NX Safety Troubleshooting Guide - Omron Automation Americasproducts.omron.us/Asset/NX-S_Safety_TroubleshootingGuide...Document: NX Safety Troubleshooting - Version 2.0 Sept. 19, 2014

Document: NX Safety Troubleshooting - Version 2.0 Sept. 19, 2014 Page 1 of 39

NX Safety Troubleshooting

Table of Contents Opening & Getting Started With Sysmac Studio .................................................................................................................... 3

Unable to open Program ..................................................................................................................................................... 3

Unable to use Program ....................................................................................................................................................... 4

Register Robot Option ........................................................................................................................................................ 5

Unregister Robot Option ..................................................................................................................................................... 6

Program Build Errors and Warnings........................................................................................................................................ 7

I030 PLCopen: Instance ‘instance name’ of single call FB “FB name” requires a call ......................................................... 9

I120 Mapped output (variable_name) cannot be assigned at two places ....................................................................... 10

I132 Unused variable is declared but never used ............................................................................................................. 12

I133 Useless variable: is assigned but never read ............................................................................................................ 13

I134 VAR_EXTERNAL ‘variable name” requires an assignment ........................................................................................ 14

I139 the value of VAR is never changed, it should be declared CONSTANT: .................................................................... 15

I392 Empty network .......................................................................................................................................................... 16

A048 Unused logical device in application ....................................................................................................................... 17

A052 Logical device contains no mapping ........................................................................................................................ 18

L511 Identifier “variable name” not defined. ................................................................................................................... 21

L520 Access to global variable ‘variable name” requires a VAR_External ........................................................................ 22

V140 No global definition found for VAR_EXTERNAL ‘variable_name’ ............................................................................ 23

V152 External declaration of I/O variables have no modifier ........................................................................................... 24

Connections and Transfer ..................................................................................................................................................... 25

Unable to Load Program into NX CPU ............................................................................................................................... 25

Not Able to go Online........................................................................................................................................................ 26

Not Able to Transfer any part of the NX Program ............................................................................................................ 28

Flashing LEDs ......................................................................................................................................................................... 29

Normal Operation ............................................................................................................................................................. 29

Normal Operation, FS on I/O Module Flashing Green ...................................................................................................... 29


Flashing Red on NJ, NX and select I/O Modules (Activate or replace safety I/O module) ............................................... 30

Flashing Red on Coupler and NJ ........................................................................................................................................ 33

Flashing Red on all I/O on Coupler .................................................................................................................................... 34

Flashing Green I/O LEDS and Red/Green CPU .................................................................................................................. 35

Function Block Diagnostic Codes .......................................................................................................................................... 36

Post Programming ................................................................................................................................................................. 37

Reset Only Works at Initial Start-up.................................................................................................................................. 37

LEDs Will Not Turn On, NJ & NX Are Running ................................................................................................................... 38

Maximum Number of Tabs ............................................................................................................................................... 38

Safe Motion Connection on G5 ............................................................................................................................................. 39

St on G5 Display ................................................................................................................................................................ 39

83 on G5 Display ............................................................................................................................................................... 39


Opening & Getting Started With Sysmac Studio

Unable to open Program This is for programs from another source that will not allow you to download any part of the program.

Cause: Program is corrupted.

Solution: Have creator built the program(s) before exporting

Cause: Sysmac Studio version programmer used is higher that your version. Therefore, some features

are not available.

Solution: Downloaded latest version of Sysmac Studios. (Caution: This can take several hours.)

An “Omron Automation Software Auto Update” icon may be available in the “Start” menu.

If not,


Unable to use Program This is a program using functionality for a special license.

Cause: Program does not have the correct license.

Solution: Add additional license

Note: Robot license may not be used with database versions.


Register Robot Option 1. Install Sysmac Studio with Standard Edition.

Note: If Sysmac Studio is Trial Edition, you cannot register Robot Option.

2. Launch Sysmac Studio, press [License] button in left side of start window and press [Register License] button.

3. Enter the license number of Robot option and press [Register] button.

4. The following message is shown after succeeding to register the license.

5. Confirm that Robot Option is displayed like following window and restart Sysmac Studio.

6. Install patch “Smc1206_0102Setup”


Unregister Robot Option When you will move the license of Robot Option to another PC, Please unregister Robot Option with following

steps.

