Robox Alarms EN ESPAÑOL

TROUBLESHOOTING GUIDE
Example of
Robox Axis connection
with typical Rewinder, LogSaw
and Core Maker.
Note: this is just an example; refer to electrical drawing

for relative machine.
Rewinder
• Perforation Roll (Master) – AXIS 2
• Rider Roll Acceleration – NO ENCODER
• Deceleration Roll – NO ENCODER
• Sincro Cam – AXIS 4
• Core Introduction – AXIS 3
• Rider Roll Diatrol – AXIS 1

Log Saw
3
~
3 • Blade support (Master) – AXIS 2
~ 3
~
• Blade Unit Advance – AXIS 3
• Blade rotation – NO ENCODER
• Pushers – AXIS 1 – AXIS 5
• Trimex – AXIS 4
Core Maker
• Forming belt (Master) – AXIS 1 • Cutting trolley – AXIS 2

Alarms
Alarm categories
Alarms belong to 3 categories:

Major alarms
Minor alarms
Warnings
Major alarms cause the POWER ENABLED relay to open, and shut power down.
Minor alarms set the machine to Hold state; this state is handled by the firmware only in the pre-
defined modalities (except when differently specified).
Warnings are just messages to the user.
The type of alarm is defined by the first 4 characters of the alarm string, as follows:
NUMBER TYPE OF ALARM

1 -:- 999 system major alarm
1000 -:- 1999 user major alarm
2000 -:- 2999 system minor alarm
3000 -:- 3999 user minor alarm
4000 -:- 4999 user warning - higher priority :display of this text has a higher priority on
text of category 5000-:-9999 and the erasure procedure is the same of
alarms
5000 -:- 9999 user warning - lower priority: display of this text has a higher priority on
not numbered texts ; their erasing procedure is the same as used for
alarms. However the first alarm belonging to his categories will be
deleted, even if it is different from the specified one
If the number is not specified or is >=4999, the alarm is treated as a warning and no action is
taken.
Command ALARM R "ntext” (n = number >=4999), if n is omitted, resets the first alarm.
To reset the whole alarm stack, use the instruction ALARM R “” (empty string)
If the instruction ALARM is used in a RULE, the string can be:

• global string variable
• local string constant
• immediate string
3
Examples:
ALARM S, "1240 *** faulty proximity ***"
ALARM R, "3025 *** lamps time out lamp ***"
With the RBXM/RBXE controllers from RRT version 4.00, the presence of alarms in the stack is
evidenced as follows:
* led L7 blinks if the stack contains at least one minor alarm or a warning.
* led L8 blinks if the stack contains at least one major alarm (alarm 50 excluded)
Alarm types
Type Name Description

1 Memory alarms This group of alarms is generated only at the RPM start-up.
2 Execution alarms These alarms occur because of time overloads. The rule execution frequency is therefore reduced to
compensate the overload. The user will take care of restoring the previous values.
3 Math expansion (old)
board alarms
4 Power alarms
5 Encoder alarms Position read-out is obtained with incremental encoders. Connection between the encoders and the RPM
module is done with the RS422 standard. These alarms monitor connection faults or encoder breaks.
6 Servo alarms These alarms monitor a too wide gap between the ideal and real positions. The above is tested only if IP, IV,
IA are assigned a value and control is enabled by the SAM mask. Therefore it is suggested that the position is
assigned also when the axis must stand still (e.g. IP (n) = IP (n) ). The alarm threshold changes depending on
the speed, with the following formula : max allowed value = abs (iv) / kd +ks. "kd" and "ks" are predefined real
registers (631.., 621..). These registers must be initialized with the user’s value, before enabling this control.
7 Crash alarms These alarms monitor if the axis position exceeds its end of strokes. The above is tested only if IP,IV IA are
assigned a value (only direct value, not predefined modalities) and control is enabled by the CAM mask.
8 Speed alarms These alarms monitor an ideal speed higher than the maximum speed specified in the appropriate registers.
The above is tested only if IP,IV IA are assigned a value and control is enabled by the SPAM mask.
9 D/A overflow alarms These alarms monitor if variable AO is assigned a value higher than the value assignable to the D/A convertor.
Assignable values range from - 2048 and + 2047. Values exceeding this range are forced within the allowed
Type Name Description
values. Control is enabled by the AAM mask.
10 Miscellaneous -
11 Zero cycle alarms They are generated only during execution of modes 1 and 2 , when the zero cycle cannot be performed.
12 Communication They are generated by errors in the communication process
alarms
13 Servo alarms (old) They are generated by the servo drives and displayed on the RPM
14 Hardware faults (old) They are generated if any fault in the hardware operation is recognized.
15 Communication They are generated if any trouble occurs in the exchange of information between different Robox’s boards.
alarms with other
Robox boards
System Major Alarms
CODE TYPE ALARM CAUSE EFFECT CORRECTION
1 1 Lost retentive memory Failure of retentive All user’s programs If the alarm occurs at each start up, contact Robox
memory and registers contents Representative
from RRT 4.00:
are cancelled upon
Register memory loss user’s confirmation.
7 1 Plc-og.memory loss Loss of PLC see alarm 1 see alarm 1
information (program
and/or configuration)
10 2 Rule time too long rule execution too long parallel tasks, Test the rules syntax. Optimize execution timing,
transmission channels where possible, by means of variables. Verify that the
handling and display rule execution frequency is not higher than needed.
refreshing will not run.
11 2 Service time too long see alarm 10 see alarm 10 see alarm 10
12 2 Command time too see alarm 10 see alarm 10 see alarm 10
long
14 2 Rule too slow Rule execution length see alarm 10 see alarm 10
spoils the execution
frequency
15 Task too slow see alarm 14 see alarm 14 see alarm 14

