Fiche Technique

BLO_AUTO_PS_4006
Aide au diagnostique / résolution de panne
Procédure de réglage / Remise en état
Bulletin technique / Information

Fault diagnostic help to the electrical stretching function

Date de publication de la fiche / version 30/11/2015 - version A
Auteurs Ahmed RAHALI, Johann FLEURY & Franck LHOMME
Machines concernées Matrix
Profil / Niveau requis Niveau 2 - Technicien Client Habilité
Temps d’intervention estimé 1h
Stratégie A la Demande

1/ PRESENTATION

Electrical stretching consists of five major parts:

1/ the linear encoder head AK LIDA 28 HEIDENHAIM (Sidel code 1135543201) ;
2/ The pre-molded cable, providing the signal to the encoder card (Sidel code 148246) ;
3/ Sub-D 15 connector plugged to the encoder card (code Sidel 121978) ;
4/ Encoder card inside the acopos Servodrive (code Sidel 147979) ;
5/ Acopos Servodrive located in the FB43 cabinet (code Sidel 147978)

All the stretching drives are located in the FB43

cabinet in the blowing wheel:

1/15 BLO_AUTO_PS_4006_Technical sheet Diagnostic Electrical Stretching Customer 07/12/2015

 2/ DIAGNOSTIC HELP ON ELECTRICAL STRETCHING FUNCTION

A/ HMI FAULTS:

Many faults are associated with the electrical drawing. Generally, a stretch fault displays two critical faults on HMI.
It’s showing a default drive number (42xxU0). Meanwhile the second fault follows the first fault, and indicates that the same
drive is "not ready" (# 120xxx). Example:

One inverter controls 2 stretching stations. Example: Inverter 4201U0 controls stations 1 and 2, the drive 4202U0
controls stations 3 & 4, the 4203U0 drive controls stations 5 & 6, etc ...
A third fault could be added to the previous two faults giving extra precision to the analysis of the problem. Example:

We can see in this example that the 4203U0 drive is faulted on the blowing station 5. The fault involves a malfunction
of the stretching unit on station 5 (excessive temperature).

B/ Stretching diagnostic :

Stretching variable speed drive fault is a general fault. Reasons of this fault should be analyzed with the stretching
fault page. To do this, press the « DIAGNOSTIC » button in the main page then the « STRETCH FAULT » tab :

(5)


  Select the blowing wheel station in fault (1).

 Acknowledge the faults until 0. (2).
  When a fault is acknowledged, number of faults is decreased by 1 and
the fault is stored in the diagnostic page with the date and time. In our
example, we had 4 stored faults on Sunday the 29th of November 2015
at 15 :19 :09 (3)
 Faults messages (4) are explained below according to the number (5)

2/15 BLO_AUTO_PS_4006_Technical sheet Diagnostic Electrical Stretching Customer 07/12/2015

4005: Controller cannot be switched on: Drive in error state
Description:

This error occurs if the motor is magnetized while the drive is in the state ‘Controller not ready '. The
RDY LED on the front panel of the drive is flashing:

Reaction:

Power is no longer permitted and the power stage is switched off.

Cause/Solution:

This fault is usually induced by other principal faults. Refer to other drive faults to know the real cause of
the failure.

If only this fault is showed:

 Turn off then, turn power on the drive after a few minutes according to the datasheet
(BLO_AUTO_PS_4003_A_EN_Restart_Combi_Matrix),
 If the fault is still on, please change the drive.

3/15 BLO_AUTO_PS_4006_Technical sheet Diagnostic Electrical Stretching Customer 07/12/2015

4007: Lag error stop limit exceeded

Description:

The electrical devise is not in the position in which it should be at 15mm.

Reaction:

The current movement is stopped and power is cut off on the axis.

Cause/Solution:

The causes of this failure are many.

 If a single fault: Movement cannot be performed because of a mechanical stress, brake not
released, etc. Proceed to a setting mode test and identify the problem;
 If other fault present: refer to the other faults and change the hardware part:

 Motor problem
 Coder problem
 Acquisition card of the motor or cable
 Inverter problem

4/15 BLO_AUTO_PS_4006_Technical sheet Diagnostic Electrical Stretching Customer 07/12/2015

6057: Position loop controller: Load encoder error

Description:

No signal is delivered from the stretching encoder to the inverter.