1. Launch Sysmac Studio, press [License] button in left side of start window and press [Unregister License] button.

2. Enter the license number of Robot option and press [Unregister] button.

3. The following message is shown after succeeding to register the license.

4. Confirm that Robot Option is not displayed like following window and restart Sysmac Studio.


Program Build Errors and Warnings

Overview

Sysmac Studio provides a list of warnings that allows the program to be built and downloaded for testing, but

may not be efficient in functionality or an optimized design. Most of these warnings appear when initially

setting up all of the hardware, by programming and testing in small sections, or after changes. They may

include topics such as:

1. Variables assigned but never used

2. Mapping

3. Constant declaration

4. Unused devices

5. Duplication

While most warnings can be ignored during the early stages of programming, they will serve as reminders of

items to be cleaned-up before final installation.

Setup

This example will use a dual channel emergency stop and dual force guided contacts.

List of warnings after the build


Hiding some warnings

It is practical to hide some of the warnings when programming and testing small sections since most of the

warning will be corrected as the program is completed.

Go to Tools -> option -> program check. As a default, all of the options are selected.

Unselect the ladder program warning display options and select OK.


I030 PLCopen: Instance ‘instance name’ of single call FB “FB name” requires a call

Cause: Extra variables are declared in the program. Function blocks are deleted or the name was changed.

1. Right click on Estop_001, Estop_002 and Estop_003 names and select “delete”.

2. Menu -> Project -> Build Controller (F8).


I120 Mapped output (variable_name) cannot be assigned at two places

Cause: Same output variable is assigned in two places.

1. Double click on the error.

2. In this case, the output S_EnableSwitchOut is used in another program, and this is duplicated. 3. Open program with the output. 4. Add a new network. 5. Insert the enable switch.

6. Use “AND” Boolean operator to add it to your existing EDM FB.



I132 Unused variable is declared but never used

Cause: Changes were made to the variable names or a function block was deleted.

1. Double click on the warning.

2. It will take you to the location where the warning is occurring.

3. It might be cleaner programming to delete the variable. If you use it later, it will be automatically added.

4. Do this for all of the I132 warnings. 5. Menu -> Project -> Build Controller (F8). 6. The warning is no longer there.


I133 Useless variable: is assigned but never read

Cause: A variable assigned in the I/O map and/or global variables that is not used in the program.

1. Open up the global variables.

2. Delete the unused variables.



I134 VAR_EXTERNAL ‘variable name” requires an assignment

Cause: Unknown (Future development).

Ignore. Note: This appears mostly in Sysmac Studio version before 1.10.


I139 the value of VAR is never changed, it should be declared CONSTANT:

Cause: Occurs with a constant variable.

Anything using timers or set values, the value should remain the same.


2. It will take you to the location where the warning is occurring.

3. Select the Constant

4. Do this for all of the I139 warnings. 5. Menu -> Project -> Build Controller (F8). 6. The warnings are no longer there.

Note: It is a best practice to activate the function block by using the Safety Connection Status, which would

verify the device is actually connected.


I392 Empty network

Cause: Network exists with no programming.


2. Here, the program was toggled to be a comment.

3. Right click on the pink area or any area away from the program.

4. Select Toggle network comment state. 5. Menu -> Project -> Build Controller (F8). 6. In this case error I711 occurs.

7. Only way to get rid of the warning and error is to delete it. 8. Right click on the pink area or any area away from the program.

9. Delete.


A048 Unused logical device in application

Cause: Device is reference as an instance. Find it in the configurations and setup under the safety I/O.

Still working on a solution …..

Note: As of Jan. 22, 2014, the locations with IL and GVL designations are still in development.


A052 Logical device contains no mapping

Cause: A device has not been assigned in the parameters and/or I/O map.

1. Open up the parameters to see what devices are not connected.

2. Connect the devices.


3. Verify the devices are mapped in the I/O Map.

4. Map the devices if needed. Note: Since these are already defined in the global variable list and used in the program, use the drop down list to select the variable name.


6. The warnings go away and two get replaced by errors. Double click on error.


7. Deselect the constant.

8. Build controller and the error will go away.

Why did this happen? Since the devices’ wiring was not assigned prior to programming, setting the constant made the device always true. Once the devices assigned, Sysmac Studio knows it needs to do a check of the safety device before it can continue the rest of the programs logic.