From RRT version 5.05 the task and step information
is available in R(719) and R(720)
16 Command too slow see alarm 14 see alarm 14 see alarm 14
17 2 Service too slow see alarm 14 see alarm 14 see alarm 14
20 14 Missing Ext. +24v dirty lack of the +24v on if the input is wired, check the aux tension
reserved input
21 2 Display task too slow see alarm 14
22 2 Display task too long see alarm 14
23 12 Bad Hardw. config. the recognized RIO RBXM operation is check the file RHW.CFG
code=val (on RBXM) configuration does not disabled
val = see manual match the one
97004 chap. 4 par. programmed in the
"Displaying the results configurator
of the
autoconfiguration
session"
48 10 Old O.S. Unable to the operating system is impossible to operate. load a newer OSF version
work too old
With the RBXM this
situation is monitored
by alternative blinking
two groups of leds: L1,
L3, L5 and L2, L4, L6
49 15 Unable to start impossible to operate communication on the check the contents of R(970). Take the appropriate
PROF.INT the PROF.INT board Profibus line are
actions depending on the value of this register.
disabled
50 4 Missing Power from input "CHOPPER OK" "ENABLE POWER" If the alarm is generated in non programmed
RRT 4.00: can be open (false) output open conditions (for instance when the emergency push-
disabled by R(622) button is pressed), check the other alarms contained
in the alarm stack. If the stack contains no alarm, test
the following:
- presence of the +24V dirty on P.OPTO connector
- if no I/O expansion is installed, check the presence
of the Minigun or relevant custom on the P.I/O
connector
- if the system installs I/O expansions, check the
wiring between the P.I/O (on the RPM) and PIOIN (on
the EIOB) and the presence of the Minigun connector
(or relevant custom) on the EIOB
- circuitry of the power chain
51 5 Encoder alarm axis 1 alarm enabled in the the position read by Check the connections between the encoder and the
EAM mask and the transducer does RPM .
inconsistency of not correspond to the
Check the encoder operation by means of the
signals real position
encoder leds on the RPM
52 5 Encoder alarm axis 2 see alarm 51 see alarm 51 see alarm 51
59 2 PLC task time too long see alarm 10 see alarm 10 see alarm 10
60 15 Prof. Com. Error code val = 8 configuration Profibus switch the controller off and on to try to enable the
(number of 32-byte communication communication
blocks) received by the disabled
master DP different
from the one set in
PFB.CFG file
val = 9 profibus
communication
hardware fault (SPC3)
61 6 Servo alarm axis 1 gap between the ideal DANGER: the axis check :
and real position wider does not follow the
* if the value of the loop gain is too low
than the max. allowed programmed path
value * if the programmed position is too far from the
previous one
* if the programmed speed is too high
* if the programmed acceleration is too high
* if the parameters calculating the threshold are too
tight
* if the real position changes correctly
* if the user program is correct
* the presence of mechanical stiffness
* the wiring between the connector P.RIF on the RPM
and the servo drive
* the wiring between the tacho generator and the
servo drive
* the wiring between the motor and the servo drive
62 6 Servo alarm axis 2 see alarm 61 see alarm 61 see alarm 61
69 2 PLC task too slow see alarm 14 see alarm 14 see alarm 14
70 15 Prof. Board Fault the transmission buffer The Profibus board is check the state of the WS led on the PROF.INT
(W.D.) has not been read by considered as not board.
the PROF.INT board enabled
contact Robox.
for at least 100ms
71 7 Crash axis 1 upper value of the if the assigned Check the rule correctness check the end of stroke
limit programmed position kinematik value was
higher than the max IP, the position is
end of stroke (set in forced to the same
RR (65x)) value of the end of
stroke
72 7 Crash axis 2 upper see alarm 71 see alarm 71 see alarm 71
limit
limit
limit
limit
limit
77 7 Crash axis7 upper limit see alarm 71 see alarm 71 see alarm 71
limit
79 15 Prof. Board not val = 2: troubles when see alarm 49 see alarm 49
working val loading the
