Category: Troubleshooting & Repair

Emerson Industrial Automation: Unidrive Classic HF Trip Codes

Joe Kaminski 1 Comment
Emerson Industrial Automation: Unidrive Classic HF Trip Codes
This document is pertinent to all Unidrive Classic models
MRO Electric and Supply has new and refurbished Control Techniques Unidrives  available now, along with our other Control Techniques products. Contact us about pricing for repairs. For more information, please call 800-691-8511 or email sales@mroelectric.com.
Emerson Industrial Automation: Unidrive Classic HF Trip Codes

HF81 Software Error (odd address word)

Unidrive Fault Code DiagnosticsHF81 HF82 HF83 HF84 HF85 HF86 HF87 HF88 HF89 HF90 HF91 HF92 HF93 HF94 HF95 HF96 HF97 HF98 HF99

HF82 Large Option Module Missing

HF83 Power Board Code Failure

HF84 Current Offset Trim Failure

HF85 A to D failure (ES-CC step)

HF86 Interrupt Watchdog failure

HF87 Internal ROM check error

HF88 Watchdog Failure

HF89 Unused Interrupts (nmi as source)

HF90 Stack Overflow

HF91 Stack Underflow

HF92 Software Error (undefined op code)

HF93 Software Error (protection fault)

HF94 Software Error (odd address word)

HF95 Software Error (odd address instruction)

HF96 Software Error (illegal ext bus)

HF97 Level 1 Noise

HF98 Interrupt Crash

HF99 Level 1 Crash

HF Faults are not recorded in the Drive Historical Fault Log

All of the above HF trips in BLUE are typically a result of some sort of hardware failure on the UD90A control PCB. This control board is common to all Unidrive Classics.

For the HF codes in RED refer to the following page

HF82 Large option module missing

If one of the UD7x large option modules is removed, the trip may be expected. There is an issue with either the large option module or the UD90A control PCB if this trip occurs at any other time than the case above.

HF83 Power Board Code Failure

Because the UD90A control PCB was unable to recognize the power rating of the power PCB it is connected to, this trip occurred.

The trip is likely due to the power PCB in the Drive or a problem with the UD90A control PCB on Unidrive Sizes 1 to 4 (which includes UNI1401, UNI1402, UNI1403, UNI1404, UNI1405, UNI2401, UNI2402, UNI2403, UNI3401, UNI3402, UNI3403, UNI3404, UINI3405, UNI4401, UNI4402, UNI4403, and UNI4404).

UD99 PCB or the UD90A PCB cause the trip on a Unidrive Size 5. The interconnects between the PCBs should also be checked, as they could also cause a trip.

HF84 Current Offset Trim Failure

Due to an issue with the current feedback on the drive, this trip occurs. The trip is likely due to the power PCB in the Drive on Unidrive Sizes 1 to 4. An issue with the UD90A control PCB may also cause this trip.

The UD99 PCB or the UD90A PCB cause the trip on a Unidrive Size 5, along with the interconnects between the PCBs.

HF88 Watchdog Failure

This trip can result from a faulty UD7x Co-Processor. With power off, remove Co-Processor and re-apply power.

HF82 Large option module missing

If one of the UD7x larger option modules is removed while the Drive is powered up, this trip is likely to occur. There is an issue with either the UD90A control PCB or the large option module if this trip were to occur at any other time.

HF83 Power Board Code Failure

The UD90A control PCB was unable to recognize the power rating of the power PCB it is connected to, which is what caused the trip.

The trip is likely due to the power PCB in the Drive on Unidrive Sizes 1 to 4, however, an issue with the UD90A control PCB is also able to cause this trip.

The trip is caused by the UD90A PCB, the UD99 PCB, or the interconnects between the PCBs on a Unidrive Size 5.

HF84 Current Offset Trim Failure

If there is an issue with the current feedback on the Drive, this trip will occur. The trip is likely due to the power PCB in the Drive, but an issue with the UD90A control PCB could also result in a trip on Unidrive Sizes 1 to 4.

On a Unidrive Size 5, the trip is cause by either UD99 PCB or the UD90A PCB. The interconnects between the PCBs could also cause this trip and should be checked.

