.png

6. Enable the drive in the control panel and start with a speed set point.
7. Check the parameter p1910 again if the identification is finish this will be 0 again.
8. If 1910 is 0 you have to look in the parameter 1984 for the identified value.

File:TDODriveOffset4.png

9. Set the parameter p 10 to 4 and put the value from 1984 to the p 431.
10. Put the parameter p10 back to 0 to enable the drive.
11. Do this Step 1 to 10 for all drives of the TDO if you have:
Inlet: Siemens 1FW6 (old version), new version is using Baumueller DST2 with adjusted encoder
Outlet: Oswald (old version not adjusted).

3.3.1.2 Start the drives

1. Start the drives normal and set the speed to 100m/min.
2. Open the expert list of all drives and check p 1778 this value should be less than +/- 1°. For the inlet drives it’s possible that this value is bigger at 100m/min but with a speed of 200m/min all have to be less than +/-1°.
3. Check all TDO drives with the instruction for the motor test.

3.3.3 Write down a Table and check the parameters

1. Make a Table and set the TDO Speed to 200m/min write down the torque and the value of the r1778 from each drive of the TDO increase the speed in 100m/min steps to maximum line speed and write down the values. Wait a moment until the torque gets stabile before you write down the values.

File:EncoderOffset1.PNG

Excel file ready for you:

Public:TDOencoderOffset.xlsx

2. Check the value of the r1778 parameter this should be stable around +/-1° than calculate the average value. E.g. for the values of the TDOOutletRight above all values apart the 100m/min value the average value is 2,7°
3. Check the value of the parameter p431 in the starter for the drive in this example it is 61.13 add the value calculated from the table so here 61.13 - 2.7 = 58,43
Template:Notice bms

4. Set the p10 value to 4 Encoder commissioning

File:TDODriveOffset9.png

5. Now add the new value for the encoder offset to p431.
6. Set the p10 to 0 back
7. Do this for all steps from 2 till 6 for all TDO drives

3.3.3.1 Start the drives

1. Start the TDO again and check if no faults present.
2. Write down the values like at the begin

File:EncoderOffset2.PNG

Now the p1778 should be less then +/-1° like in the examples above. Check the values above 200m/min the lower maybe not correct.

4 Motor module

4.1 Basic Steps

• Switch the main switch off to de-energize the DC supply unit.
  • Wait until the DC-Voltage is less than 50V
  • Check the orange LED of the Motor Module and measure the voltage, before working on the system!
• Remove all power connectors and jumpers from the module you need to replace

File:Replace Sinamics Motormodule Hardware Connection.jpg

• Replace the motor module and connect everything back again.
  • Tightening torque is 16Nm of DC-bar screws
• Reconnect 24 V plug
• Most likely the Motormodule will get an firmware update from the CU. It is indicated by the Orange LED flashing with 0,5Hz during the update and with 2Hz after the update is done.
• Reboot the motor module after the firmware update by disconnecing and reconnecting the 24 V plug.
• Reboot the CU

4.2 Motor Module Type is same like original

• Connect online with the starter and check that no alarms are active

If the safety extended fucntions are active, you will most likely see one of this faults: - F1670 (SI Motion: Invalid parameterization sensor module) - F1650 (SI CU: Acceptance test required) - F30650 (SI MM: Acceptance test required)

Check in the expert list of the drive if r9898 and r9899 are the same. Template:Image

If they are different, open the expert list and change P10 from 2 to 95. Open the “Safety Integrated” in the Drive Functions:

File:Safety integrated Screenshot.JPG

Change Settings Template:Image

Click copy parameters and Activate Settings (p9899 will be copied to r9898) Template:Image

After “Activate settings” you will be asked for password input. Template:Image

For the password input put to every input field “0” (New password should always be “0”). Template:Image

Accept with “Yes” Template:Image

The alarm history should show Information “ok”. No more faults/warnings should be active.