PFLMvvrr.O51 file onto
the PROF.INT board
val = 3: troubles when
loading the
PFEMvvrr.O51 file
onto the PROF.INT
board
80 10 VT cfg failed code xx Error generated during HMI (operator panel) is Modify configuration file PANOP.CFG
line yy configuration file not handled
reading.
81 7 Crash axis 1 lower limit value of the see alarm 71 see alarm 71
programmed position
lower than the min end
of stroke (set in RR
(64x))
82 7 Crash axis 2 lower limit see alarm 81 see alarm 81 see alarm 81
89 10 VT communic. Fault : Communication is no the operator’s panel check the wiring and operation of the operator’s panel
VT xx more active(selectable operation is interrupted
with the status
register)
91 8 Overspeed axis 1 the programmed if the assigned Check the rule correctness
kinematik value was
speed is higher than Check the the max speed
IV, the speed is forced
the max allowed value to the max value .
(set in RR (66x))
92 8 Overspeed axis 2 see alarm 91 see alarm 91 see alarm 91
99 2 VTCom task too slow see alarm 10 see alarm 10 see alarm 10
100 2 VTCom task too long see alarm 10 see alarm 10 see alarm 10
101 9 Reference overflow AO exceeds the range The max positive or check the AO variable in the assignment formula
axis 1 of validity negative value for the
analog reference is
issued
102 9 Ref. overflow axis 2 see alarm 101 see alarm 101 see alarm 101
109 10 CAN comm. fault on Definition error in the the Canbus connection modify the file
line n COMMANDS file for is not activated
Canbus operation on
the line specified by n
110 9 Axes splitting in a rule containing an check if the GROUP instruction for the new rules is
modality with RRT interpolation mode for active only when execution of the interpolation
<5.00 (this alarm, for more axes is modality is terminated.
RRT version < 5. 00, abandoned before it is
had nr. 107) satisfied
111 5 Enc. ch 0 alarm axis 1 During execution of a The axis origin cannot see alarm 51
zero cycle modality the be individuated
RPM has not detected
the presence of CH 0
112 5 Enc. ch 0 alarm axis 1 See alarm 112 See alarm 112 See alarm 112
113 5 Enc. ch 0 alarm axis 3 see alarm 112 see alarm 112 see alarm 112
119 10 Memory allocation ROBOX alarm the current operation contact Robox specifying the nn code present in the
fault:nn will not work alarm and describing the operation running when the
alarm was issued.
120 10 Too many D.D. CAN the file COMMANDS The Canbus Load the file into the flash memory
Boards for Canbus operation connection is not
is missing active
121 11 Micro 0 alarm axis 1 with modality 1 the zero cycle mode check the zero micro wiring and the min and max
search of the zero cannot be performed threshold values defining its length
micro is terminated but
no micro change is
found
122 11 Micro 0 alarm axis 2 see alarm 121 for axis see alarm 121 for axis see alarm 121 for axis 2
2 2
123 11 Micro 0 alarm axis 3 Micro 0 alarm axis 3 Micro 0 alarm axis 3 Micro 0 alarm axis 3
4 4
5 5
6 6
127 11 Micro 0 alarm axis 7 See alarm 121 x axis 7 See alarm 121 for axis see alarm 121 for axis 7
7
8 8
129 15 CAN Board#nn not Inconsistency in the Information is not contact Robox specifying the ccc code present in the
ready! Ccc information exchange updated alarm and describying the operation done.
between the main CPU
and the CAN board
131 11 Missing end of stroke with modality 2 the zero cycle mode check the min and max threshold values defining its
for axis1 search of the zero cannot be performed length
micro is terminated but
the micro is not found
132 11 Missing end of stroke see alarm 131 for axis see alarm 131 for axis see alarm 131 for axis 2
for axis 2 2 2
for axis 3 3 3
for axis 4 4 4
for axis 5 5 5
for axis 6 6 6
137 11 Missing end of stroke Missing end of stroke see alarm 131 for axis Missing end of stroke
for axis 7 for axis 7 7
for axis 7
for axis 8 8 8
140 CANOPEN nn CANOPEN I/O Check the wiring
Communication
communic. Fault missing
141 4 Missing chopper ok for feed-back alarm on check the wiring between the RPM and the servos
axis 1 axis 1
142 4 Missing chopper ok for see alarm 141 for axis see alarm 141 for axis 2
axis 2 2