L511 Identifier “variable name” not defined.

Cause: Variable needs to be defined in the internal list in the program.

1. Right click on the internal variable list inside the program. 2. Select “create new”. 3. Select the variable name from the pull down list.


L520 Access to global variable ‘variable name” requires a VAR_External

Cause: Variable need to be defined in the external variable list.

1. Right click on variable list inside the program. 2. Select “create new”.

3. Select the variable name from the pull-down list.


V140 No global definition found for VAR_EXTERNAL ‘variable_name’

Cause: Variable is used in multiple programs but is not defined as a global variable.

Define in the global variable list.

Safety CPU -> Programming -> Data -> Global Variables -> Right click -> Create New -> type variable name.


V152 External declaration of I/O variables have no modifier

Cause: Variable was declared a constant.

In the internal / external variable list, make sure “Constant” is not selected.


Connections and Transfer

Unable to Load Program into NX CPU

Happened when an existing program in NJ and NX was loaded into an existing Sysmac Studio program.

There was a difference between the NX safety programs, and the coupler version.

Had to uncheck all of the NX modules.

Reconfigure the nodes and I/O map.

Re-enter the program.


Not Able to go Online Cause: Bad cable, not connected, or port is locked

Solution: Replace cable, set dip switch 4 on the NJ so it is in safe mode, check port on computer.

This pops up when you go online.

In top menu bar -> Controller -> Communications Setup

Select the communication types

When you go online, this pop-up will appear. Select the connection type.

If you are still not able to go online, from the Start menu on your computer, go to “All Programs”.


Select “Omron”

Select “Communications middleware utilities”

Select “DirectEthernetUtility”

In the popup, unselect “Disable the direct Ethernet connection function”

But, I was just online …..

Cause: Something is locked up.

Solution: Restart the system and the computer.


Not Able to Transfer any part of the NX Program

Cause: EtherCAT network does not see devices

Solution: Merge and compare should give you a device(s) that are different or not connected. Check cable

connections. Verify the devices are securely attached to the DIN rail.

Go to NJ CPU

Configurations and Setup -> EtherCAT -> right click on NJ CPU -> Merge and compare with actual

configuration -> apply actual network configuration

Check for I/O modules, couplers and the NX CPU connection


Flashing LEDs

Normal Operation

NJ – Run and NET RUN – Green

NJ – LINK/ACC – Flashing orange if EtherCAT cable is connected and running

Coupler – RUN and TS – Green

Coupler – L/A in and L/A OUT – Flashing green if connected and running

NX – FS, TS, and RUN – Green

NX – Valid – Orange

I/O Module – FS and TS – Green

I/O Module – I/O connection – Orange if signal is high.

Normal Operation, FS on I/O Module Flashing Green

Cause: Module is not active


Flashing Red on NJ, NX and select I/O Modules (Activate or

replace safety I/O module)

NJ – Error – Flashing Red

NX – FS/Valid/Debug – Flashing red

FS of I/O modules on coupler with minor fault – flashing red (Note: TS is solid green)

Cause: NX does not recognize the safety I/O modules since the FSoE watchdog timers do not match. They

might have been added at a later time or were deactivated and then reactivated in a different program.

Solution: Reset memory

1.) In Sysmac Studio -> Configurations and Setup -> Communications -> Safety -> double click on Safety I/O 2.) In the “Active” column, make sure the I/O modules are all selected.


3.) Connect the USB cable to the coupler with re-activated modules.

4.) In Sysmac Studio -> select NJ CPU -> Configuration and setup -> EtherCAT -> right click on the node (coupler) with the reactivated modules -> Coupler Connection (USB) -> Online

5.) Double click on the node (coupler)

6.) Right click on the re-activated module -> Clear All Memory -> Execute


7.) Confirm. This will appear while it is clearing.

8.) This will appear when the memory is cleared.

9.) Right click on the node (module) -> Coupler connection (USB) -> Offline

10.) Rebuild NJ and NX programs. 11.) Go online with NJ. 12.) Download NJ and NX programs. 13.) Power may need to be recycled.


Flashing Red on Coupler and NJ

NJ – ERROR & NET ERR – flashing red NJ – Link/ACC - flashing orange

Coupler – ERR – flashing red Coupler – RUN – flashing green

Coupler – TS – red NX & I/O modules – FS & TS - flashing green

NX – VALID - orange

Cause: One of the devices listed may be a different version.