A trip could be caused by either UD99 PCB, UD90A PCB, or the interconnects between the PCBs on a Unidrive Size 5.

HF88 Watchdog Failure

A faulty UD7x Co-Processor and large option module, ( includes UD70, UD71, UD73, UD74, UD75, and UD76) can cause this trip. Remove Co-Processor and re-apply power with power off.

Unidrive Fault Code DiagnosticsHF81 HF82 HF83 HF84 HF85 HF86 HF87 HF88 HF89 HF90 HF91 HF92 HF93 HF94 HF95 HF96 HF97 HF98 HF99

FANUC Controls Alarms

FANUC Troubleshooting Manual – FANUC CNC FAQ

Joe Kaminski 8 Comments

FANUC CNC machine is an extremely useful tool – but like many tools, it’s susceptible to breaking. Read on to learn common FANUC issues and how to best troubleshoot to solve the problem.

What is the proper method to test a motor for a short?
The proper way to troubleshoot a FANUC motor for a short is to first lock out the machine, remove the cable from the drive, and test all three motor phases to ground with a megohmmeter. This will test both the motor and the cable for problems.

Why am I getting errors when I connect to my FANUC drive’s RS-232 port?
There are a number of explanations for these errors. The RS-323 port is a high-fail component on a FANUC drive as it is very susceptible to electrical surges. However, the RS-232 cable is also another high-fail item. Ensure that you are using a cable that is known to be functional when communicating. Otherwise when you attempt to read-in or punch-out a cable, you will get an 086 alarm that is going to indicate that the cable is incorrect, or that the port has failed.

To test whether the cable or the port has failed, take a known good cable and insert it into the RS-232 port. Next, set your machine up to receive a file. The screen should being to flash “READ”. Next, transmit your file into the machine tool. If the machine continues to flash “READ” (or “LSK” on modern controls) but never receives the file, you have a defective communications port on either the memory board or the master board. These boards or your machine will need to be sent in for repair.

What is an Axis Communications Error?
An Axis Communications Error indicates a communications problem between the motor encoder and the CNC control. This can be caused by the motor encoder itself,  the cable going to the encoder, or the axis control card the cable is plugged into.

What is an Excess Error Alarm and why is it caused?
Generally, an Excess Error means that the machine has moved beyond its allowable tolerance. The CNC has told the FANUC servo drive to make a move, the servo drive moves the motor,  which in turn moves the encoder. As the machine moves, there will be some deviation. This deviation is known as the Excess. The parameters set how much deviation/excess should be allowed.

These errors can be caused by a variety of problems. For example, a dull tool can caused the axis to be pushed out of position which results in a deviation error. Debris build up can cause deviations while the machine is stopped. Additionally, a failed servo drive can also cause deviation errors.

What is FANUC 401 Servo Alarm?
Alarm 401 is a very generic FANUC alarm. It simply means that the servo’s did not obey. The CNC, which is in charge of the servos, tells the servo drives to turn on and remain on. If for whatever reason the servo drive turns itself off without the permission from the CNC, the CNC will generate a 401 alarm. This alarm will usually occur with other alarms, such as the 414 Alarm.

What is FANUC Servo Alarm 414?
The FANUC Servo Alarm 414 is an alarm issued by the CNC that says a problem has been found in either the servo drive or the feedback system. The alarm will show which axis is causing the problem. To identify the specifics of this alarm, you must go into the CNC diagnostics page. Diagnostics number 200 on the 16th row will indicate what is causing the problem.

What is the difference between a High-Current Alarm and an Over-Current alarm?
A high current is an abnormal current that can be caused by noise. When the system detects this, it will generally shut the machine down and generate a High-Current Alarm. This FANUC alarm code is usually caused by defective servo drive or cooling contamination inside of the motor windings or cable.

An Over-Current Alarm indicates that too much current has flowed through the DC link. This is usually caused by a short in the system, an unplanned contact, a defective transistor module, or dull tooling attempting to make a cut. 