axis 3 3
axis 4 4
axis 5 5
axis 6 6
axis 7 7
axis 8 8
160 15 CPU AUX not working val = error code see R CPU AUX not working take the appropriate actions depending on the value
val; can be disabled b (972) of val
y R( 660)
161 5 CPU AUX transducer encoder 1 alarm on see alarm 51 see alarm 51
1; can be disabled b y CPU AUX
R( 660)
162 5 CPU AUX transducer encoder 2 alarm on see alarm 51 see alarm 51
2; can be disabled b y CPU AUX
R( 660)
163 15 163 15 CPU AUX CPU AUX no more CPU AUX no more check the CPU AUX pro gram.
Watch Dog! active
active contact Robox
can be disabled b y
R(660)
170 CANOPENnn init. Error during the CAN CAN OPEN Check the error code (ccc) on the CANOPEN
fail:ccc board inizialization communication not paragraph and operate consequently.
phase for the CAN active.
OPEN I/0 handling
N.bB: the alarm is
generated only once at
the ignition
171 13 D.Driver Fault ! Axes Alarm on the servo check the type of alarm on the drive and take the
#1 drive digitally appropriate actions
connected via Canbus
(the alarm code will be
available subsequently
and can be read throu
MAL or DD_FAULT)
172 13 D.Driver Fault ! Axes see alarm 171
#2
173 13 D.Driver Fault ! Axes See alarm 171
#3
#4
#5
#6
#7
#8
180 12 D.D. CAN Communic. Fatal error on the Impossible to turn power off and on to re-establish communication
Fault Canbus communicate
Communication
181 12 D.Driver#1 Com. Communication Data are not updated check the wiring and operation of the servo
Problem:ccc problems with the
servo drive.
182 12 D.Driver#2 Com. See alarm 181
Problem:ccc
183 12 D.Driver#3 Com. see alarm 181
Problem:ccc
Problem:ccc
Problem:ccc
Problem:ccc
Problem:ccc see alarm
181
Problem:ccc
191 11 D.Driver#1 0 Cycle Failure of the Canbus Zero cyclo aborted
problems commands handling
the storage of the
positions depending on
the appropriate input
variations (only when
the real position of the
axis performing the
zero cycle is updated
via Canbus)
192 11 D.Driver#2 0 Cycle See alarm 191
problems
problems
problems
problems
problems
problems
problems
211 10 D.Driver#1 Not Present At power on the servo check the drive correct operation
drive is not
acknowledged
212 10 D.Driver#2 Not Present See alarm 211 Check the drive correct operation
213 10 D.Driver#3 Not Present See alarm 211 Check the drive correct operation
214 10 D.Driver#4 Not Present see alarm 211 check the drive correct operation
500 10 Stack OVF task x step routine nesting higher task execution is check the routine nesting level
nnnn than 16 levels stopped
check that the routine final instruction is RETURN
(not GOTO)
501 10 Stack UDF task x step "RETURN" instruction task execution is check that all routines are entered with instruction
nnn without destination stopped GOSUB label (not GOTO label)
address
check that no "RESET_STACK" instruction is
contained in the subroutines
502 10 Stack OVF task x step routine nesting higher task execution is check the routine nesting level
nnn than 16 levels because stopped
check that the routine is abandoned with the
of the execution of the
instruction RETURN (not GOTO)
instruction ON
condition GOTO entry
503 10 ILL step n. task x step execution of a step not task execution is check if the rule contains some "ON condition GOTO
existing in the program stopped entry" or "ON condition GOSUB entry" instructions
nnnn
and the relevant entry is not contained in the task
504 10 Message lost mail box More than 16 The current message Check the user’s messages in the user ’s program
full messages received will be lost
without directive prefix
505 10 ILL mode def. rule x illegal parameter The modality will not Amend the modality call
invoking a predefined be executed
ax n
modality
996 10 xxxxxx compiler version the RPM module Install compatible versions of the RC and RRT (see
incompatible with RRT cannot be operated appendix K
version
997 10 software error (write) Illegal situation RPM block Contact Robox representative
998 10 software error (read) see alarm 997 see alarm 997 see alarm 997
999 10 software error (malloc) see alarm 997 see alarm 997 see alarm 997
System Minor Alarms
Code Alarm Cause Effect Correction