Restart the CU

4.3 Motor Module Type is different

File:Replace Sinamics Motormodule Different Module Error.jpg

• Connect online with the starter
• Open the expertlist on the CU:
  • Change P9 to 1 (Device Configuration)
  • Change P9905 to 2 (scan the Topology)
  • Change P9 to 0 (Ready)
• Open the expertlist on the drive:
  • take over the value from r200 in the Parameter p201
  • Change P10 back to 0
• Restart the CU

• Reconnect online and open the Safty integrated panel of this drive

--> Functions --> Safety Integrated --> "Acknowledge hardware replacement"

File:Encoder Replacement Open Safety Integrated Acknowledge HW Replacement.jpg

In the Safety Integrated window you have to press the “Acknowledge hardware replacement”

• Copy RAM to ROM

4.4 Double Motor Module

There are two motors connected to a Double Motor Module. When you are running the configuration script for the first motor for the first time, the script will fail. The script fails while trying to leave the Safety Integrated Commissioning mode (p10: 95 -> 0). Make sure it is this position where the script fails and not some other error:

   11:43:25 Symbols("p9762").ActValue = {0x2:0} ; Ok
   11:43:25 Symbols("p9763").ActValue = {0x2:0} ; Ok
   end of additional steps for safety extended first time
   11:43:25 Symbols("p10").ActValue = {0x2:0} ; Failed: hr=0, bumc=0xbe090030
   11:43:25 Symbols("p10").ActValue = {0x2:0} ; Failed: Error occurred while writing the symbol: SOM_NEG_RT_RESPONSE (0x80040030)

If the script fails during this step, cancel the execution of the script and run the configuration script for the second drive of the Double Motor Module. After that you can run the script for the first motor again; this time without errors.

The reason for this error is that on a Double Motor Module the parameters p9511 and p0115[0] must be the same on both motors. That is not the case during the first commissioning of the first drive.

4.5 DC Supply Unit Replacement

• Connect online with the starter
• Open the expertlist on the CU:
  • Change P9 to 1 (Device Configuration)
  • Change P9905 to 2 (scan the Topology)
  • Change P9 to 0 (Ready)
• Open the expertlist on the drive:
  • take over the value from r200 in the Parameter p201
  • Change P10 back to 0
• Copy RAM to ROM
• Restart the CU

5 Trace recording

There are a few different standard trace recording scenarios. Here are some common samples.

Open the trace window from the tool bar:

File:Sinamics Starter Trace Button.png

Trace Button

Select the control unit:

File:Sinamics Starter Trace Select CU.png

select CU for trace

Add parameters, set the "Factor" or sampling time, and then you get a recording duration according to the available memory. You can accept the maximum with the button (arrow down) or you can choose a shorter time. You can also use a trigger as shown in the example. After finishing configuration press the button with the symbol load to target system below the safe button.

The trace settings are now within the drive but the trace function is not yet activatet. Press the "Run" button to activate the trace recording:

File:Sinamics Starter Trace Settings.png

trace settings, sample rate, trigger

Now the trace waits for the trigger condition. If the threshold value is exceeded the data will be gathered.

File:Trace recording completed.png

trace recording completed

As a difference to Drive Monitor all current measurements are available in "Measurements". If you want to save them permanently, choose "Measurements" and select one of them:

File:Sinamics Starter Trace Measurements.png

Measured trace data

5.1 Trace recording mathematical functions

There is the possibility to analyze curves with for example a FFT function. Adding a calculated curve out of a measured curve can be done in "Trace" or "Measurements".

File:Sinamics Starter Trace Measurements Select.png

Measurements List

File:Sinamics Starter Trace Measurements Math Function.png

Trace FFT example

Press the "Accept" button as a result you see now one curve more:

File:Sinamics Starter Trace Measurements With Math FFT.png

Trace FFT measurements

If you change to "FFT diagram" you can see the frequency range of the particular curve:

File:Sinamics Starter Trace FFT.png

Trace FFT result

5.2 Encoder Signals

Some encoders are using to sinusoidal signals shifted by 90°. The amplitude of these signals is 1Vpp. The square sum of the two signals is 0,5V.