Why do I get a Soft Overtravel Alarm when I try to reference a newly installed motor?
When the CNC power down, it remembers its last known position. When you restart the machine, an incremental encoder will ask that the machine be re-positioned. When you try to do a re-reference of the machine tool, and it doesn’t agree with where the last known position was, the machine with automatically go into a default that indicates a Soft Overtravel Alarm. These alarms can occur as any point in the travel of the machine. To bypass this alarm, power the machine down and hold down the key with the letter “P” on it as well as the “Cancel” button (at the same time). Then power the machine up while you continue to hold down both of these buttons. If you do this, the machine will ignore all Soft Overtravels until the first zero referenced position has been done on that axis, and will clear the Soft Overtravel Alarms.

I unplugged my AC or DC FANUC motors, and now I am getting a 300APC Alarm. What is that?
A 300APC Alarm indicates that you are using an absolute pulse coder. The difference between an absolute pulse coder and a incremental pulse coder deals in the memory retention of the position. Using a CNC control with an incremental pulse coder, you must reference the machine every time you turn the machine back on.

With an absolute pulse coder, there is a battery backed memory that retains the position of the machine tool when it powers down. When the CNC machine turns back on, it asks the encoder its position, and the encoder then responds back with its current position. If it is within tolerance of where it was when it shut down, the CNC will continue to run the program. However, if you lose the memory retention due to an encoder cable being unplugged, you will end up with the 300 level APC alarms. These FANUC alarms simply signify that the machine must be re-referenced. The re-referencing procedure is determined by the machine tool builder – consult your machine tool builder manual for the proper operation.

If this FANUC troubleshooting manual was not comprehensive enough, MRO Electric stocks new and refurbished FANUC products, and also offers reliable FANUC repairs. Please call 800691-8511 or email sales@mroelectric.com for a quote.

Schneider Electric Magelis HMIs – Frequently Asked Questions Part II

Joe Kaminski Leave a comment
MRO Electric carries new and refurbished Magelis HMIs. To request a quote, please call 800-691-8511 or email sales@mroelectric.com.

Magelis HMIs
Magelis HMIs

Why is the Magelis XBTRT511 is not giving me the correct floating point value reading on the alphanumeric display when communicating with a Momentum?
If you address the alphanumeric display as a %MW that is incorrect. To read a floating point value, you need to address the alphanumeric as a %MF.

Does the Magelis Panel PC, HMIPUC9D0E01, have line out to connect a speaker?
Yes, the Panel PC HMIPUC9D0E01 have a Line out to connect an external speaker.

Can I lose my alarms log in Vijeo Designer V4.5 when power cycling my Magelis XBT-GT?
Each alarm group can have 2 such alarm buffers: one for History alarm events (size defined by the “Num of History Alarms” property) and one for Log alarm events (size defined by the “Num of Log Alarms” property).
These alarm buffers are stored in the DRAM (Dynamic RAM: similar to the RAM of a PC) of the target. Therefore, if the target is turned off, the alarm buffers are wiped out. If you need them to be saved even when the target is turned off, you can enable the “Backup Alarm Group” property (at the global alarm level). This way, these alarm buffers will be stored in the DRAM and in the SRAM (Static RAM: doesn t get wiped out when the target is turned off) as well.
Since the size of these alarm buffers is limited (the maximum value for the “Num of History Alarms” and “Num of Log Alarms” properties is 10000), they won t always contain the whole history of alarm events on the target. To obtain that behavior, you can enable the “Save To File” property (at the alarm group level). This way, the alarm events will be saved into Excel files (on the CF card) and these Excel files will contain the whole history of alarm events for the corresponding alarm groups.

Is there a RS-485 cable to connect a M221 to a Magelis XBTN401?
No. There is no cable you must make your own the pin out is as follows;

4——–4
5——–5
7——–7
8——–8

No other pins can be used because the M221 can also be configured for RS-232. (can not use a straight through Ethernet cable).

What is the meaning of “PLC Returned error code 02H” for Magelis Targets HMIGTO ?The error “PLC Returned error code 02H”, means that you are trying to access an address in the slave device which is not defined or inaccessible or there can be issue with communication card , cable, or communication settings done inside IOmanager communication equipment channels must be checked. Mostly the issue observed is related to register mismatch between target and slave device. Correcting this will resolve the issues.