2001 Pulse OVF task x step n request for more than 8 Only the first 8 outputs will Check the user’s program
simultaneous outputs with the be correctly controlled
Pulse OVF rule x ax n Check if the same PULSE instruction is
PULSE instruction
executed more times while already in
execution
2002 DBL POS set rule x ax n More than one assignment to Only the first assignment is Check the rules.
the kinematic variables during assumed as valid
execution of the same group of
rules.
2003 WRG rule n. rule x ax n execution of a rule has been no rule for the current axis check the parameters of the GROUP
enabled with a non existing is executed instructions in the user’s programs (tasks
GROUP instruction & rules)
2004 ILL axis n. rule xx ax n the axis number specified in the None Amend the rule or the GROUP instruction
rule in execution does not
coincide with the number set by
the GROUP instruction
2005 MLT axis n. rule xx ax n two rules of the same group None Amend the rule or the GROUP instruction
contain the same axis number
2006 Miss. param task x step An R instruction has been Instruction not executed Amend the rule
nnn invoked with an insufficient
Miss. param rule xx axis number of parameters
n
2007 ill. param task x step An R instruction has been Instruction not executed Amend the rule
nnn invoked with illegal parameters
ill. param rule xx axis n
2008 ill. funct. task x step nnn An R instruction has been Instruction not executed Amend the program
ill. funct. rule xx axis n invoked in an illegal state.
2009 ill. index task x step the value of a register index The assignment is not Verify the program
nnnn exceeds the allowed range executed and/or value 0 is
rendered
ill. index rule xx axis n
2010 ill. arg. task x step nnnn A function has been invoked Function not executed Amend the function
with illegal parameters
ill. arg. rule xx axis n
2011 p not found task x step A function has been invoked Function not executed Amend the function
nnn with an insufficient number of
parameters
p not found rule xx axis
nn
2015 CPU AUX ill. communic. illegal contents of R(659) lack of communication to set the correct data
mode the CPU AUX
it can be disabled by
R(660)
2016 CPU AUX ill. register illegal value in the index of the see 2015 check the program on CPU AUX
index communication registers
between
it can be disabled by
R(660) main CPU and CPU AUX
2017 CPU AUX ill. register len illegal number of the see 2015 see 2015
it can be disabled by communication registers
R(660) between main CPU and CPU
AUX
Warnings
Code Type Alarm Cause Effect correction
4003 15 No more Profibus Comm. no more Profibus The Profibus connection check connection
communication would not operate
4004 12 VT communic. Fault : VT communication no more VT operation interrupted. check the VT connection nad
xx established (selectable with the operation
status register)
4005 10 Alarm history 80% : VT xx buffer for alarm history has
reached 80%
4006 10 Alarm history full : VT xx buffer for alarm history full
4007 10 Battery Low on : VT xx VT low battery Replace the VT battery
4008 10 CAN Command file missing lack of COMANDI file for Can CAN connection Load the file into flash
disactivated
4009 10 Too many special com. def. Presence of more than one CAN connection
board for Drive handling disactivated

Robox Alarms EN ESPAÑOL

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Robox Alarms EN ESPAÑOL

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TROUBLESHOOTING GUIDE

Note: this is just an example; refer to electrical drawing

• Perforation Roll (Master) – AXIS 2

• Rider Roll Acceleration – NO ENCODER

• Deceleration Roll – NO ENCODER

• Sincro Cam – AXIS 4

• Core Introduction – AXIS 3

• Rider Roll Diatrol – AXIS 1

• Blade rotation – NO ENCODER

• Pushers – AXIS 1 – AXIS 5

• Forming belt (Master) – AXIS 1 • Cutting trolley – AXIS 2

Alarms belong to 3 categories:

NUMBER TYPE OF ALARM

If the instruction ALARM is used in a RULE, the string can be:

Type Name Description

15 Task too slow see alarm 14 see alarm 14 see alarm 14

Code Alarm Cause Effect Correction

4007 10 Battery Low on : VT xx VT low battery Replace the VT battery

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