Hickory input loss

[darin]

all plc inputs suddenly go off and we lose Hickory coms.

report_0008DC111213-0425240147_2024-08-21_15-34-30.zip

(863.69 KiB) Downloaded 9 times

[darin]

I think I found the problem, I was not cycling power to the hickory after a program change.

[darin]

Scratch that still having the same problem.
When the system goes down, all inputs on the plc monitoring screen go red but all inputs on the hickory board are still energized.
The Yaskawa drives for z and x go into a "aa12" fault. This does not happen right at start up but rather after the machine has been
on for awhile.

[tblough]

Inputs are just that - inputs. Hickory does not turn those on or off. The external devices you have connected to those inputs determine whether they are on or off.

You will probably need to provide a lot more information if you want meaningful help. Detailed photos of your machine and wiring, a video of the problem occuring, a list of components you used and the wiring diagram for your machine.

[eng199]

I assume the drive error is A12 "EtherCAT Outputs Data Synchronization Error".
The EtherCAT chain failed 13 minutes after start.

Check the routing, condition, and type of the RJ45/Ethernet cables. Check for any coils without snubbers or high power devices switching near the time of failure. The chain from HICKORY to the drives and jog panel is having a problem (not the cable from HICKORY to PC).

[darin]

The system has been up and running for several days with centroid supplied ecat cables with no changes to the routing.
The machine is idle when this happens, nothing being energized or de-energized and the x and z are not in motion.
The only coils without snubbers are the e-stop relays and that will be addressed.
The normal inputs are energized as show by the following attachment

The PLC monitor in CNC12 is falsely reporting that the inputs are de-energized as show by the following attachment

[darin]

Correct pic for Hickory board

[eng199]

Create a report before the error occurs, around 10 minutes after start up. This may provide additional clues about what is going on. The slaves are already down before the other report, so no information could be retrieved from them.

[darin]

I temporally rerouted the Ecat cables with that being said its been up for about 20 hours with no problems.
The next issue is that this is a vertical lathe and Z axis is having trouble with inertia in a -Z move.
Can you help size a regen resistor.