Reaction:

The current movement is stopped and power is cut off on the axis.

Cause/Solution:

No power supply on the coder or bad signal reading.

 If the coder LED is off :
o Switch Off the power of the machine following the Sidel preconisation, change the
encoder and power ON the machine again:
o If the LED is always OFF, switch Off the power of the machine following the Sidel
preconisation, change the acquisition card and the cable/connector, then switch On the
machine;
o If the LED is always OFF, switch Off the power of the machine following the Sidel
preconisation, change the inverter, then switch On the machine;
o If the LED is always OFF, please call your local Sidel technical support.

 If the LED is ON : check the status of the LED (color) :

Clean the encoder and his encoder scale tape in order to optimize the LED status. If the problem is not
solve:
o Switch Off the power of the machine following the Sidel preconisation, change the
encoder and switch ON the machine following the technical sheet
(BLO_AUTO_PS_4003_A_EN_Restart_Combi_Matrix);
o If the LED is always OFF, switch Off the power of the machine following the Sidel
preconisation, change the acquisition card and the cable/connector, then switch On the
machine;
o If the LED is always OFF, switch Off the power of the machine following the Sidel
preconisation, change the inverter, then switch On the machine;
o If the LED is always OFF, please call your local Sidel technical support.

5/15 BLO_AUTO_PS_4006_Technical sheet Diagnostic Electrical Stretching Customer 07/12/2015

6059: Enable2: Voltage sag
Description:

No 24v on the Enable2 of the inverter while the motor is the motor is magnetized.

Reaction:

The power on his axis is cut.

Cause/Solution:

Check for 24V between « Enable2 » terminal (terminal 3 or 9 following the faulty axis) and his associated
COM terminal (COM (3) or COM (9) on the X1 terminal of the inverter)

6/15 BLO_AUTO_PS_4006_Technical sheet Diagnostic Electrical Stretching Customer 07/12/2015

7030: Encoder: Incremental signal amplitude too large

Description:

The coder delivers a higher voltage than permissible by the acquisition card (1.42Vpp).

Reaction:

The current movement is stopped and power is cut off on the axis.

Cause/Solution:

This fault is usually induced by other principal fault. If default is unique, the encoder voltage outputs >
1.42Vpp (orange LED on encoder) or encoder card is defective:
o Switch Off the power of the machine following the Sidel preconisation, change the
encoder and switch ON the machine following the technical sheet
(BLO_AUTO_PS_4003_A_EN_Restart_Combi_Matrix);
o If the LED is always OFF, switch Off the power of the machine following the Sidel
preconisation, change the acquisition card and the cable/connector, then switch On the
machine;
o If the LED is always OFF, switch Off the power of the machine following the Sidel
preconisation, change the inverter, then switch On the machine;
o If the LED is always OFF, please call your local Sidel technical support.

7/15 BLO_AUTO_PS_4006_Technical sheet Diagnostic Electrical Stretching Customer 07/12/2015

7032: Encoder: Incremental signal amplitude too small (Disturbance, no
connection)

Description:

The coder delivers a lower voltage than permissible by the acquisition card for the functioning.

Reaction:

The current movement is stopped and power is cut off on the axis.

Cause/Solution:

If a single fault, the encoder reading is impaired and may be due to the presence of grease between the
encoder strip and the encoder:

If several consecutive faults, an element in the measurement chain has failed (see page 1)

LED on encoder) or encoder card is defective:

o Switch Off the power of the machine following the Sidel preconisation, change the
encoder and switch ON the machine following the technical sheet
(BLO_AUTO_PS_4003_A_EN_Restart_Combi_Matrix);
o If the LED is always OFF, switch Off the power of the machine following the Sidel
preconisation, change the acquisition card and the cable/connector, then switch On the
machine;
o If the LED is always OFF, switch Off the power of the machine following the Sidel
preconisation, change the inverter, then switch On the machine;
o If the LED is always OFF, please call your local Sidel technical support.

8/15 BLO_AUTO_PS_4006_Technical sheet Diagnostic Electrical Stretching Customer 07/12/2015

9010: Temperature sensor (Motor|Choke|External): Overtemperature

Description:

L’un des deux moteurs est équipé d’une sonde analogique et d’une sonde TOR. La sonde ana est reliée au
bornier X4 de son variateur respectif. Ce défaut apparait si la lecture issue de cette sonde excède 130°C.