Solution: Match the version without affecting the configuration.

Online -> Select “NJ controller” -> Configurations and Setup -> double click on EtherCAT -> right click on

“Master” – select ”Compare and merge with actual network configuration.”

See if any of the devices are different and close the window.

Note: you do not want to merge and compare since it will delete

your node and I/O map settings.

Go offline.

Right click on the coupler with the device -> “Edit slave terminal

configuration” -> Right click on the device -> “Change device” ->

select the correct version. (Note: if only 2 versions are available, it

automatically gives you only the other version to select.)

Rebuild NJ and NX programs and transfer them to the CPUs.


Flashing Red on all I/O on Coupler

NJ – ERROR and NET ERR – Flashing red

NJ – LINK/ACC – Flashing orange

Coupler – TS and ERR – flashing red (with Run flashing green in between them)

NX – FS – Flashing red NX – TS – Flashing green

I/O modules on the coupler- FS and connected inputs / outputs – flashing red

Cause: Lost EtherCAT connection

Solution: Check EtherCAT cables for loose connection.

If online with a computer and Sysmac Studio, open up troubleshooting and select “reset all”.

OR Recycle power to the system.


Flashing Green I/O LEDS and Red/Green CPU

NJ – RUN - Solid Green NJ – ERROR and NET ERR - Flashing Red

NJ – LINK/ACC – Flashing orange Coupler – RUN – red

Coupler – L/AIN and L/A OUT – Flashing green (super fast)

I/O module – FS and TS – Flashing green

Cause: Issue during transfer of the program

Solution: Open new project

Open up new project

Configurations and Setup -> EtherCAT -> right click on NJ CPU -> Merge and compare with actual

configuration -> apply actual network configuration

Transfer from Controller

Make sure the options are not selected.


Function Block Diagnostic Codes

Decimal Hexadecimal

0 0000 FB is disabled FB is not operating or Safety CPU has stopped

32768 8000 FB is operating and there are no errors

32769 8001 FB is already started

Solution: See if S_StartReset is required

32770 8002 FB is waiting for device input signal to change to true

Solution: make sure reset is false before input signal goes to true

32771 8003 Waiting for reset to turn to true after the input is true

32772 8004 A safety request was detected

Solution: Need device input to change to true

32773 8005 Waiting for reset

Check S_AutoReset or Reset since they are not changing to true

32785 8011 Waiting for operator to request unlocking the guard

32786 8012 Guard is unlocked and open

32787 8013 Guard is unlocked and closed

32788 8014 S_SafetyActive was restored but need reset signal

49152 FB is operating and an error exists

49153 C001 Undetected change to true for the reset input

49154 C002 Undetected change to true for the reset input

49155 C003 Undetected change to true (during safety lost state)

49156 C004 Safety device was activated (guard opened or unlocked)

49169 C011 Equivalent signals for reset and EDM1 device input


49201 C031 Equivalent signals for reset, EDM1 and EDM2 device input


Thru 49297 Reset error


Post Programming

Reset Only Works at Initial Start-up

Solution: Check reset functions and see if reset signal remains high

G5 servo drive saw high signal for reset button once it was initially pressed. Add SF_TOF and SF_F_TRIG

to turn reset signal off for the NJ.


LEDs Will Not Turn On, NJ & NX Are Running

Cause: Unknown

Solution: Recycle power,

If that does not work, rebuild NJ and NX programs, transfer programs to CPUs, recycle power.

Maximum Number of Tabs Cause: Too many windows are opened.

Solution: Click on “X” in the tab to close several tabs.

Note: Maximum number of tabs allowed is 10.


Safe Motion Connection on G5

St on G5 Display Cause: G5 is waiting for the safety

Solution: Press reset button.

If using multiple reset pushbuttons, make sure they are OR instead of AND.

83 on G5 Display Cause: G5 does not see the safety

Solution: Check the cable connections. Check the program.

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Documents

NX Safety Troubleshooting Guide - Omron Automation Americasproducts.omron.us/Asset/NX-S_Safety_TroubleshootingGuide...Document: NX Safety Troubleshooting - Version 2.0 Sept. 19, 2014