What is the the number of candela per square meter for the Magelis XBTGTO?
HMIGTO 3.5″ = 450
HMIGTO 5.7″ = 500
HMIGTO 7″ = 350
HMIGTO 7.5″ = 400
HMIGTO 10.4″ = 450
HMIGTO 12.1″ = 450

Can a Magelis HMI communicate to a M241 SL2 using SoMachine protocol?
The M241 can communicate to an HMI via SL2. The default communication settings for SL2 does not match the settings for the COM of the HMI (baud rate and parity are different). If the settings are adapted, the communication works fine.
Below is the RS485 pinout:

HMI to M241 SL2
Pin 4 to D1
Pin 5 to D0

Can the Magelis HMIPPF7A2701 be mounted at a 45 degree angle?
The unit can be mounted at a 45 degree angle as long as the ambient air temperature does not exceed 85F and that there is enough air flow surrounding the unit.

Why does Magelis HMI tell me to change my password when I log in?
In Vijeo Designer, there is a feature called Password Management. If this is enabled, and password expiry is enabled, your password will expiry in two cases:
1) At first login and
2) After the defined time has elapsed.

You will need to change your password in the runtime with the user manager part or redownload the application again.

Can I have two Magelis HMI to the same serial port of a M238?
No you cannot, there are two possibilities to realize configuration of a M238 + 2 XBTGTs.
You can connect an HMI to the SL1 of the M238 and the second HMI can be connected to SL2.

Why is there only some data logged in my Magelis HMI?
Vijeo Designer Runtime is designed to optimize storage for data logging by only creating a record when the value of the variable changes. If the value of the variable remains static, a new record will not be created (other than the initial record). Each record made is for a unique value. Vijeo Designer cannot send emails via SMTP2Go on the Magelis but is successful via simulation

When this situation occurs, it is likely the network settings on the HMI are incorrect. Ensure that the IP, Subnet Mask, Default Gateway, and DNS server are all set up correctly. Typically you can compare your PC’s settings vs the HMI’s settings to find the differences (if they are on the same network).

Can the TM2 expansion modules be used on the Magelis STU and STO?
No, if you want an HMI that can use the TM2 modules you will need to go to the HMISCU series.

Is there a Magelis HMI that can withstand 80psi of pressure?
The HMIGTO xx15 series has been tested to withstand 10 bar of high pressure washing machinery. (10bar = 145 psi)

Magelis HMIs – Frequently Asked Questions Part I

Joe Kaminski 4 Comments
MRO Electric carries new and refurbished Magelis HMIs. To request a quote, please call 800-691-8511 or email sales@mroelectric.com.

Magelis HMIs
Magelis HMIs

Is it possible to download to a Magelis HMISCU with SoMachine using the IP address connection mode?
SoMachine V4.1 SP1.2 does not support this feature. It is only possible to download using the Node name connection mode.

What methods are there to put a Magelis back to factory settings?
Use the Vijeo Designer Runtime Installer found in the Start menu under Schneider Electric\ Vijeo-Designer to re-install the Runtime.

What are the Magelis XBTGT7340 DIO output specifications?
The Run, System Alarm and Event Buzzer outputs are rated for 24VDC and 50ma.

What is the MTBF for the Magelis HMISTU855?
-LCD and touch panel of STU655/855 is 50,000 hours
–HMISTU655/855 is 2,087,918 hours without LCD screen

Can the MBX Driver V7.0 be installed on a Magelis iPC Smart box with a primary 1GB CF card?
No there is not enough available space on the primary CF card. MBX Driver requires Microsoft .NET Framework 2.0 which requires about 150MB of available space on the primary CF card.

Can I use a VESA mount on the Magelis iDisplay MPCYT90NAN00N?
Yes. The iDisplay MPCYT90NAN00N can be mounted using a 100mm VESA mount.

Why can’t my Magelis HMI Communicate over Ethernet?
One common mistake people make is plugging the Ethernet cable into the RJ45 COM port of the HMI. First thing to check is to see if your Ethernet cable is actually plugged into the Ethernet port (it is labelled accordingly).

Is there a replacement keypad membrane for the Magelis XBTR410?
No. There are no replacement keypad membrane for the XBTR410.

Does the Magelis HMISCU support 3rd party drivers?
The HMISCUs only support Schneider Electric protocols. It does not support any 3rd party protocols. It was a Marketing decision to not include 3rd party drivers.