One of the two motors is equipped with an analog sensor and one digital sensor. Analogic probe is
connected to the terminal X4 of each inverter. This fault is displayed if after reading this sensor exceeds
130 °C.

Reaction:

The current movement is stopped and power is cut off on the axis.

Cause/Solution:

The rise of T° can be induced by a significant effort during the stretching movement.

 If the fault occurs after a few cycles, mechanical stress is responsible for this situation. The digital
sensor triggers the following message in the HMI:

If the motor is hot, make a movement in setting mode in order to identify the mechanical stress.

 Si le défaut est immédiat, le moteur, le câblage de la sonde analogique ou le variateur est

défectueux. Procéder au changement du matériel dans l’ordre ci-dessus et noter l’élément
défectueux. If the fault is immediate, the motor, the wiring of the analogue probe or the inverter is
defective. Please change each parts explain above and record the defective part.

9/15 BLO_AUTO_PS_4006_Technical sheet Diagnostic Electrical Stretching Customer 07/12/2015

9011: Temperature sensor (Motor|Choke|External): Overtemperature -
Limiter active

Description:

This fault appears if during the emergency deceleration after a fault “9010”, the temperature does not go
down.

Réaction:

The power on the axis is cut immediately

Cause/Remède:

Cf. défaut 9010

10/15 BLO_AUTO_PS_4006_Technical sheet Diagnostic Electrical Stretching Customer 07/12/2015

29203: Drive not ready
Description:

This error occurs if the motor is magnetized while the drive is in the state 'controller not ready'. The RDY
LED on the front panel of the drive is flashing:

It appears 10s after switching on the drive, it is not passed in the state "Ready" (internal bit).

Reaction:

The power is cut if it was active, otherwise it cannot be delivered.

Cause/Solution:

This fault is usually induced by other principal fault. Refer to other fault identified to know the real cause.

If a single fault, switch off the machine, change the inverter, then switch on the machine following the
technical sheet (BLO_AUTO_PS_4003_A_EN_Restart_Combi_Matrix). If this still missing, contact your
local Sidel technical support.

11/15 BLO_AUTO_PS_4006_Technical sheet Diagnostic Electrical Stretching Customer 07/12/2015

29209: Drive in error state
Description:

The drive cannot be magnetized due to an error.

Reaction:

The power is cut if it was active, otherwise it cannot be delivered.

Cause/Solution:

This fault is usually induced by other principal fault. Refer to other faults identified to know the real
cause.

12/15 BLO_AUTO_PS_4006_Technical sheet Diagnostic Electrical Stretching Customer 07/12/2015

29216: Continuous movement not possible.
Description:

The drive cannot be magnetized due to an error.

Reaction:

The power is cut if it was active, otherwise it cannot be delivered.

Cause/Solution:

This fault is usually induced by other principal fault. Refer to other faults identified to know the real
cause.

13/15 BLO_AUTO_PS_4006_Technical sheet Diagnostic Electrical Stretching Customer 07/12/2015

29226: Drive error. Call MC_(BR_)ReadAxisError for details.
Description:

An error is active or has not been reseted. Refer to other fault to know the real cause of the fault.

Reaction:

The power is cut if it was active, otherwise it cannot be delivered.

Cause/Remède:

Correct the actual fault, switch off the machine and then restore power following datasheet
(BLO_AUTO_PS_4003_A_EN_Restart_Combi_Matrix);

14/15 BLO_AUTO_PS_4006_Technical sheet Diagnostic Electrical Stretching Customer 07/12/2015

41011: Temperature sensor (Motor|Choke|External): Overtemperature

Description:

The temperature from the analogic KTY probe connected to the drive terminal block X4 exceeds
0.95*110°C (104.5°C).

Réaction:

No reaction of the drive. The fault display is only an information.

Cause/Solution:

Cf. erreur 9010

If a fault is not identified or for any other additional information, please

contact your local or central Technical Support.

15/15 BLO_AUTO_PS_4006_Technical sheet Diagnostic Electrical Stretching Customer 07/12/2015