Most of the encoders have 2048 sine per revolution. In order to verify the proper function of the signals there is the possibility to trace/record the signals. Change the access level to service:

Password = 37483

After you have access level Service you will see parameters p496, r497, r498, r499

Change parameter p496 to 10 and you will see within r498 + r499 the signal of track A + B. A decimal value of 21299 is equal to 0,5V. Set up the trace like in the following picture: The example here is for a StrMdoPrh4 drive! Template:Image

You can use the mathematic functions (red circle in the picture above) to calculate the sum of the signals:

sqrt(sqr($1)+sqr($2))/21299*0.5

File:Sinamics Starter Trace Math Formula Encoder Signal.png

Encoder Trace configuration mathematical processing

Press Accept and load the configuration to the target system. You can use the option arrange curves in tracks (click with the right mouse button on the Y-axis):

File:Sinamics Starter Trace Encoder Signal.png

Encoder signal processed

File:Sinamics Starter Trace Encoder Signal Zoomed.png

Encoder Signal zoom

A fault will be triggered if signal is outside range 0,23V – 0,75V

A decimal value of 21299 is equal to 0,5V

5.3 Trigger on bits

There is the possibility that you are triggering the trace on a bit pattern. This for example is useful if you want to use the "operation" status.

File:Sinamics Starter Trace Trigger Settings.png

File:Sinamics Starter Trace Trigger Settings Bit Pattern.png

trace trigger condition bit pattern

Lots of status bits are within the r899 parameter.

5.4 Synchronous trace recording on multiple CUs

There is a bit in the command word which is used exclusively for synchronizing the trace recording on multiple axis. This bit is set in the variable table of the PLC. Because the command word is sent to every drive within 4ms the recorded trace data of multiple control units does match each other very closely. Template:Image

Setup the trace on every control unit which should record data with the same trigger condition. Template:Image

On the rising edge of bit value change, the trace recording starts on all control units:

After that you all measurements are available: Template:Image

5.5 Trace recording offline

There is the possibility that you want to get the data later, for example you do not want to wait until the trigger condition is fulfilled. Therefore setup the trace and activate it (you can see wait for trigger). Go offline with the drive. If the trigger condition is not fulfilled and you go online again, the status will still tell you wait for trigger. If the trigger condition was fulfilled any time the drive was recording the trace. You can upload the data by pressing the upload curves button:

File:Sinamics Starter Trace Offline.png

upload data from drive offline/online

5.6 Function generator / Transfer function

There is an integrated tool for measuring the transfer function of the drive system.

File:Sinamics Starter Function Generator.png

Function generator window

Select the right control unit and connect online. Afterwards you can "assume control priority". You can start/stop the drive from the programming device.

File:Sinamics Starter Measuring Function.png

Function generator setup

As a result of the measurement you get a bode diagram.

File:Sinamics Starter Measuring Function Bode Plot.png

Function generator frequency response from measurement

Areas with an amplitude peak are supposed to be poles. You can add notch-filters who are damping the frequency or you can add low pass filters (with a bit restriction on dynamic behaviour).

File:Sinamics Starter Filter Settings Panel.png

Filter settings

If you press on one of the buttons a configuration screen is opened.

File:Configuration screen.png

Configuration Screen

Do not forget to set the "filter effective" selection. After filter setup is finished, those parameters should be added to the drive scripts finally. Below you can see the result with two low-pass filters set to 50Hz.

File:Low-pass-filter.png

Low-Pass-Filter

5.7 Bittracks

some information is contained in words as a binary information. In order to get a more detailed view, you can arrange this information in bit tracks.

Within the measurement window you can select the bit tracks:

File:Sinamics Bittrack 1.JPG

Bit track

Withing this window you can specify the signal, which you want to display as a binary information. Note, as soon as you shown parts of the signal as bit track, this signal is removed from the "analog display"

File:Sinamics Bittrack 2.JPG

Bit track

If signal subindizes have names, they even will be shown in the legend of the trace window

File:Sinamics Bittrack 3.JPG

Bit track

5.8 Endless trace

for a in deep analysis of longer time intervals please select endless trace.

Advantages:

• recording lengh only limited by free harddisc space of computer (data is loaded cyclically)
• in deep analysis afterwards by zooming the interesting areas
• powerful analysis with other tools possible on the large data after exporting to CSV type of file
• trigger condition must not be known because trace is running in background, you will not miss the interesting event

Disadvantages:

• minimum sample time only 2ms up to 4 channels (aliasing might be a problem)
• trigger condition to start measurement can not be defined

Recommended channels:

• r482 as mechanical angle / in old versions we was using r497 but therefore you need a password, r482 is easier
• r80 torque actual
• same for drive 2 and 3 if necessary and/or available

=> for a 2 drive system you can set up a trace with a total of 4 channels, so we can record with 2ms, which is quiet nice.

File:Sinamics trace endless.JPG

endless

5.9 Endless trace multiple CUs

for a in deep analysis of longer time intervals please select endless trace on multiple CUs.

