When researching a problem

[jcsb]

When researching a problem where you're unable to clear a fault, and the fault is a configuration problem, which files in the backup zip should be looked at first, assuming the electrical components are all fine. Something along the lines of either a plc configuration problem or parameter problem.

[Centroid_Liviu]

What is the fault? If you post a report we can take a look.

[jcsb]

Here you go

[cncsnw]

Working from a report (without immediate access to the machine):

1) Extract the error message log (msg_log.txt, from inside urf.zip) and look to see what error and fault messages might have appeared recently.
Your msg_log.txt file includes:

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(1)   06-15-2023 11:00:55 UNDEFINED PLC MESSAGE (28)
(1)   06-15-2023 11:01:13 UNDEFINED PLC MESSAGE (28)
...
(4)   06-15-2023 11:23:52 999 Parm #32 modified: 26.00000 -> 27.00000
(4)   06-15-2023 11:23:52 999 Parm #305 modified: 0.00000 -> 6.00000
(4)   06-15-2023 11:23:52 999 Parm #313 modified: 0.00000 -> 6.00000
...
(1)   06-15-2023 11:25:13 CNC12 Mill v5.02
(4)   06-15-2023 11:25:13 9099 Message Cleared
(1)   06-15-2023 11:25:13 412 S axis(6) encoder differential error
(1)   06-15-2023 11:25:13 949: Drive map does not match hardware
(1)   06-15-2023 11:25:14 UNDEFINED PLC MESSAGE (28)
(1)   06-15-2023 11:25:56 UNDEFINED PLC MESSAGE (26)
...
(1)   06-15-2023 11:26:13 412 S axis(6) encoder differential error
...
(4)   06-15-2023 11:28:21 999 Parm #313 modified: 6.00000 -> 0.00000
...
(1)   06-15-2023 11:29:35 949: Drive map does not match hardware
(1)   06-15-2023 11:29:36 UNDEFINED PLC MESSAGE (26)
(1)   06-15-2023 11:29:42 UNDEFINED PLC MESSAGE (26)
(1)   06-15-2023 11:29:47 406 Emergency stop detected
(4)   06-15-2023 11:31:17 999 Parm #305 modified: 6.00000 -> 0.00000
(1)   06-15-2023 11:32:30 Creating report...

There appear to be several issues going on. A servo drive might be coming and going; there is some uncertainty about whether a spindle encoder exists, and if so what axis it belongs on; and the PLC program is trying to generate at least two messages that are not defined in the plcmsg.txt file.

2) Look in the mpu_info.txt file to see what hardware (e.g. servo drives) were present at the time the report was created.

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 DriveNumber DriveType                      Version1 Version2
           1 DC1                                   4      ---
           2 ALLINONEDC                            4      ---
           3 ALLINONEDC                            4      ---
           4 ALLINONEDC                            4      ---

So, we have an Allin1DC with one DC1 drive added. Presumably it was the addition (and maybe removal and restoration) of the DC1 drive that triggered the "949 Drive map does not match hardware" messages. That is okay. We do need to note to ourselves that, with a DC1 in place, drive #1 is the DC1, and drives #2, #3 and #4 are the Allin1DC drive outputs. That determines what values we should put in parameters 300-303.

3) Look in the report*.txt file to check on axis configuration, drive number, and spindle axis assignment.
There is a stray report*.txt file from back in January that wound up in your report, so we need to take care to look at the current one (from June, with a file name that matches the base name of the report*.zip file).

In the report*.zip file, we see that the control is running CNC12 v5.02.
We see that it currently has just X, Y and Z axes, but that configuration values consistent with a rotary table have been entered for axis#4.
We see that parameters 300-303 are correctly set to 2, 3, 4 and 1, respectively (X, Y and Z are on the Allin1DC; the rotary axis is on the DC1).
We see that axis #6 has been labeled 'S', but that parameter 35 has not been set. If you want to make use of a spindle encoder, you should connect it to encoder input #6; you should set Parameter 35 = 6; and you should set Parameter 313 = 6. Parameter 305 should remain zero, since a spindle "axis" is just for encoder mapping and display, and does not require a servo drive on the drive bus.

4) To investigate the "UNDEFINED PLC MESSAGE (26)" and "UNDEFINED PLC MESSAGE (28)", we need to look at the PLC program source and the plcmsg.txt file. First we need to identify the PLC program source that is actually in use. Looking in the mpu.plc file, we see that it was compiled from "Centroid_ALLIN1DC_Mill_RotaryClamp-r2.src" on May 19th. So we locate that file and open it.

In the message constants section near the top of the file, we find:

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LUBE_FAULT_MSG_C                IS 6657;(1+256*26)
PROBE_JOG_TRIP_MSG_C            IS 6914;(2+256*27)
SPINDLE_FAULT_MSG_C             IS 7169;(1+256*28)

This suggests that when the PLC program requests message #26, it is trying to report a lube fault (INP9 LubeOk_I is apparently open); and when it requests message #28, it is trying to report a spindle drive fault (INP10, SpindleInverterOk_I is apparently open).

So, we know we need to check on our low-lube and inverter fault connections to INP9 and INP10; or to either jumper or invert those inputs if we have no such devices.

To see why the correct fault messages are not displayed, we look at and in the plcmsg.txt file. First, we see that the plcmsg.txt file dates back to July 2010. It is very unlikely that the messages it contains are correct or complete for an updated-in-2023 factory-standard PLC program.

The relevant section of the plcmsg.txt file has:

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22  9022 PLC Communication In Fault  (Fiber 3)
23  9023 PLC Communication Out Fault (Fiber 1)
24  9024 PLC Faults Cleared
30  9030 SPINDLE FAULT!
32  9032 SERVO DRIVE FAULT!
34  9034 FAULT! REMOVE PROBE FROM SPINDLE!!!
35  9035 KEYBOARD JOGGING DISABLED 
36  9036 LUBE FAULT
37  9037 PROBE TRIPPED WHILE JOGGING
38  9038 SPECIFIED SPIN SPEED < MIN SPIN SPEED 
39  9039 Software Ready Fault

This file has no definitions for messages 26 or 28. It apparently went with a PLC program that used message #36 for a lube fault, and message #30 for a spindle inverter fault.

There should have been a plcmsg.txt file provided with the factory-standard PLC program. If for some reason one was not, you could probably use the plcmsg.txt file that goes with another current, basic, Allin1DC PLC program such as the one you find in the mpuplcprograms\_Mill\_ALLIN1DC\_Centroid_Standard\cncm folder in your installation package.

[jcsb]

Got it going now!!! First, I changed parameter 35 to 0 and 313 to 0. The spindle doesn't have an encoder. Second, I jumped the lube pump input and that was ok. I really appreciate you taking the time to lay out the events, errors, and flow so that it was more apparent to me how to proceed. By no means would I be cocky and say I know how everything reacts, but your explanation allowed me to fix the faulty events. Knowing the relationship of the different files and how they contribute is important to me. It doesn't appear to be the normal ladder logic, but more of a hybrid. I would assume there was a flow chart in the beginning. No matter, I'm up and running. Thanks again for your assistance!
John