Basic knowledge of the diagnostic system

An elaborate plausibility check is performed throughout the entire process sequence in the AX5000. The resulting diagnostic messages are displayed in coded form on the display of the AX5000 and the message is displayed in plain text in the notification area of the “TwinCATDriveManager”.

Diagnostic Objects

Diagnostic objects are understood to be events that are diagnosed and for which a corresponding message is stored. In the AX5000 two groups of diagnostic objects can be distinguished.

Parameter channel diagnoses (SoE)

The SoE objects can cause messages that concern only the service or parameter channel of the communication profile. These messages must be evaluated and processed with the aid of programs in the PLC, in the TCDM or the HMI. The AX5000 continues to run without error and does not output any message.

Device diagnoses

Device objects can cause messages that concern certain hardware and software components of the drive system. In relation to the global diagnostics, several messages are displayed in direct succession in many cases and only the first remains visible on the display. In the event of a malfunction it is important to judge the entire diagnostic environment, i.e. to observe all diagnostic messages. For this purpose the so-called history file was created, in which all AX5000 diagnostic messages are accumulated.

Diagnostic messages

The diagnostic messages for SoE objects and device objects differ only insignificantly in their structure. Since diagnostic messages for SoE objects do not directly concern the function of the AX5000, there is no type, no reset and no reaction to the message; the other information is, however, also present.

Structure of the diagnostic message

Diagnostic code (Hex.)

The diagnostic code is represented in hexadecimal. This syntax is also used for the representation on the display of the AX5000.

0xF... = error
0xE... = warning
0xD... = information

Diagnostic code (Dec.)

The diagnostic code is represented in decimal.

Class

Diagnostic class	Information
1: Error	An error always causes the axis to be stopped. We recommend the following procedure for the rectification of errors: Disable the axis (e.g. via the MC_Power block) Rectify the error Execute the reset command “S-0-0099” (e.g. FB_SoEReset block) Execute a reset of the set value generation (e.g. FB_NcReset block) Enable the axis (e.g. MC_Power block) Put the plant into operation again
2: Warning	Warnings are displayed, but the AX5000 does not react directly.
3: Information	Information is displayed, but the AX5000 does not react directly.

Diagnostic class

Information

1: Error

An error always causes the axis to be stopped. We recommend the following procedure for the rectification of errors:

Disable the axis (e.g. via the MC_Power block)
Rectify the error
Execute the reset command “S-0-0099” (e.g. FB_SoEReset block)
Execute a reset of the set value generation (e.g. FB_NcReset block)
Enable the axis (e.g. MC_Power block)
Put the plant into operation again

2: Warning

Warnings are displayed, but the AX5000 does not react directly.

3: Information

Information is displayed, but the AX5000 does not react directly.

Type

Diagnostic type	Information
Runtime error	A general error has occurred.
Parameter error	The parameters entered cannot be verified.
Software error	A general error has occurred.
Hardware error	A general error has occurred.
Command error	An error occurred during the execution of a command.
Bootload error	An error occurred while initialising the AX5000.
Warning	A warning has no effect on the AX5000.
Information	Information has no effect on the AX5000.

Reaction

The AX5000 can react in different ways to a diagnostic. See also “AX5000_DiagMessages_General_IDN”.

Reaction to the diagnostic	Information
none	No special reaction takes place; the AX5000 remains in the normal operating condition.
The axis is not ready for operation	The EtherCAT “OP” status is not reached because there are parameterisation or initialisation problems.
NC control	There is no special reaction by the AX5000; the reaction takes place under the control of the NC. (The reaction time can be parameterised (see “AX5000_DiagMessages_General_IDN”))
A “closed loop” ramp is driven	By means of a “closed loop” ramp the axis is brought to a standstill in a controlled manner. The ramp can be parameterised. By means of an “open loop” ramp the axis is brought to a standstill in an open loop, control is no longer possible. The ramp can be parameterised.
An “open loop” ramp is driven	By means of an “open loop” ramp the axis is brought to a standstill in an open loop, control is no longer possible. The ramp can be parameterised.
The armature short circuit brake is activated	The motors are braked, wherein the motor coil has to absorb the brake energy.
Torque-off	The AX5000 switches the axis Torque-off

The diagnostic reactions are hierarchically structured. Not all reactions are currently implemented: The reaction tree clarifies the corresponding diagnostic reactions including the hierarchy.

NC control (starting from firmware version 2.x)
“Closed loop” ramp
“Open loop” ramp (not implemented)
Armature short circuit brake (not implemented)
Torque-off

Depending upon the diagnostic, an attempt is made to perform a certain reaction. If this reaction cannot be performed due to further events or because it is not implemented, operation continues with the next reaction according to the reaction tree.

Examples

Expected reaction according to diagnostic	Reaction performed by AX5000
NC control	“Closed loop” ramp, ("NC control" starting from firmware version 2.x)
“Closed loop” ramp	“Closed loop” ramp
“Open loop” ramp	Torque-off
Armature short circuit brake	Torque-off
Torque-off	Torque-off

IDN P-0-0350 - Error reaction check word

With the “error reaction check word” you can disable the standard reaction to the diagnostic and allow only the reaction parameterised in the “error response check word” in the event of an error.

Reset

Reset	Information
A RESET is not possible. A fatal hardware or software error has occurred in the AX5000.	Exchange the servo drive if necessary.
A fatal error has occurred; the AX5000 must be restarted.	Interrupt the 24 V supply voltage for at least 10 sec. or switch to the EtherCAT status “Bootstrap”
The Reset command (S-0-0099) must be executed
Warning: Reset not necessary	For most warnings there is no reaction by the AX5000.
Information: Reset not necessary	There is no direct reaction by the AX5000 to information.

Possible causes

All causes that could have caused the diagnostic message are listed here. Please always read all of the causes.

Solutions

Analogous to the causes, all solutions are listed here. The ordinal numbers before the “possible causes” and the “solutions” correspond to one another.