Advantages:

• same as endless trace
• detail analysis on whole machine component

Disadvantages:

• traces can not be sychronized and triggered

See tutorial video: Trace_endless_multiple_CUs.mp4

00:00 connect to CUs online

00:45 start trace on multiple CUs

01:15 watch live data in time diagram, use functions like cursor or arrange curves in tracks

03:00 stop trace on multiple CUs

03:50 start again trace on multiple CUs

...

04:55 stop trace again on multiple CUs

05:35 save all traces together in one big trace file

5.10 Ring buffer FW4.6 and higher

Data can be saved at CF card in a ring buffer. You can set values > 10 for number of recordings, but you can see only the last 10 measurements. If you are repeating the measurements make sure you do not exceed the write cycles of the CF, for example it is not a good idea to write traces every minute for years.

Unfortunately the drive names get lost. Therefore make a screenshot of your configuration or make a note what was the configuration of the channels. For example if you record r482[0] of 2 drives, later on you see two channels in the trace with the name r482[0] but you can not distinguish, if the first was StrDrv001 or StrDrv002 for example.

File:Sinamics trace ring buffer.JPG

ring buffer

you can see the data on the web interface (login as SINAMICS):

File:Sinamics trace ring buffer webinterface.JPG

ring buffer webinterface

you can load the data to starter:

File:Sinamics trace ring buffer starter load.JPG

ring buffer load to starter

5.11 save data to file

Data can be saved to harddisk and sent by email, stored to any directory ...

Therefore go to "measurements". As you can see there can be several measurements, in order to get a more detailed info, please write a meaningful comment besides the measurement. Press the save button and select the desired measurements in a single file.

File:Sinamics trace save measurements.JPG

save measurement

6 FAQ

Not all Faults and Alarms are listed here. Check the Sinamics manual for more details or other faults and alarms

6.1 Warnings

Number	Short description	Cause	Remedy
A01697	SI Motion: Motion monitoring functions must be tested	drive was never in ready state, only in ready state Switch off path of IGBTs can be tested	remove all disables from the drive, Switch drive on/off, every time drive is switched off test will be performed, check if r21830 changes from 0H to 1H when drive Status changes from on to off after the delay time if r21830 does not exist, old version of control/DCC
A30693	SI MM: Safety parameter settings changed	Safety parameters have been changed	Restart the CU
A31421	Encoder 1: Coarse position error	For the actual value sensing, an error was detected	known Problem with Baumueller Motors just mask the warning Interchange A with A* and B with B if Hand made Encoder cable