Does the Magelis HMISTO have e-mail functionality?
Only the HMISTO531 and HMISTO532.

Can I delay the Startup on the Magelis HMIGTO?
A Startup delay can be added from the Target Properties under Startup Options.

What is the fusing recommendation for the Magelis HMISCU?
We recommend using a slow-blow, 2A type T fuse. Type T and Class refer to different characteristics.
Type T is a time-delay slow blowing fuse. They are available in a wide variety of form factors and amperages. They typically have a fast over current link for surge spikes and a slower over current link for longer overload conditions.

Which Magelis HMI models support DH485?
The following HMI series support the DH485 protocol:
XBTGT
HMIGTO
HMISTU
HMISTO
XBTGK
HMISCU
HMIG3U

Is a Magelis HMISCU capable of logging data?
A HMISCU is capable of logging data onto an USB memory stick. Only the Vijeo Designer part of the controller will be able to do data logging. The SoMachine Logic Builder part cannot do data logging.

What is the communication cable to connect a Magelis XBTN401 to a Twido TWDNAC485D MiniDin port?
The cable part number is XBTZ968.

What software is used to program Magelis HMIGXU series ?
Vijeo Designer Basic V1.0 and higher is used to program the Magelis HMIGXU series.

Can the keypad on the Magelis XBTGK’s be replaced?
No, the keypad or membrane on the Magelis XBTGK’s are not field replaceable. There are no replacement parts for these and it will most likely have to be sent in for a repair.

What are the MTBF’s of the Magelis HMIGTU series?
See attached for the MTBF’s for the Magelis HMIGTU ranges.

Is the Magelis HMIGTO work with neoprene gloves?
The Magelis HMIGTOs use a resistive touchscreen. The touch is activated when pressure is apply to the screen and can be used with neoprene gloves.

Can the Magelis HMI be mounted vertically?
No, the Magelis series of HMIs programmed with Vijeo Designer cannot be mounted vertically. The reason for this is because Vijeo Designer software assumes that the (0,0) coordinate is the top left corner of the screen.

Are the Magelis HMIGTO series ATEX Certified?
Yes, the Magelis HMIGTO’s are ATEX certified and the models are listed below.
– HMIGTO1300
– HMIGTO1310
– HMIGTO2300
– HMIGTO2310
– HMIGTO2315
– HMIGTO3510
– HMIGTO4310
– HMIGTO5310
– HMIGTO5315
– HMIGTO6310
– HMIGTO6315

Magelis HMISTU boots to the message Runtime Unsupported : The hardware platform does not match the target type defined in the application. Is there a way to recover from this?
This usually can affect the following parts: HMISTU655/855, and HMIS5T. The HMISTU targets do not have a way to recover the Runtime. It is recommended that the unit be sent in for repair, or purchase a replacement unit.

FANUC Servo & Spindle Motor Repair

Joe Kaminski 1 Comment

MRO Electric and Supply provides fast and reliable FANUC servo motor repairs on all types of FANUC motors. Our factory-trained repair technicians have years of expertise with FANUC servo systems, and our facility provides them best-in-class testing equipment that will have your FANUC motors repaired, tested, and aligned precisely to the manufacturer’s specifications.

Our large inventory of spare parts and replacement components allow for us to repair your motor quickly to get you back up and running with minimal downtime. MRO Electric is able to recondition and test each of your motor’s components. This includes performing re-windings and replacing bearings, as well as repairing armatures, housings, encoders, resolvers, output shafts, and flanges.

FANUC Servo Motor Repair
FANUC Servo Motor Repair

As one of the nation’s leading FANUC servo motor repair specialists, MRO Electric places a strong emphasis on reliable customer service, great pricing, fast turnaround, and quality repairs. Each of our FANUC servo repairs come with a minimum 12-month warranty. MRO Electric can repair all FANUC motors and parts, both new and old.

FANUC Motor Repair
FANUC Motor Repair

Once your motor is received, it is thoroughly cleaned and reconditioned. Our trained technicians disassemble, inspect, and troubleshoot each individual motor component. After each non-functioning component is replaced or repaired, we test motor function fault, brake, encoder, and thermistors. We then commission the motor using one of our drives, testing it in both forward and reverse for at least an hour.