6.2 Faults

Number	Short description	Cause	Remedy
F01611	SI CU: Defect in a monitoring channel	F_Dest_Add (ProfiSafeAddress) in Hardware Config and Drive Script are not match.	Set in the Drive Script the right F_Dest_Add, always in HEX!
F01681	SI Motion P1 (CU): Incorrect parameter value (Parameter: 9511, supplementary information: 2)	On a Double Motor Module, no different values in p9511 and p0115[0] are permitted between the drives.	Run the script for the second motor module Then run the script for the first motor module again. see also here
F01910	PROFIBUS/PROFINET: Setpoint timeout	Interruption of PROFIBUS/PROFINET connection	Could happen if a previous CU get a reboot Check connection of the Profinet cabel (on the own CU and previous one)
F07011	Drive: Motor overtemperature	Wire break on the sensor Motor was running -> Maybe overload	Check connection of the temperature sensor Check the type of the sensor (KTY, PT100...) If the Motor was already running, check the load, brake open?, gear ok?
F07412	Drive: Commutation angle incorrect	An incorrect commutation angle was detected	Correctly set the angular commutation offset (p0431) Check the Drive-Script (Variable: AngOffset) and the Motor-Scripts (SetAngOffset(xx.x)) Normaly is 0° For Baumüller motors set: 180° Use the commissioning script for encoder commissioning
F07443	LR: Reference point coordinate not in the permissible range	The reference point coordinate received when adjusting the encoder via connector input p2599 lies outside the half of the encoder range and cannot be set as actual axis position. Maximum permissible value for the reference point coordinate	The number of turns (4096) is not enough for the complete traveling range. Set p2720 to "1". This activates position tracking, meaning that internally the revolutions are increased further. Problems will occur when the postion of the spindle is changed while the sinamics is without power (power drill, wrench, by hand...)
F07453	LR: Position actual value preprocessing error	An error has occurred during the position actual value preprocessing.	check if encoder cable is damaged, specially points where screen is connected to EMV rail. Often during installation inner wires are cut and damaged. change encoder cable move SMC away from power components use different EMV-rails for encoder cable shield and motor cable shield check on linear encoders if head is correctly adjusted corresponding to linear scale (experts only)
F08501	COMM BOARD: Monitoring time process data expired	The set monitoring time expired while transferring process data via COMM BOARD.	Take-Out the COMM BOARD from the CU and also from the previous CU and check the contacts Check the cable between the CU's, also the connectors inside
F30611	SI MM: Defect in a monitoring channel	subcode 1951: module temperature not plausible	check if firmware 4.4 HF2 was used => update to firmware 4.4 HF11 there can be accidently any other 4.4 versions if update was not performed correctly, update to 4.4 HF11
F31125	Encoder 1: Amplitude error track A or B overcontrolled	The signal level at the encoder input board was to high, this can sometimes even not be seen in the trace, as short disturbances are only detected by the SMC itself	check that the encoder cables and shielding are routed in compliance with EMC, if possible connect spare cable and run it at the floor far away from cable tray (>1m) replace the encoder or encoder cable if encoder cable is interconnected by terminal, ensure that inner shield is NOT connected to outer shield, inner shield should be on a isolated terminal NOT connected to ground change the position of the SMC in the switchboard away from power modules
F31126	Encoder 1: Amplitude AB too high	The signal level at the encoder input board was to high, this can sometimes even not be seen in the trace, as short disturbances are only detected by the SMC itself	same as F31125
F31150	Encoder 1: Initialization error	Usually the absolut positioning track (EnDat) is broken. But many times sin/cos tracks still work.	Turn off absolut positioning and use PolID instead. The parameters from BaumEndatCA31 in the Linedrive.vbs can be used. Further information can be found in Confluence https://brueckner.atlassian.net/l/cp/oDL2Q5mu

6.3 Warnings generated by the DCC

DCC_parameters.xlsx explains in sheet faults_alarms everything in detail

6.3.1 Speedcontrolled drive

Number	Short description	Cause	Remedy
A51062	Speed Ramp Deviation	Check PLC funtion call of Sinamics libs (cycletime must match with Global Var setting) Check P22001 which cycle time is adjusted in the drive	Correct GlobalVar.vbs Script and download again
A51066	Position Controller Output limited	The position controller output is limited and hold there	Check if drive is operating at its load limits and reduce load

6.3.2 Positioning drive

Number	Short description	Cause	Remedy
A51062	Position Calibration failed		Ask Template:EEC-Support

6.3.3 Operating hours fan

Number	Short description	Cause	Remedy
A30042	Power unit: Fan has reached the maximum operating hours	The maximum operting time of at least one fan will soon be reached, or has already been exceeded.	Replace the involved fan, reset the operating hours counter (p0251)

How to reset operating hours after fan replacement:

• Open Starter

• Search for the CU/drive/infeed with the affected fan

• Connect online to the target device

• Open the Expert list and change the Access Level to:
  • Service (4); Password: 37483

File:Starter Access Level.png

• Search the parameter p0251 (often only p251) "Operating hours counter power unit fan" and set the operating hours to "0"

File:Starter P0251 Operatinghours.png

• After the setting of the operating hours, copy RAM to ROM, afterwards the alarm in the PVSS should be automatically reseted

File:Starter Copy RamtoRom.png

6.4 MDO Drawing Drives show negative torque while in idle run

The reason was that the pulse frequency was set to 2kHz.
When changing the pulse frequencx to 4kHz the problem with the negative torque was gone.
Check Motor Scripts if pulse frequency is correct.

File:MDO Drawing Drives showed a negative torque while in idle run.png

6.5 S120 Melt Extruder Drive have no communication, but no fault on the drive/visualisation

Melt extruder drive is stopped, but on the visualisation, it still shows "Run" and "SpdAct". There is no communication, but no warning/fault on the visualisation and the CU. On the CU all LED are red.
This is a known behaviour, when the CF Card is disconnected/removed while the CU is running or the CU is booted without CF Card.
​Remedy: Exchange CU and CF-Card