MRO Electric also stocks both new and refurbished FANUC motors with rush shipping options available. If you require a working motor immediately, you can take advantage of our core exchange policy to return your non-functioning motor in for credit.

We recently rebuilt some Fanuc AC Spindle Motors, including one motor part number A06B-0828-B302. The customer was in a rush and needed this 357 lb motor so that he could get back up and running right away. We didn’t have the motor in stock, but we did have all of the parts in stock to build the motor. Check out all of our Fanuc CNC products on our website.

Within 3 days we were able to rebuild, repaint, and fully test the motor with our FANUC Spindle drives to get it ready to go back out via freight to the customer, so they were back up and running in less than a week.

Our rebuilds for these size motors usually take 2-3 days, so we were right on schedule for this Fanuc motor. We have the full list of motors that we stock and repair here, and you can email sales@mroelectric.com for more info. We also have pictures of the finished product below as an example.

For a free FANUC servo motor repair quote, please email sales@mroelectric.com or call 800-691-8511.  For more information on our FANUC repair capabilities, you can visit our FANUC Repair page.

FANUC Drive Repairs from MRO Electric and Supply

Joe Kaminski Leave a comment

Here at MRO Electric and Supply, our repair shop is designed to provide the highest quality drive repairs on all FANUC spindle and servo amplifiers. With a variety of testing platforms and a large stock of replacement components, we can fully repair and refurbish your FANUC drive to “like new” condition.

Each of our FANUC Drive repairs come with a 12-Month Warranty.

Our Process:

  1. Inspection / Disassembly
    When your non-functioning FANUC drive is first received, our repair technicians go to work inspecting, disassembling, and thoroughly cleaning your unit.  Throughout this process, we will evaluate your drive to determine the primary cause of failure.
  2. Component Replacement
    Our technicians test and replace any non-functioning components on your FANUC Drive. We also replace any worn parts, as well as components that are prone to failure. This includes resistors, diodes, IGBT’s, capacitors, electrolytic caps, relays, and fans. We have one of the largest stocks of FANUC circuit boards on the globe. We continue to troubleshoot and replace components until we are confident that your FANUC drive can move onto the testing phase.
  3. Testing
    With our numerous testing platforms, we perform a variety of dynamic functional tests on your FANUC drive to ensure reliability. After these procedures, your FANUC drive is left to run overnight in our facility to certify its consistency.
  4. Shipping
    Once your FANUC drive has passed our strict testing and quality control procedures, it is carefully packaged and shipped back to you in perfect working condition.
Our repair pricing can save you up to 75% compared to buying new drive. Save time and reduce costs by having your FANUC drive refurbished by the experts here at MRO Electric. 
For more FANUC Drive repair information or to request a free quote, please call 800-691-8511 or email sales@mroelectric.com.
Simodrive Repair

Siemens Drive Repair

Joe Kaminski 1 Comment

Have a Siemens Drive down? Get an Instant Quote now.

At MRO Electric, we are constantly fine-tuning and upgrading our repair capabilities and turnaround times. We perform Siemens drive repairs and refurbishments on Simodrives, Sinamics, Sinumerik, Micromaster, and Simoreg drive series. We also perform repairs on Simatic panels and a variety of Siemens motors. We offer quick, pre-priced repair estimates so you know from the beginning how much your repair will cost.

Our mission is to keep our Siemens drive repairs to the highest quality standards while retaining our lowest cost guarantee. We want to get your machine back up and running as quickly as possible. Our normal turnaround time for Siemens drive repairs is 7-10 days, but we can often accommodate rush repair jobs if necessary.

Simodrive Repair
Dynamic Testing being performed on a Simodrive

Once we receive your Siemens drive, it is thoroughly cleaned and visually inspected for any visible deficiencies. We then methodically test every component on the drive, replacing any that no longer function or meet our strict quality standards. After all faulty components are replaced, the drive must complete all of our functional testing requirements before being packaged and shipped back to its owner.

All of our repairs come with a 12-Month Complete Coverage Warranty. If any problems occur in that time frame, MRO Electric will repair or replace your drive at no charge.

For more information or to request a repair quote, please visit our Siemens Repair page. You can also email sales@mroelectric.com or call 800-691-8511.